The main objective consists in improving the European manufacturing capability for high voltage (>6kV) and high temperature applications (Tmax : 180°C).
The targeted improvements include enhanced thermal stability and insulation properties of adhesive potting for high voltage applications. In addition, a specific attention has been given to EU sourced materials for development.
The current Technology Readiness Level (TRL) for new materials is TRL2. Activities performed in this project targeted to improve the TRL in order to reach TRL4.
The technical goals are:
The main challenge is to succeed in finding a material suitable with all our criteria:
The state of the art and the materials trade off led to identify a broad range of commercial resins that were evaluated for their suitability for replacing our current resin set as a reference in this study.
The complete tests sequences performed throughout this project lead to identify a resin suitable for our requirements and processes.
The Technology Readiness Level (TRL) improvement was also an objective. It has been targeted to improve the TRL for these new materials from TRL2 to TRL4. This target has also been reached; the selected material passed the validation in laboratory environment.
The objectives of this project were ambitious but we succeeded to identify a class H material that fulfills our requirements and processes except the sourcing location. Even if the European sourcing was a strong criterion, the technical performances of the US selected resin are better than the ones EU candidates. This is the reason why we finally selected a material from a US source.
The main product features are:
The architecture is not an issue in this project because we dealt with a material and its implementation and we did not design a specific product.
Nevertheless, the assessment of the material performances has been undertaken through samples and breadboards.
We designed several types of samples:
This project has been divided in 9 tasks:
The project is completed.
The goals of the contract have been reached.
This project permits to identify a material that seems suitable with all our requirements (at material and at processes levels).
The Technology Readiness Level (TRL) has been improved: TRL4 has been reached as targeted at the beginning of the project.
This project has lead TAS-B to acquire extensive knowledge about high voltage and high temperature potting materials.