Manufacturing and Application of Low-Cost Potting Adhesive with High Thermal Conductivity

TL;DR

This paper introduces a low-cost, high thermal conductivity adhesive for improving heat dissipation in air-cored linear synchronous motors.

Contribution

A novel multi-scale filler strategy is proposed to significantly enhance the thermal conductivity of potting adhesives for motor windings.

Findings

The BN-AlN sample achieved a thermal conductivity of 1.182 W/m·K at 25 wt% filler loading.

The modified adhesive reduced winding temperature by 8.82 °C and improved temperature uniformity by 29.8%.

Abstract

The air-cored linear synchronous motor (ACLSM), characterized by high precision and stability, is widely applied in high-precision manufacturing. However, due to the absence of an iron core, the windings must be fixed with low thermal conductivity epoxy-based potting adhesive, leading to poor heat dissipation and significant temperature rise, which risks the motor’s lifespan and accuracy. To improve heat dissipation in ACLSM, this research proposes a multi-scale filler-based strategy to enhance the thermal conductivity of the adhesive. A series of comprehensive characterizations and thermal tests demonstrates the effectiveness of this approach. The results demonstrate that the BN-AlN sample exhibits superior thermal conductivity of 1.182 W/m·K at 25 wt% filler loading, a 48.7% enhancement over commercially adhesive 381-4DZ, with only a 38% increase in cost. Meanwhile, it possesses superior electrical insulation properties and appropriate hardness, making it highly suitable for the potting of ACLSM windings. The winding encapsulating with the modified adhesive achieves a maximum temperature reduction of 8.82 °C, while improving temperature uniformity by 29.8%, confirming its exceptional thermal management capability.

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