Search Results

Tau paves the way for transport electrification at Coiltech Italia 2022, the international coil winding exhibition, held in Pordenone on September 28-29. Electric car manufacturers are racing to launch more advanced models at a rapid rate. Most importantly, industry experts are mastering innovative winding technologies for high voltage motors featuring high-power density. This helps to improve the electric vehicles’ efficiency, range and reduce recharge time. After successfully passing laboratory testing, Tau has now unveiled a new hairpin stator prototype for automotive e-traction developed in partnership with Additive Drives, a manufacturer of state-of-the-art e-motor components for mobility, automotive, industrial and racing sectors. One of the highlights of Tau winding wire is that it has all the characteristics that future mobility requires. Its partial discharge resistance and voltage resistance are 60% higher than that of competing products. In comparison to modern conductor solutions, the Tau wire delivers a higher power output and is suitable for applications above 800 volts. “We are proud to be partnering with Additive Drives to deliver our shared vision of the next level electric motor technology. At the current stage of pre-production development, we have a rare opportunity to shape decisions on product design and material sourcing based on our product performance. This milestone is of the utmost importance for Tau, now and in the future, as we want our magnet wire to play a key role in the energy transition”, said Filippo Veglia, co-founder and CSO of Tau. Tau’s magnet wire characteristics - electrical, mechanical and chemical - have been tested by FAPS and PEM Institutes in laboratory settings. Having successfully passed all tests, Tau further partnered with Additive Drives and built the first stator with Tau wire. This confirmed that Tau wire can be processed and allows for a smaller bending radius of the wire in the stator, lower friction, and a higher electrical fill factor. By rethinking traditional coating methods, Tau is leveraging the benefits that “from scratch” approach gives to put in place more sustainable practices. The DryCycle® solvent-free coating process significantly reduces any negative impact on the environment owing to the use of solid-state dry varnishes preventing VOC emissions. "We use only the materials we need and no more. Our one-layer insulation has already demonstrated very good mechanical robustness and superior dielectric strength, so we don't need to apply more polymer to obtain better results, which reduces not only the manufacturing cost but also carbon footprint. And we want to do much more than that. Our DryCycle coating is the only technology that allows 100% copper and thermoplastic polymer recycling - thus making our high-performance wire more environmentally friendly," added Veglia. The company will continue its partnership with Additive Drives to deliver an end-to-end e-motor solution that weighs less, consumes less energy and resources, and achieves the absolute maximum power density and range, Veglia said. To see the very latest technologies designed for the winding industry, visit Coiltech Deutschland 2023 in Ulm on March 29-30, where Tau will be exhibiting at Booth 7-D09. About Tau Tau is a technology company at the core of the electrification of transport and the decarbonization of energy. Its patented technologies reconcile the necessity of sustainable manufacturing with the power, reliability and performance that electrification requires to enable smaller, greener and more powerful motors, transformers and generators. Tau focuses on carbon-conscious protective coatings for high-performance and standard copper, aluminium and steel wires. Visit www.tau.group or follow Tau on Twitter and LinkedIn. About Coiltech Coiltech Italia is an annual international exhibition for the coil and winding industry that gives an excellent opportunity to keep up with the materials and methods innovation for further improvement of efficiency in production, distribution, transformation, and consumption of electrical energy. For more information visit https://www.quickfairs.net.

On April 06-07, Tau took part in the Coiltech Deutschland 2022 in Ulm, the fair dedicated to the supply chain of coil winding, electric motors, generators and transformers industry. For this occasion, the company showcased its unparalleled high-performance magnet wire coated with fluoropolymer to enable future electric motor architecture. Today’s battery-powered electric cars are significantly heavier than combustion vehicles and thus have high energy consumption. This represents the biggest challenge for transport electrification. OEMs and Tier1 companies strive to improve performance and efficiency of their upcoming models. The move towards 800V technology ensures faster charging and wider range. However, higher voltages stress primary insulation even more and cause partial discharge leading to the motor failure. Modern design concepts use rectangular wires in hairpin or wave windings with a thicker insulating layer. Filippo Veglia, Tau’s co-founder and CSO, speaker at the fair’s World Magnetic Conference, pointed out that with increased insulation thickness, made to withstand higher voltage, the slot fill factor has to be reduced. This lowers power density and efficiency of the motor. Since voltage and fill factor are two competing parameters, motor designers must find an optimal equilibrium which depends on the primary insulation resistance to partial discharge. “The use of special polymers like PEEK and PI, both already highly resistant to partial discharge, allows to increase the voltage without jeopardizing the fill factor of the motor. Nevertheless, fluoropolymers such as PTFE and PFA have the lowest relative permittivity among the insulating polymers and demonstrate superior partial discharge performance compared to commonly used polymers. And this advantage becomes even more evident at the usual operating temperatures of electric powertrains. A wire coated with a fluoropolymer is calculated to work with three times the voltage of the equivalent wire enameled with PAI and almost two times the equivalent wire coated with PEEK”, says Veglia. This represents a game-changing advantage for systems of 800V and more. However, fluoropolymers are rather soft materials and have relatively poor resistance to abrasion and minor clamping force. They show low adhesion and are difficult to extrude. Therefore, traditional technology of wire enameling and wire extrusion was unable to work with fluoropolymers. Tau answered these requirements with its self-developed, proprietary DryCycle technology, which guarantees operational peace of mind when coating with PFA, PTFE, ETFE and other fluoropolymers, with no solvents or primers. Based on the recent report by PEM Motion, Tau’s PFA coated wire has a much lower level of partial discharge – 75% less than PAI-coated and 30-40% less than PEEK-coated wire. Tau will again be displaying its high-performance wire for e-mobility and grid applications at Coiltech Italia 2022 in Pordenone on September 28-29, at Booth 7-A31. Save the date! About Tau Tau is a technology and sustainable manufacturing company at the core of the electrification of transport and decarbonization of energy. Its research, development and incubation have resulted in patented technologies that pair environmental responsibility with superior performance and peace-of-mind operating simplicity. Tau focuses on carbon-conscious protective coatings for high-performance and standard copper, aluminium and steel wires. Tau has offices in Turin (Italy) & Berlin (Germany). Visit www.tau.group or follow Tau on Twitter and LinkedIn. About Coiltech Coiltech Italia is an annual international exhibition for the coil and winding industry that gives an excellent opportunity to keep up with the materials and methods innovation for further improvement of efficiency in production, distribution, transformation, and consumption of electrical energy. For more information visit www.quickfairs.net.