Electric Motor Industry-Silicone Product Application Solutions

作者 Gubang | Jul 24, 2026

Scope: NEV motors, industrial motors, servo motors and micro motors across all categories

1. Electric Motor Industry Overview

1.1 Electric Motor Industry Trends

As the core component converting electrical energy into mechanical energy, electric motors continue to see growing demand in industrial automation, new energy vehicles and smart homes. The global motor market exceeded USD 180 billion in 2025, with NEV traction motors the fastest-growing segment at a CAGR above 20%. As motor technology advances toward higher power density, higher efficiency, higher speed and lighter weight, heat flux density keeps rising, imposing more demanding requirements on thermal management, insulation protection and vibration damping. The adoption of oil-cooled motors, hairpin windings and carbon-fibre rotors also creates new application challenges for electronic silicone materials.

1.2 The Core Value of Electronic Silicones in Electric Motors

Value Dimension

Application

Benefit

Thermal management

Stator winding potting, magnet cooling

Reduces temperature rise by 15–30℃ and increases power density

Insulation protection

Stator end-turn insulation, slot opening protection

Prevents turn-to-turn short circuits and withstands high-voltage surges

Structural fixation

Magnet bonding, end-turn winding fixation

Withstands centrifugal loads above 20,000G and resists vibration

Sealing and protection

Housing sealing, terminal box sealing

IP68 dust and water protection, resistant to oil and coolant

Lubrication and friction reduction

Bearing grease

Reduces friction losses and extends bearing life

Vibration and noise reduction

Elastomeric potting compound damping

Reduces electromagnetic noise by 2–5 dB(A)

1.3 Motor Types and Corresponding Silicone Requirements

NEV traction motors: Stator (hairpin end-turn potting / trickle impregnation / insulation coating) → magnets (thermally conductive bonding) → oil-cooling port sealing. Industrial servo motors: Stator (potting / slot wedge fixation) → encoder (protection) → brake (sealing). Micro and stepper motors: Magnet bonding → bearing lubrication → end cap sealing. High-voltage motors: Stator insulation potting → slot corona protection → lead wire sealing.

2. Product Portfolio Overview

2.1 Core Product Series

Product Series

Product Name

Typical Model

Key Features

Thermally Conductive Potting Compound

Motor-specific potting compound

MT-2803/2804/2806/2808

Thermal conductivity 0.8–2.0 W/m·K, low viscosity, reworkable

Thermal Grease

High thermal conductivity grease

MT-3203/3205

Thermal conductivity 1.0–4.6 W/m·K, low oil bleed, long service life

Magnet Adhesive

High-strength magnet bonding adhesive

Bond strength >8MPa, withstands 200℃

Bearing grease

High-Speed Bearing Grease

Low starting torque, wide temperature range -60℃ to 260℃

Insulating Conformal Coating

Winding end-turn conformal coating

MT-2806

Dielectric strength >20kV/mm, full environmental protection

Housing Sealant

Oil-resistant silicone sealant

MT-6655

Resistant to ATF and coolant, FIPG formed-in-place

Insulating Impregnation Resin

Trickle-impregnation insulating resin

Low-viscosity penetration, fast cure, Class H insulation

2.2 Technical Advantages

Motor potting compound: low viscosity (≤3000cP) penetrates deep into stator slots and completely fills micro-gaps

Magnet adhesive: room-temperature or fast heat cure, oil and heat resistant, shear strength >8MPa

High-speed bearing grease: base oil uses ultra-high viscosity index silicone oil, evaporation loss <1% (180℃/24h)

Insulating impregnation resin: compatible with VPI (vacuum pressure impregnation), thermal class H (180℃) and above

All products comply with RoHS, REACH and UL certification; UL Yellow Card available

3. Motor Stator Solutions

Figure 3-1 Motor stator potting and magnet bonding solution

Figure 3-2 Servo motor sealing and selection guide

The stator is the focal point of motor thermal management. Copper losses in the stator winding are the dominant heat source, accounting for roughly 60–70% of total motor heat generation. End-turn heat dissipation, in-slot heat transfer and insulation protection are the key application areas for electronic silicones.

3.1 Stator End-Turn Potting Solution

Application area: stator end turns of hairpin and round-wire motors (exposed winding ends). Recommended product: MT-2804 motor-specific thermally conductive potting compound

Parameter

MT-2804

Industry Requirement

Assessment

Thermal conductivity

0.8~1.2 W/m·K

≥0.6

Excellent ✓

Mixed viscosity

2500 cP

≤5000

Good penetration ✓

Cured hardness

Shore D 45

Shore D 30~60

Well balanced ✓

Dielectric strength

22 kV/mm

≥15

Outstanding ✓

Thermal class

Class H (180℃)

Compliant ✓

Cure shrinkage

<0.15%

<0.3%

Low shrinkage ✓

Working time (25℃)

45min

≥30min

Ample ✓

Recommended potting processes. Option A — full mould potting:

Pre-heat the stator to 80℃ to remove moisture
Install the potting mould and seal the end-turn area
Vacuum-mix parts A and B → degas → pour under low pressure
Step cure: 80℃ × 1h → 120℃ × 2h → cool naturally. Option B — trickle potting for end-turn fixation:
Position the stator at a 45° tilt
Feed the compound from the highest point of the end turns and let capillary action carry it in
Rotate the stator to cover all end turns evenly
Heat cure at 120℃ × 1h

3.2 In-Slot Insulation Impregnation Solution

Parameter

Process compatibility

Viscosity (25℃)

800 cP

Suitable for vacuum pressure impregnation (VPI)

Gel time (130℃)

5~8 min

Suited to fast production line cycles

Bond strength (to copper)

12 MPa

Firmly secures conductors

Dielectric strength

25 kV/mm

Higher than insulation paper

Thermal class

Class H (180℃)

Meets NEV motor requirements

Tg (glass transition temperature)

170℃

Maintains rigidity at high temperature

Recommended VPI process:

Pre-heat the stator to 100–120℃ and hold for 2h to remove moisture
Place in the VPI vessel, evacuate to ≤100Pa and hold for 30 min
Introduce ID300 resin and vacuum-impregnate for 15–20 min
Return to atmospheric pressure, then pressurise to 0.3–0.5MPa and hold for 10 min
Allow 30 min for excess resin to drain
Heat cure: 130℃ × 1h → 160℃ × 2h

3.3 Hairpin Weld Joint Protection Solution

Application area: hairpin winding weld ends (King Coil Crown zone). Recommended product: MT-2806 insulating conformal coating. Technical requirements:

Apply immediately after welding to ensure full wetting of the terminals before cure
Insulate the weld joints against high voltage and partial discharge
Protect weld joints from coolant and oil mist attack
No cracking under -40℃ to 180℃ thermal cycling
Selective spraying or dip coating is recommended, with a coating thickness of 100–300μm

4. Motor Rotor Solutions

4.1 Magnet Bonding Solution

Parameter

Test Condition

Shear strength (to ferrite)

10 MPa

25℃

Shear strength (to NdFeB)

8 MPa

25℃

High-temperature shear strength

4.5 MPa

150℃

Operating temperature

-55℃~200℃

Continuous operation

Cure method

80℃ × 30 min or 25℃ × 24h

Can be accelerated by heat

CTE (coefficient of thermal expansion)

80 ppm/℃

Well matched to metals

Oil resistance

Retains >75% strength after 1000h in ATF oil at 150℃

Long-term immersion

Key bonding process points:

Degrease the core slot walls and magnet surfaces (plasma treatment recommended)
Complete assembly within 15 min of adhesive application
Apply 0.1–0.3MPa clamping pressure after inserting the magnet
Heat cure: 80℃ × 30 min (recommended for production lines)
Sample-test magnet pull-out force after cure; standard ≥3kN
Re-confirm that magnets have not shifted after high-speed rotor balancing

4.2 Magnet Thermal Management Solution

Application areas: the thermal interface between magnets and rotor core, and rotor end cooling. Recommended products: MT-3203 thermal grease / MT-2804 thermally conductive potting compound. Demagnetisation risk rises sharply at high temperature, so effective heat dissipation is essential to keep magnet temperature down. Option 1 (magnet slot filling): MT-2803 potting compound fills the gap between magnet and core, thermal conductivity 1.0 W/m·K. Option 2 (magnet back coating): MT-3203 thermal grease applied to the magnet backside at 100–150μm. Option 3 (rotor end coating): MT-2806 conformal coating over the rotor ends for supplementary heat dissipation. Result: magnet temperature reduced by 15–25℃ and demagnetisation resistance improved by more than 30%.

4.3 Rotor Dynamic Balancing Compensation Solution

5. Motor Controller Solutions

5.1 IGBT / SiC Module Thermal Management Solution

Application area: interface between the IGBT / SiC power module and heat sink in the motor controller

Comparison Item

MT-3204 thermal grease

Thermal conductivity

3.7 W/m·K

3.0 W/m·K

Thermal resistance (@50psi)

0.05 ℃·cm²/W

0.12 ℃·cm²/W

Applicable gap

50~150μm

0.5~3mm

Automation efficiency

Stencil / screen printing — fast

Pad placement — slow

Ease of rework

Requires cleaning and re-application

Easily peeled and re-applied

Recommended use

High-volume automated production lines

Multiple chips with height variation / low volume

5.2 Controller PCB Protection Solution

Application areas: motor controller control board and driver board. Recommended product: MT-2806 insulating conformal coating. Automotive-grade requirements:

Thermal shock resistance: -40℃ ↔ 125℃, 500 cycles
Vibration resistance: 20G random vibration for 100h
Corrosion resistance: 100h salt spray with no migration
Coating thickness: 40–100μm

5.3 DC-Link Capacitor Potting Solution

Application area: internal filling of DC-link capacitors. Recommended product: MT-2804 (high dielectric strength grade). Key requirements:

High dielectric strength: ≥30kV/mm
Low dielectric loss: Df ≤0.001 @1kHz
Low CTE matching: consistent with the aluminium can and film
Long life: no performance degradation after 2000h at 85℃/85%RH

6. Bearing and Lubrication Solutions

6.1 Bearing Lubrication Applications

Application areas: front and rear motor bearings, deep-groove ball bearings, angular contact ball bearings

Motor Type

Bearing Specification

Recommended Grease

Life Target

NEV traction motor

6305~6315

≥150,000 km or 8 years

Industrial servo motor

6200~6208

20,000h continuous operation

In-wheel motor

Custom formulation

≥100,000 km

EPS steering motor

Miniature bearing

Maintenance-free for life

Oil-cooled motor

Special sealed bearing

≥8000h

6.2 High-Speed Bearing Grease — Technical Data

Parameter

Base oil

Modified silicone oil

Perfluoropolyether (PFPE)

Thickener

Polytetrafluoroethylene (PTFE)

Operating temperature

-60℃~220℃

-40℃~260℃

DN value (n × dm)

≤1.0×10⁶

≤1.5×10⁶

Starting torque (25℃)

≤30 g·cm

≤40 g·cm

Evaporation loss (180℃/24h)

<1.0%

<0.5%

Water resistance

Outstanding

Typical application

Standard motors and servo motors

NEV traction motors and oil-cooled motors

Key grease filling process points:

Degrease, clean and dry the bearing
Fill volume: 25–35% of internal bearing space (high speed) or 35–50% (medium to low speed)
Run the bearing for 2–3 min after filling to distribute the grease
Re-check grease distribution after fitting the dust cover or seal ring
Never mix greases of different brands or base oils

7. Motor Housing and Sealing Solutions

7.1 Housing Sealing Solution

Application areas: front and rear end cap-to-housing joints, cable outlets, oil and water ports

Sealing Area

7.2 Terminal Box Potting Solution

Application area: three-phase lead terminals inside the motor terminal box. Recommended product: MT-2804 (oil-resistant grade). Key requirements:

Insulation resistance ≥500MΩ (DC 1000V)
Withstand voltage ≥3kV for 1 min with no flashover
No degradation of electrical properties after oil immersion
UL94 V-0 flame retardancy

8. Selection Guide and Technical Data Comparison

8.1 Quick Selection Matrix

Application

Primary Requirement

8.2 Product Selection Flowchart

Motor silicone applications ─┬─ Stator ─┬─ End-turn potting → MT-2804 │ ├─ VPI impregnation → ID300 │ └─ Weld joint protection → MT-2806 │ ├─ Rotor ─┬─ Magnet bonding → MA600 │ ├─ Magnet cooling → MT-3203/MT-2804 │ └─ Balancing compensation → MA600 (weighted) │ ├─ Controller ─┬─ IGBT cooling → MT-3204/TSP │ ├─ PCB coating → MT-2806 │ └─ Capacitor potting → MT-2804 (high dielectric) │ ├─ Bearing ── Grease → LG100/LG200 │ └─ Housing ─┬─ Sealing → MT-555-1 └─ Terminal box → MT-2804

9. Competitive Advantages

9.1 Technical Advantages

Motor-specific formulation platform: dedicated formulations for different motor types (hairpin / round wire, high / low voltage, oil / water cooled)

Low-viscosity penetration technology: MT-2804 potting compound has a viscosity as low as 2500cP and penetrates deep into micro-gaps within the slots

In-house magnet adhesive: replaces imported brands at 30–50% lower cost with performance benchmarked against world-leading products

High-speed bearing grease: PFPE-based perfluoropolyether grease delivering the longest life under extreme operating conditions

All products validated in our own laboratory, with complete reliability test reports available

9.2 Quality Advantages

Quality Metric

Industry Standard

Maxtor Control Level

Batch stability Cpk

≥1.33

≥1.67

Viscosity tolerance

±20%

±10%

Cured hardness tolerance

±10 Shore

±5 Shore

Thermal conductivity tolerance

±0.2 W/m·K

±0.15 W/m·K

Shear strength tolerance

±15%

±8%

Batch traceability

Batch traceable

Samples retained for 5 years with complete process records

9.3 Service Advantages

Free samples: trial samples matched to the customer's process shipped within 24 hours
On-site production support: engineers deployed on site for the first mass production run
Process optimisation: assistance in optimising dispensing and potting parameters to raise yield
Joint development: custom formulation development for new motor designs
VAVE support: ongoing cost-reduction proposals to help customers optimise material cost

10. Case Studies

Case 1: Stator potting for an NEV traction motor

Customer background:

A top-3 Chinese NEV e-drive supplier, 200kW hairpin motor platform

Requirement:

Stator end-turn potting with thermal conductivity ≥0.8 W/m·K, thermal class H, and a post-potting temperature reduction of at least 15℃

Solution:

Customised MT-2804 formulation with thixotropy tuned for vertical potting

Results:

Stator end-turn temperature reduced by 18℃
Potting cycle time cut from 5 min to 3 min
Passed million-kilometre reliability validation
Annual consumption exceeds 200 tonnes

Case 2: Bearing lubrication upgrade for high-speed servo motors

Customer background:

The China plant of a Japanese servo motor brand, 15,000 rpm high-speed servo motors

Requirement:

Bearing grease life ≥20,000h, low noise, suitable for high-speed operation

Solution:

Results:

Bearing life increased from 12,000h to 25,000h
Motor noise reduced by 3 dB(A)
Cost reduced by 25%
Rolled out across the customer's global plants

Case 3: Magnet bonding process optimisation

Customer background:

An NEV motor manufacturer facing a cycle-time bottleneck on its IPM rotor line

Requirement:

Magnet adhesive cure time had to be cut from 4h to under 30 min while maintaining shear strength ≥8MPa

Solution:

Results:

Line cycle time reduced from 4.5h to 45 min (including cure)
Magnet pull-out force ≥5kN (requirement ≥3kN)
End-of-line yield improved from 96% to 99.2%
Line capacity increased by 40%

11. Technical Service System

11.1 Pre-Sales Service

Service

Scope

Response Time

Technical consultation

Product selection, application design and process assessment

Within 2 hours

Free samples

Trial samples matched to the customer's process, plus process recommendations

Within 24 hours

Application testing

Trial application and testing on the customer's actual motors

Within 5 business days

Process plan

Preparation of a complete application process plan and SOP

Within 5 business days

On-site visit

Technical exchange and production line review

Arranged within 1 week

11.2 Service During Implementation

On-site support for first mass production: engineer guidance to ensure a smooth ramp-up
Operator training: standardised work instructions (SOP) prepared and on-site training provided
Equipment integration: parameter packages for dispensing, potting and coating equipment
Quality documentation: MSDS, TDS, COA and RoHS/REACH reports provided

11.3 After-Sales Service

Quarterly review: quality review visit and joint assessment every quarter
Batch traceability: samples retained for 5 years with fully traceable production records
Failure analysis: response within 24 hours with an 8D corrective action report
Technical upgrades: regular recommendations of new formulations and cost-reduction options

We are committed to providing the electric motor industry with complete professional solutions for thermal management, potting, bonding and lubrication

Electric Motor Industry-Silicone Product Application Solutions

Table of Contents

1. Electric Motor Industry Overview

1.1 Electric Motor Industry Trends

1.2 The Core Value of Electronic Silicones in Electric Motors

1.3 Motor Types and Corresponding Silicone Requirements

2. Product Portfolio Overview

2.1 Core Product Series

2.2 Technical Advantages

3. Motor Stator Solutions

3.1 Stator End-Turn Potting Solution

3.2 In-Slot Insulation Impregnation Solution

3.3 Hairpin Weld Joint Protection Solution

4. Motor Rotor Solutions

4.1 Magnet Bonding Solution

4.5 MPa

4.2 Magnet Thermal Management Solution

4.3 Rotor Dynamic Balancing Compensation Solution

5. Motor Controller Solutions

5.1 IGBT / SiC Module Thermal Management Solution

3.7 W/m·K

3.0 W/m·K

0.05 ℃·cm²/W

0.12 ℃·cm²/W

5.2 Controller PCB Protection Solution

5.3 DC-Link Capacitor Potting Solution

6. Bearing and Lubrication Solutions

6.1 Bearing Lubrication Applications

6.2 High-Speed Bearing Grease — Technical Data

7. Motor Housing and Sealing Solutions

7.1 Housing Sealing Solution

7.2 Terminal Box Potting Solution

8. Selection Guide and Technical Data Comparison

8.1 Quick Selection Matrix

8.2 Product Selection Flowchart

9. Competitive Advantages

9.1 Technical Advantages

9.2 Quality Advantages

9.3 Service Advantages

10. Case Studies

11. Technical Service System

11.1 Pre-Sales Service

11.2 Service During Implementation

11.3 After-Sales Service