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Industrial process for isolation of a winding wire without solvent

The aim of this project is to develop an effective european industry to isolate winding wires with an innovative solvent-free and technico-economical competitive process. The properties of the winding wires will be directly assessed by evaluating the performance of a derived motor.

Today, classic magnet wires used to realize the windings of electric machines are still industrially produced with polluting processes. Each year they represent 25 000 tons of very polluting and carcinogenic solvents and 50 000 tons of CO2 emissions in Europe. Furthermore, enamelling process requires very high energy consumptions. Besides to ensure the sustainability of the production of magnet wires in Europe and the manufacture of motors, it is necessary to develop a new manufacturing less polluting and more economical process. Indeed the actors have to innovate to insure the competitiveness and to respect the future environmental rules imposed by the new European directives. It will be also a good mean for the partners to find growth opportunities because new products will be demanded by the market. The main goal of this project is to develop an effective European industry to isolate winding wires with an innovative solvent-free and technico-economical competitive process. The properties obtained for the winding wires are directly measured by evaluating the properties of a motor made from these wires. The original process is environmentally friendly, solvent-free, and proceeds to the coating of copper and aluminium wires with a photocurable varnish and an innovative combined technique based on UV and extrusion processes. This technique has been developed at laboratory scale and supported by a European project of basic research (V Frame Work Programme, European Commission) launched in 2000. The theoretical technical viability of a varnish polymerized by UV without solvents, nor emission of CO2 and NOX was established. However, the scope of that project was limited to that conclusion. It didn't allow the development of a real/optimum formulation. So the aim of this project is to develop efficient production process at industrial scale in order to fulfill technical and economical needs of the market. In order to reach this objective it is essential to gather all the partners of the industry as proposed by this project (from material producer to final integrator). The objectives of the ECOWILINE project are wire copper and aluminium insulation process optimization, verification of the economic performance of the process, validation of the technical and environmental properties of the wires, test of the optimized process on aluminium wires, optimization of formula / process couple and regulatory acceptance (REACH and standards) (cf project appendix parts 4 to 6). All of these objectives will respect industrial conditions for the manufacturing of the wires and the motor. At the end of the project, the Ecowiline partners will propose new ecodesigned products with mass production and will be able to conquer new markets (railway etc.). Ecowiline will generate additional income and employment for the partners and their subcontractors. Various phases of this process require not only knowledge but also innovative solutions brought by the following partners gathering together all the skills of the industry (cf project appendix part 1): - SOFILEC (main participant and wire manufacturer) will develop the ecodesigned insulated wires and conductor. It will participate in the process prototyping settings, the process optimization, and the wires manufacturing. SOFILEC will also submit the new wires for Certification ; - PRODUCTOS CONCENTROL (chemical manufacturer) will develop new product formulation and will produce at industrial scale the new optimized varnishes and resins. They will also discuss REACH organizations about the new process evaluation in comparison with actual one ; - LEROY SOMER (electrical motor manufacturer) will integrate these new solvent-free insulated wires to produce ecofriendly motors and test these motors. The company will also participate to the preliminary tests and specifications to define targeted functions (technical and cost) and to certify the final products. It could be noticed that the Ecowiline partners will rely on three main subcontractors : -Green Isolight International (GII) is the expert in the project since this company developed the process at the lab scale. Thanks to a very good knowledge of the technology. He will be the technical referee of the technology allowing a good consideration and optimization of the overall process (chemical,electrical and mechanical fields) -Two academic laboratories (LSEE, Université d'Artois and the IES, Université Montpellier 2) that will bring their know-how for evaluation of life cycle analysis of the process and coils performances and will work on wires complete characterization to give information about properties, comportment and aging of these innovative wires. As a recognition of its interest and innovation, the Ecowiline project has been labelized by Viaméca, the French cluster of the mechanics and advanced processes (cf project appendix part 3).
Acronym: 
ECOWILINE
Project ID: 
8 750
Start date: 
01-09-2014
Project Duration: 
36months
Project costs: 
2 080 000.00€
Technological Area: 
Generators, electric engines and power converters
Market Area: 
Speciality/performance materials: producers and fabricators

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.