Optimizing automotive bearing cages for Electric vehicles with Stanyl® PA46

EV bearing cages: the challenge of high speed and high-power density EV motors

EV motors are generally more powerful than conventional internal combustion engines and operate at significantly higher torque and higher rotational speeds compared with combustion engines. The need for more compact and lower weight EV motor units often leads to a need for even higher rotational motor speeds to compensate for the motor torque and motor power output losses resulting from lower weight and more compact motor designs, putting additional speed requirements on the bearings used in these high-power density motor units. The cages used in the motor bearings are exposed to high centrifugal loads and high operating temperature and to maintain a reliable bearing operation, materials with high temperature mechanical and tribological performance are often required for the bearing cage. Stanyl® PA46 offers the best in class mechanical and tribological properties in a high temperature environment as commonly seen in high-speed bearing applications.

Compared to other high-performance polymers also used in high-speed bearing cages, for example PEEK, Stanyl often achieves the cage performance need at significantly lower cost.

Stanyl® PA46: the ideal solution for EV bearing cages

Stanyl® PA46 offers a high-performance solution that helps address application challenges faced by automotive bearing manufacturers in a cost-effective manner. This high temperature thermoplastic material delivers:

• Outstanding stiffness, fatigue resistance and wear resistance at elevated temperatures: the material's superior stiffness and fatigue resistance reduce the risk of part failure, even under extreme temperature conditions.
• Lightweight and thin-walled designs: Stanyl® PA46 enables the production of thinner, lighter bearing cages that maintain the necessary mechanical performance for high-stress applications.
• High weldline strength: Stanyl® PA46 provides at elevated temperatures higher weldline strength than PA66, significantly reducing the risk of failure as result of formation of weldlines that are often unavoidable in many bearing cage designs.
• Faster production cycle times: with its high flow and fast crystallization speed, Stanyl® PA46 helps achieve shorter molding cycle times, reducing production costs.

Proven performance in real-world applications

Extensive testing and real-world applications have demonstrated that Stanyl® PA46 often exceeds the performance of other materials like PA66 and many other engineering plastics. Key benefits include:

• Reduced part deformation: at speeds of up to 30,000 rpm, bearing cages made from Stanyl® PA46 exhibited 21% less part deformation compared to those made with PA66.
• Heat and chemical aging resistance: Stanyl® PA46 has been tested to perform well at high temperature conditions and also resists chemical attack from commonly used automotive oil and grease lubricants, ensuring a reliable, long-lasting performance in demanding automotive bearing applications.

Advanced simulation tools to help ensure reliability and performance

At Envalior, we provide more than just advanced materials—we offer comprehensive CAE services to ensure the highest quality and performance of your components. These include:

• Moldflow analysis: predicts mold filling behavior and fiber orientation effects to ensure both good processing behavior during manufacturing and part performance during operation.
• Finite element analysis: simulates part behavior under realistic conditions, ensuring stiffness, strength and durability performance throughout bearing service life.
• Material testing: mechanical, tribological and chemical resistance properties and other material properties relevant for plastic bearing components.