Effects of Potting and Slot Liner Material Characteristics on Thermal Behavior of a Traction Motor

The push for greater sustainability in the transportation sector has propelled advancements in electric vehicle (EV) technology, driving a growing demand for high power density traction motors. Achieving higher power from a small volume requires effective thermal management. While significant research has been conducted on optimizing the electromagnetic (EM) and thermal performance of traction motors, limited studies have explored the impact of materials such as potting and slot liners on the overall motor thermal performance. This study addresses this gap by using the Hyundai IONIQ 5’s rear motor as a reference to quantitatively assess how varying potting and slot liner cross-sectional areas and material properties influence heat dissipation and peak temperature within the motor’s stator. Based on the results, it is recommended to use a thick slot liner with high thermal conductivity paired with a relatively low thermal conductivity potting to lower peak hairpin temperatures.