Summary
- Profile Type
- Technology offer
- POD Reference
- TODE20250221021
- Term of Validity
- 14 May 2025 - 14 May 2026
- Company's Country
- Germany
- Type of partnership
- Commercial agreement with technical assistance
- Research and development cooperation agreement
- Targeted Countries
- All countries
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General information
- Short Summary
- A German Start-up has developed coils for electrical machines that are manufactured by casting. Advantages include higher efficiency, power density and torque as well as lower costs, CO2-emissions and weight. This can improve the performance of electric motors by up to 60%. Sought are companies from application fields such as e-mobility, industrial automation or ammonia refrigeration that want to integrate the technology. Also sought are manufacturers of e-drives that wish to acquire a license.
- Full Description
-
Electric coils are part of every electric motor, thus a key component for a climate-neutral future.
To date, coils are usually wound coils made of copper, which are relatively expensive, heavy and labour-intensive to manufacture. In addition, their geometries have disadvantages in terms of the filling factor of housings, which is a maximum of 55%, with corresponding effects on performance and efficiency. A German start-up has developed a process which allows coils for electrical machines made from Aluminum or Copper to be manufactured by casting. The casting can be carried out either by die casting, low-pressure casting or investment casting. The coils can be cast from copper for high performance as well as aluminum for lightweight solutions. An automated production by casting the coil significantly reduces the production costs of electric motors and allows flexibility in terms of materials, size and geometry. Their unique geometries with a flat conductor arrangement offer decisive advantages over conventionally manufactured windings.
The coils are particularly suited for application in electromobility (motors for drones, eVTOLs, electric aircraft, traction motors and steering drives for electric cars, railways or ships), energy generation (especially wind turbines) or industrial automation. Due to their corrosion resistance, the aluminum coils are also very suitable for refrigeration systems operated with ammonia, in contrast to copper coils.
The German start-up is looking for companies from respective application fields such as e-mobility, industrial automation or ammonia refrigeration that would like to integrate the technology. Also sought are manufacturers of e-drives that wish to acquire a license.
The company is a spin-off of a renowned institute for applied science. The core business is the transfer of technology into production and the licensing of the comprehensive patent portfolio. - Advantages and Innovations
-
• Improved space utilization: Slot fill factor of up to 90% compared to a maximum of 55% slot fill of conventional wound copper coils.
• Lower temperature, better heat dissipation and higher density: The flat conductor arrangement allows for a significantly improved thermal behaviour while the negative influence of the skin effect is minimized. The combination of high slot filling factor and excellent thermal behaviour allows to double the current density per slot area.
• Higher torque: Tested electric drives for e-bikes achieved, compared to drives with traditional wound copper coils, up to 50% higher continuous torque with aluminum cast coils and 100% higher continuous torque with copper cast coils.
• Reduced weight: The higher utilization of installation space and flexible geometry design of the coils allow for smaller, lighter motors, which is crucial for drones and electric vehicles. A cast aluminum winding is 40% lighter than a conventional copper winding.
• Flexibility in material, quantity and size: As various casting methods are, coils can be produced with aluminum or copper in a variety of different sizes and quantities. For the production of prototypes, a precision casting process chain is available that allows the creation of a coil geometry in hardware in a minimum of time.
• 30% lower CO2-emission: Aluminum enables lower energy consumption in production and recycling, 30% lower CO2 emissions and the use of CFC-free refrigerants in refrigeration and air conditioning technology.
• Reduced costs: The cast coil technology reduces costs by optimizing material usage, lowering production complexity, and increasing energy efficiency, which leads to lower operational expenses. - Stage of Development
- Already on the market
- Sustainable Development Goals
- Goal 7: Affordable and Clean Energy
- Goal 9: Industry, Innovation and Infrastructure
- IPR status
- IPR granted
- IPR notes
- several countries
Partner Sought
- Expected Role of a Partner
-
The German start-up is looking for companies from respective application fields such as:
• e-mobility: manufacturers of drones or electric aircrafts, traction motors and steerings drives for electric cars, railways or ships and others
• energy generation: manufacturers of wind turbines, hydroelectric plants or gas turbines and others
• industrial automation: manufacturers of conveyor systems, robotic arms, CNC machines, pumps, and packaging equipment and others
• manufacturers of refrigeration systems operated with ammonia
Role of the partner would be to integrate the technology.
Also sought are manufacturers of e-drives that wish to acquire a license. The German start-up offers customized consulting to identify the tailor-made solutions for the use of cast coils in the desired application. The company offers prototype manufacturing of coils. The company ensures a transfer of knowhow and expertise needed to independently produce and implement cast coils in high quantities and quality. - Type and Size of Partner
- SME <=10
- SME 50 - 249
- SME 11-49
- Big company
- Type of partnership
- Commercial agreement with technical assistance
- Research and development cooperation agreement
Dissemination
- Technology keywords
- 04002005 - Generators, electric engines and power converters
- 02009014 - Automotive electrical and electronics
- 02009002 - Hybrid and Electric Vehicles
- 03004004 - Electrical Engineering/ Electrical Equipment
- 04001004 - Transmission of electricity
- Market keywords
- 06011 - Energy for Transport
- 03004003 - Other electronics related equipment
- 08002005 - Machine vision software and systems
- 08003007 - Other industrial equipment and machinery
- 06002004 - Hydro-electric
- Sector Groups Involved
- Aerospace and Defence
- Energy-Intensive Industries
- Renewable Energy
- Targeted countries
- All countries
