C/M The Shrink + EV

 

C/M CYPRESS MOTOR SPORTS

The Shrink (Materials not for Bio-Brains)


A global race to drive down costs for end user affordability tiers & sustainability 

EV MATERIAL REVIEW - AUTOMOTIVE 

Electric vehicles generally always require around 80 kg of copper per vehicle for conductive lines 

A range of emerging technologies and strategies mean that electric vehicles will push copper requirements as low as 20 to 30 kg per vehicle, perhaps lower. For instance, shifting to higher-voltage architectures (800 volts or greater) reduces the necessary cable thickness, saving 6–10 kg of copper per vehicle.

Shrinking electric vehicle (EV) copper windings, specifically through the adoption of rectangular (hairpin) wire, allows for a significantly higher "fill factor" (less wasted space), resulting in motors that are smaller, lighter, and more efficient while delivering the same or higher power. These advancements can produce high-performance motors in the 20–30 kg range that achieve peak power densities up to 17 kW/kg. 

Key Impacts of Shrinking Copper Windings

• Equivalent Power, Smaller Size: Utilizing rectangular wire allows more conductive material to be packed into the same stator volume compared to round wire. This enables motors to deliver equivalent power output while reducing weight and volume.

• Higher Power Density: Modern manufacturing techniques like [hairpin windings] permit motors to achieve peak power densities over 10 kW/kg.

• Reduced Copper Usage: Advanced motor designs, including axial-flux and optimized busbars, can reduce copper requirements by up to 50% per motor while maintaining performance.

• Thermal Advantages: Compact windings reduce heat production due to lower resistance (12R losses) and allow for better cooling, enabling the motor to handle higher currents and thus higher power output within a smaller footprint.

Improved Efficiency: Moving to dense windings reduces "end windings" (the wire that doesn't contribute to torque), lowering copper losses and making the motor more efficient. 

Alternative Material Technology

To further enhance power density and reduce weight, researchers are developing Carbon Nanotube-Copper (CNT-Cu) composites for EV windings, which show improvements in conductivity and thermal stability, allowing for enhanced performance compared to traditional copper windings.


THE SHRINK 

Shrinking or removing copper windings from electric vehicle (EV) motors is a critical step in recycling, often required to extract the copper from the, now, very tight and varnished-packed stators.

Methods for Removing Copper Windings:

• Heat Treatment (Softening): Heating the stator is the most effective method, as it softens the tough epoxy and varnish that bind the copper wires, allowing them to slide out easily.

Mechanical Removal:Air Chisel with V-Groove: This tool is used to pull the windings out, and can be used on the cut side of the motor.

Cutting and Prying: Cutting one end of the windings flush with the laminated steel housing allows for easier removal, usually with a hammer and punch.

Stator Recycling Machines: Specialized machines are available that combine the cutting and pulling steps, which is designed to make the process more efficient.

Burning: Burning the motor in a controlled way is a method for destroying the insulation and glue. 

Key Considerations:

• Safety: When removing windings, it's important to use appropriate safety gear, like gloves and eye protection.

Efficiency: The goal of these methods is to make the extraction process faster and more efficient, reducing the time and labor involved.

Value: Extracted motor windings are often, for recycling purposes, considered number two copper, because of the residue. 

Techniques for Extraction:

• Cutting and Pulling: After cutting one side of the windings, the remaining windings can be pulled through the slots of the stator.

Using a Vise: Clamping the motor in a vise and using a hammer or other tool can be effective in freeing the copper, particularly for smaller motors.

Heating: A propane torch or fire can be used to melt the varnish. YouTube·Intelligent 

The process of removing copper from EV motors is challenging because of the high-quality materials and construction methods, but it is a necessary step for recycling and reusing the copper.

Reference 

https://medium.com/the-future-is-electric/the-copper-constraint-that-isnt-58cbfcd48f9e

https://chargedevs.com/features/scimo-bets-automated-flat-wire-windings-can-beat-hand-built-specialty-motors-in-high-performance-niches/

https://www.jingdawire.com/blogs/rectangular-magnet-wire-revolutionizing-evs-and-transformers/

https://www.nature.com/articles/s41598-025-32761-w

MINIMAL 7 TABLET RESERVE PACK IN KM OR MILES

Pur $250-300 Packs Vs up to $1500 with different materials earning more cycles & kilometers or miles before replacing & repressing/ recycling materials 

0.5-2 km per tablet & 7 before return

3.5 - 14 km or 3500 km - 14,000 k.

2174.799 miles - 8699.19 miles


CYPRESS MOTOR SPORTS 

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