UL Epoxy & Urethane Projects From 2006 to 2010  Nearly $2,000,000 in Sales

Mike, I say Yes 3x.  I enjoyed working with you, you knew the product, you could see how it would enhance my product/process.  In terms of future contact, I'm not sure what you'll be rep'ing but definitely keep in contact, I can pass on your info at a minimum. Yes, I believe that Michael possess the technical knowledge to be a manufacturer’s representative.   T.N. 
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"When I began the process of looking for a replacement for the epoxy I was using, Michael was the only representative that brought the whole package to the table in a way that I felt comfortable with.  He had an encapsulate solution, along with the meter mix equipment.  Through the testing process, Michael answered numerous questions on a host of different topics, and made me feel confident in the decision that I ultimately made, which was going with the EFI polymer/EXACT meter mixing solution."

"I want to reiterate the point that Michael was the ONLY rep that was willing to form a relationship with me, and was the only rep that allowed me the time to get comfortable with my decision on my own time table, not pressuring me into a decision that I didn’t feel comfortable with.  This is the main reason that EFI polymers has my business, even today."

"I believe that Michael understands the epoxy insulation business, and how it applies to my business.  His first an only recommendation for an encapsulant was the one that I ultimately ended up choosing.  After a year of use, the material has performed to my expectations, along with the meter mix equipment.  If Michael hadn’t taken the time to figure out what I needed, and the knowledge to recommend an appropriate solution, the outcome could’ve been much different."

"With what has transpired between EFI and Michael, I am under the impression that I can no longer go to Michael for any of my encapsulant needs, especially in regards to my business with EFI polymers.  This bothers me, because I do business with people that I enjoy working with, and have faith in.  I have not met anyone else from EFI, just received some letter with some contact information.  This to not the relationship that I had with Michael, which bothers me about EFI." J.S.

2006 Project Start: Submersible Motor/Pump Made In Illinois

Originator of the Centrifugal Sealless Magnetic Drive Pump.
The ultimate in reliable, trouble-free performance for chemical, OEM, industrial, hydronic, medical, marine, solar and biofuel applications. 

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Stator using 3 pounds of epoxy

Places a PO every Quarter
Resin 55 Gallon Drum               500 lbs.                $2.45            $1,225.00

Hardener 55 Gallon Drum               420 lbs.                $3.23            $1,356.60

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Motor & Pump Epoxy Encapsulated

Not currently Using a 
Meter Mix Machine

They hand mix:
Gel Time: 150g @ 77f 
= 80min 

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2006 Project Start: Condenser Motor Used in Harsh Environments

Oil & Gas H2 He N2  CO2 C1 Methane C2 Ethane  C3 Propane C4 IsoButane C4 Normal butane C5 Iso Pentane C5 Normal Pentane C6 Hexanes C7 Heptanes C8 Octanes Condensables “Wellhead Gasolne” C7-C30 Benzene, Tolulene, o-Xylene 100 % relative Humidity Salts H2S 500 PPM Iron Sulfur reaction byproducts Pipe scale Sand Gas the encapsulated stator will be exposed to.  The two applications we are most interested in are Oil & Gas and Pipeline natural gas.  The others may have some minor future applications.  Concentrations are anyone’s guess except for H2S.  For now 500 PPM is the limit, higher would be good.

No news is good news.  Two weeks ago we sent a compressor with an encapsulated stator to a customer that has experienced failures that were caused by conductive debris.  This customer is relatively close and we are able to monitor the results ourselves instead of depending on a third party.  The bad news is the time to failure ranges from as low as 50 to as high as 12,000 hours.  The system runs 24 X 7 so time alone will tell.

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Resin & Hardner

Designed for ambient cured applications requiring complete impregnation. System may be used with or without vacuum.  The cured system has excellent thermal shock resistance.  Excellent for motors that have a  Cut-Core (BLDC) brushless dc stator thermal potting requirement.

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Gel Time Characteristics

Resin/Hardener has a 
Gel Time (ASTM D-2471)           
200 grams @ 77 F (25 C)          >5 hours                
200 grams @ 120F (49 C)       45 minutes

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2006 Project Servo Motor 20,000 Units US 20,000 Units EU.

2006 The good news is that there is an engineer and technician assigned to the Potting Material Project.  The bad news is that because these are not the same people, the tests will need to be run again.  Good news for you in that I need to order more material.  

Can you get me pricing on 1 and 5 gallon pails of resin 20206 and 1 gallon pails of hardener 50013?

Here is a rough timetable.  The new Manager wants all of this completed by year end. 


Mike:
I will pot the stator  as soon as possible after getting the material.  I have started the paperwork on my end and hope to have parts to pot next week, it depends on the workload on the production floor.  I will send you a note when the material comes in, and I have the parts in hand.  Then you can come on over if you have time.
The tests will consist of running the motors at peak torque at various speeds over a 3 day period and recording the temperature at various points inside the stator.  So with 5 motors, it will take about 3 weeks to get all the results.  So just before Thanksgiving.

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Mike:
Got the e-mail, placed order based on that pricing.  Can be changed if necessary.   If material comes in by Oct. 30, will try to pot on Nov. 1.  If not then, will have to wait Until Nov. 15 because of scheduled training Nov. 6 to 10.  This moves the testing past Thanksgiving.

If you are in Mpls. stop by if you have time. 

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Meter Mix Machine Specifically For Motors In use since 2007

I'm waiting for final approval on this project. I would expect it this week. Then I can get PO's to  Sheepscot and EFI.
I'll be in touch. Thanks  

Hello Michael,
I have been told that Poland will be doing about 34% of the motors. Would you please send me a quote on the Michaels Potting system, CE compliant.  Thank you,

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2006 Project Epox-E-Pak Motors protection from harsh environments!

Assisted with tooling, cure cycle, time, temp and training with MMD.
Epox-E-Pak is a highly engineered process that increases the ability of an electric motor to withstand harsh environments.Motor manufacturers mold windings on a production basis.  Endeavor Technologies has perfected Epox-E-Pak, making it economical to upgrade a single motor, or to duplicate or improve a molded winding supplied by a motor manufacturer.   Please keep reading to find out how it can benefit you.

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Large AC Drives using 5 to 15 pounds

Epox-E-Pak increases the ability of an electric motor to withstand harsh environments, including contamination and elevated temperatures.  Ordinarily, coils in an electric motor are protected only by a thin coat of epoxy or polyester varnish.  The varnish bonds the individual conductors into a rigid assembly, protecting the enamel on the magnet wire from the mechanical stresses imposed by current flow during operation.  Unfortunately it does little to protect against a fault caused by coolant or other contaminants.

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Meter Mix Machine Specifically For Motors In use since 2007

Hi Mike,

I sincerely hope this is last resin order I place before the dispensing equipment gets here.

Thanks

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Water Well Pump Application 500,000 to 750,000 pounds of Epoxy per Year. 
Full penetration within end turns. Most critical and generates the most heat.

Typical applications include homes, farms, restaurants, schools, coalbed methane recovery and small factories. Complete line of submersible motors for groundwater and other submerged pumping applications. Our 4-inch submersibles (1/3 through 10 hp) feature the industry's widest range of voltage and frequency ratings in both single- and three-phase models. For deeper wells and applications requiring higher flow ratings, Franklin's 6-inch and 8-inch submersibles are available from 5 through 200 hp.

Assisted in a cure cycle, tooling and process that was critical in the security of the thin inner SS lining. CTE was eliminated by developing a cure cycle that minimized the expansion of the related elements from -40 to 160c.

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Full Penetration between copper wire.

Long gel time and a temperature schedule allows for a highly filled epoxy to penetrate the windings. Vacuum is not necessary but helps accelerate the process of impregnation.

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Prototype Meter Mix Device

For the first 10 to 1000 motors we properly chose a low cost meter mix device. I assisted in the instalation, maintenance,
build and rebuild. Start up and shut down procedures.

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2007 Hydraulic Pump Motor Back Up System 

[ INQUIRY FROM CATALOG NAVIGATOR (SM) ]
This is a request for more information originating from
your website. Please respond at your earliest convenience.
Sender Information: 
Title: Technology Team Leader
Company: Parker Aerospace, Hydraulic Systems Division
Country: USA
Requesting Information On
-------------------------
1) Item # 20206/50013, AC/DC & Linear Motors, Stators, Coil Windings. UL 1446

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2009 US Airways Flight 1549 floating on the Hudson River

The generators that routinely provide electricity weren't available because they are driven by the aircraft's engines -- which weren't putting out sufficient power after apparently having ingested several geese. 
All 155 people on board the flight from New York's La Guardia airport en route to Charlotte, N.C., were able to escape safely, a feat air-safety experts consider one of the most difficult in aviation.
The back up generator drives back up hydraulics that allowed this plane to land in the Hudson River.  

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2007 Project Testing Begins in Ohio.

Michael: Very well.  We just performed a test where we put current through the coils and heated the potted assembly up to 275°F.  The results were good and we are continuing to the next step, which will be to build the motor up and run the heck out of it. Thank you for your help.

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MMD Install and operational training.

Mike,
Thank you for the assistance on Wednesday with start up and trial run of the equipment as
well as yesterday's inquiry regarding results after oven cure.

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2007 Solenoid Project 

[ INQUIRY FROM CATALOG NAVIGATOR (SM) ]
Sender Information
Title: Engineer
State: Ill
Country: US
Email: frank.blum@magnet-schultz.de
Requesting Information On
-------------------------
1) Item # 20203/50015, Strobe, Ignotors, Balast, Lighting, UL 1446

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Current Solenoid Had a Problem 

He maybe looking for a epoxy to work for multiple applications. I will definitely contact you soon.  I actually have two applications for an epoxy. 


Kevin,
 We’ll plan to process the remaining coils on Wednesday.  This happens to be a difficult week for us, and if for some reason we can’t do them on Wednesday, we’ll have to wait until Monday.  We’re assuming you want 3 in each resin. Epox-E-Pak Motor Company

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Current CATALOG & CAD client

Hi Mike,
Thanks again for taking the time to meet with us this week. Your insight into the TR website, and the exercises we went through to prove that the TR site not only includes the data needed to accomplish what MSA desires, but also has the capability to achieve our search goals, were a great step forward.David L. Stockwell - President
 Magnet-Schultz of America

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Gear Motor Manufacturer to dominate the wash down market.

Hey Michael,
Sorry for that delay.  I was in the lab quite a bit for a few days, and until now I had forgotten that you sent this email.  The motors turned out good once again.  This time they did not drop as much as the previous batch, but they did settle a little bit more after we baked them.  We’ve got the thermal testing on the 34 frame motors done, which turned out as good as we expected.  The epoxy transfers the heat so well that the temperature we are getting on the shell is only a few degrees away from the temperature we are getting on the coils.  I’ll be testing the 49 frame motors today and tomorrow. I just started getting into mountain biking this past year, and I’ve been waiting to take a trip until this summer.  I’m hoping to go with my brother somewhere in Wisconsin, but I’m not sure where it is.  Is Kettle Moraine pretty awesome? 

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Motor/Stator Preparation @ 165F 

This is how to set up a motor to be potted.

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Motor/Stator/Epoxy @ 140F

This is the temperature of a motor that has epoxy 

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24 Hour Cycle. Remove Bore Plug

This is the Motor & Stator after it has cooled.

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Cured Motor with Hardened Epoxy

This is the motor and rotor and gear casing attached.

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Intended Start Date JUNE 2009

Michael,
Thanks again for coming in the other day.  I’m hoping you can send me the name of the guy I have to contact for samples of that release agent.  Thanks
Michael,
We were just talking about needing more encapsulant.  Is this a good deal because it is extra or something?  I’m pretty sure we will not be ready to pot motors by Thursday.  Right now we are getting another stator prototype made and doing some more thermal testing to get better data. Hey Michael,
We are ready to pour our next motor.  We could probably manage by ourselves, but we would appreciate your help once more.  I am thinking that the stator will be ready by Wednesday at the latest, and although we don’t have material, I think that it should arrive soon.

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Wash down Motors Mfr.

Resin & Teta  - Just waiting for a new supplier from me.

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Epoxy Creep In a Motor Stator and How to get rid of it.

Tooling and Cure Cycle Temperatures coupled with gel time can cure creep.

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Servo Motor Project In USA & Europe

About 40,000 to 50,000 motors produced per year.

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$100,000 in Domestic Purchasing

Hey – could you go ahead and give Michael the PO to cover this test. IF you remember this is the new Epoxy. Let me know if you have any question. Thanks.

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500k Motors/Y ave. 1 to 2 pounds each.

Deep Water Well Pumps

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This is a machine I created to fill motors.

This machine made 5 motors perfectly the first time.

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