Von Roll Inno­va­tion Lab

Let’s get creative


There are good rea­sons why lea­ding manu­fac­tu­rers from indus­tries like auto­mo­tive, Indus­try 4.0 and aero­space count on the inspi­ra­tion and ambi­tion of our glo­bal R&D team. They all appre­ciate the open atti­tude and inno­va­tive start-up men­ta­lity at Von Roll.

The results are visio­nary solu­ti­ons that pro­vide strong advan­ta­ges for our cus­to­mers in their markets.

Get­ting the che­mi­stry right.

With a top team, lea­ding-edge ana­ly­tics and AI-based tools, we are already working today on the che­mi­stry of tomor­row. Our Resins Lab is focu­sed on three key areas: impro­ved tech­ni­cal func­tio­n­a­lity, sim­pli­fied indus­trial pro­cessa­bi­lity and maxi­mum eco­lo­gi­cal compatibility.

Sili­cone-free up to more than 150 °C

For years, the auto­mo­tive indus­try has been loo­king for alter­na­ti­ves to sili­cone resins to pro­tect elec­tro­nic con­trol­lers. Our ans­wer: a sili­cone-free poly­bu­ta­di­ene pot­ting resin with a so far unmat­ched tem­pe­ra­ture resis­tance of over 150 °C.

Com­pa­red to sili­cone-based pro­ducts, this resin is par­ti­cu­larly cost-effi­ci­ent and high-per­for­mance. In addi­tion, it fea­tures high ther­mal con­duc­ti­vity, mecha­ni­cal resis­tance and very good envi­ron­men­tal com­pa­ti­bi­lity — without the use of hazar­dous sub­s­tan­ces sub­ject to labe­ling requirements.

Our imp­reg­na­ting resins — a boos­ter for large serial productions

Our new epoxy-based Dol­ph’s® imp­reg­na­ting resin with excel­lent ther­mal, che­mi­cal and mecha­ni­cal pro­per­ties is espe­cially sui­ta­ble for the insu­la­tion and mecha­ni­cal rein­for­ce­ment of win­dings for highly stres­sed electric motors in all-electric and hybrid vehi­cles. Due to its high reac­ti­vity and rapid curing, it allows extre­mely short cycle times in the pro­duc­tion process.

Green resins — the envi­ron­ment will say Thank You.

Supe­rior per­for­mance and maxi­mum envi­ron­men­tal com­pa­ti­bi­lity are not a con­tra­dic­tion to Von Roll! Our Dol­ph’s® brand has been pionee­ring the deve­lo­p­ment of high-per­for­mance green resins for more than 50 years.

The jour­ney con­ti­nues: we invest a lot to per­ma­nently opti­mize the envi­ron­men­tal com­pa­ti­bi­lity of our ent­ire resin port­fo­lio. Avoiding sol­vents and hazar­dous sub­s­tan­ces does not only help the envi­ron­ment. It sim­pli­fies indus­trial app­li­ca­ti­ons and redu­ces pro­ces­sing costs.

Cur­rent sta­tus: The majo­rity of our pro­ducts already con­tains no or only very low levels of sol­vents and hazar­dous sub­s­tan­ces; some of our pro­ducts are even com­ple­tely label-free.

Lon­ger range. More safety.

Fur­ther tech­ni­cal advan­ces are nee­ded for the final bre­akthrough of elec­tro­mo­bi­lity. We are making major con­tri­bu­ti­ons to this area: In the eDrive Labo­ra­tory of the Von Roll Insti­tute, our experts are deve­lo­ping new solu­ti­ons to mas­si­vely incre­ase the safety, effi­ci­ency and ser­vice cycle of motors and batteries.

Impro­ving the electri­cal and ther­mal design remains the key here. Our cus­to­mers bene­fit from our more than 100 years of know-how in the engi­nee­ring of electri­cal sys­tems and advan­ced composites.

E‑motors with maxi­mum efficiency

For a noti­ce­able exten­sion in range, it is necessary to design not only more power­ful bat­te­ries, but also more energy-effi­ci­ent drives.

Our new insu­la­tion sys­tems will enable a revo­lu­tio­nary new class of highly effi­ci­ent, com­pact and extre­mely dura­ble e‑motors. Com­bi­ning high-level pro­tec­tion against par­tial discharge with excel­lent ther­mal con­duc­ti­vity, sets the stage for the 800 V dri­ves of the future.

Bat­te­ries — solid power

The gro­wing energy den­sity in vehi­cle bat­te­ries pla­ces high demands on ther­mal manage­ment. Ope­ra­tio­nal heat must be dis­si­pa­ted effec­tively — and in the event of ther­mal over­load, chain reac­tions from cell to cell must be prevented.

Our Shield T pro­ducts sepa­rate the indi­vi­dual cells wit­hin the vehi­cle bat­tery in both electri­cal and ther­mal dimen­si­ons. They pro­vide a highly effec­tive bar­rier while kee­ping weight and volume to a mini­mum. At the same time, they are highly fle­xi­ble in adap­ting to the size of the cells, which varies depen­ding on the bat­te­ry’s level of charge. Extre­mely pre­cise and mil­lion times over.

Advan­ced Mate­ri­als Lab — Power­ful stuff for heavy-duty applications.

Our com­po­si­tes are desi­gned to handle mecha­ni­cal and ther­mal stress with ease — and for long-term use. The ground­work for this is being rese­ar­ched in our Com­po­si­tes Lab.

This is where we deve­lop, among other things, pionee­ring solu­ti­ons for bat­tery pro­tec­tion in electric vehi­cles, ther­mal pro­tec­tion mate­ri­als for indus­trial ovens and pres­ses, pro­ducts for bal­listic app­li­ca­ti­ons and cer­ti­fied solu­ti­ons for avia­tion and rail transport.

Arti­fi­cial intel­li­gence to dis­co­ver new solutions

Our che­mi­cal engi­neers have lea­ding exper­tise in resin tech­no­lo­gies — and they use advan­ced methods: for example, an AI based tool deve­lo­ped in col­la­bo­ra­tion with exter­nal sci­en­tists. The use of arti­fi­cial intel­li­gence is a very power­ful gate­way to new discoveries.

One example of suc­cess­ful AI-sup­por­ted deve­lo­p­ment is our EP200 Nxt­Gen resin sys­tem for Pre­p­res and Core Fil­lers. It pro­vi­des the foun­da­tion for our inno­va­tive aero­space pro­ducts. The expoxy resin out­per­forms con­ven­tio­nal phe­n­o­lic resins in terms of envi­ron­men­tal and health pro­tec­tion. At the same time, it exceeds the per­for­mance of cur­rent mar­ket solu­ti­ons regar­ding mecha­ni­cal pro­per­ties, anti-fire per­for­mance and sim­pli­city of pro­ces­sing. In addi­tion, the EP200 resin sys­tem fea­tures excel­lent shelf life at room temperature.

Our ser­vice — take advan­tage of our know-how


Tell us your spe­ci­fic requi­re­ments for high and low vol­tage insu­la­tion sys­tems. We will respond with cus­to­mi­zed and fully tes­ted insu­la­tion systems. 

Insu­la­tion trai­ning incl. e‑drive

In our trai­ning cour­ses you will gain a detailed over­view of insu­la­tion mate­ri­als and sys­tems for rota­ting high and low vol­tage machi­nes. This inclu­des topics like selec­tion, pro­ces­sing and testing.


A look into the prac­tice

Class H sys­tem of next generation

Gene­ra­tors will become even more effi­ci­ent in the future thanks to our new Sami­c­abond system.

Top story wind

Coil shop

Von Roll is expan­ding the site in Ban­ga­lore into one of the most advan­ced cen­ters for the pro­duc­tion of insu­la­ted coils in India.

Press release

E‑Drive Test Lab 

Busy days in the eDrive Lab of our High-Vol­tage Institute. 

Press release

110 years Dolph’s®

Foun­ded in 1910, our Dol­ph’s® brand recently cele­bra­ted its 110th anni­ver­s­ary. Electri­cal Appa­ra­tus maga­zine cove­red it. Curious?

Read arti­cle