Product Parameters
Conductor Material: 99.95% pure copper (ETP grade) or 99.7% aluminum (1060/1350 series)
Dimensions:
Width: 1.0mm – 15.0mm
Thickness: 0.2mm – 5.0mm
Insulation Thickness: 0.03mm – 0.2mm (single/multi-layer options)
Insulation Class: Class 180 (H), Class 200 (N), Class 220 (R) (polyimide, polyesterimide, or polyurethane coatings)
Tensile Strength: Copper core ≥ 205 MPa; Aluminum core ≥ 90 MPa
Elongation: ≥ 15% (copper); ≥ 12% (aluminum)
Breakdown Voltage: ≥ 2.5kV (single layer); ≥ 5kV (double layer)
Standards Compliance: IEC 60317. NEMA MW 1000. GB/T 6109
Product Advantages
Space Efficiency: Flat shape reduces winding volume by 20-30% compared to round wire, enabling more compact device designs.
Thermal Performance: Thin, high-grade enamel insulation (e.g., polyimide) withstands continuous operating temperatures up to 220°C, preventing overheating.
Conductivity Balance: Copper versions offer 98% IACS conductivity for high-efficiency applications; aluminum options provide 61% IACS with 30% weight savings.
Mechanical Durability: Enamel coating resists abrasion, solvents, and moisture, ensuring long-term reliability in harsh environments.
Cost Flexibility: Aluminum variants lower material costs by 40-50% without sacrificing basic performance, ideal for budget-sensitive projects.
Product Features
Uniform Insulation: Precision coating ensures consistent thickness (±0.005mm) for reliable dielectric strength.
Edge Treatment: Rounded corners minimize insulation stress during winding, reducing risk of cracking.
Adhesion Strength: Enamel bonds tightly to conductor, resisting peeling during bending or thermal cycling.
Solderability: Specialized coatings (e.g., polyurethane) allow direct soldering without stripping insulation.
Customizability: Available in bare, tin-plated, or annealed forms with tailored hardness for specific winding needs.
Product Process
Conductor Preparation: Copper/aluminum rods are rolled into flat strips, then annealed to adjust ductility.
Surface Cleaning: Chemical etching removes oxides, ensuring strong enamel adhesion.
Enamel Coating: Multiple layers of liquid enamel (dip or spray application) are applied, with each layer cured at 350-450°C in a vertical furnace.
Cooling & Sizing: Controlled cooling prevents enamel cracking; precision rolling ensures exact dimensions.
Quality Checks: Each batch undergoes dielectric testing, adhesion tests, and dimensional verification.
Spooling: Wound onto plastic or metal spools (10-50kg capacity) for easy handling during winding operations.
Main Application Fields
Electrical Motors: High-efficiency AC/DC motors (e.g., EV traction motors, industrial pumps) where space and heat management are critical.
Transformers & Inductors: Power transformers, planar inductors, and choke coils requiring compact windings.
Generators: Alternators in automotive, marine, and power generation systems.
Appliances: Compressors, fans, and HVAC motors in refrigerators, air conditioners, and washing machines.
Renewable Energy: Wind turbine generators, solar inverter transformers, and energy storage system components.
Aerospace & Automotive: Lightweight aluminum versions for aircraft actuators; high-temperature copper variants for EV battery management systems.
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