Product Parameters
Conductor Material: 99.95% pure copper (ETP grade) or 99.7% aluminum (1060/1350 series)
Diameter Range: 0.02mm – 5.0mm (copper); 0.1mm – 6.0mm (aluminum)
Insulation Thickness: 0.005mm – 0.2mm (varies by diameter and insulation class)
Insulation Classes: Class 130 (B), 155 (F), 180 (H), 200 (N) (polyester, polyurethane, polyimide options)
Tensile Strength: Copper ≥ 200 MPa; Aluminum ≥ 85 MPa
Elongation: ≥ 15% (copper); ≥ 12% (aluminum)
Breakdown Voltage: 1.5kV – 15kV (increases with insulation thickness)
Standards Compliance: IEC 60317. NEMA MW 1000. GB/T 6109
Product Advantages
Universal Compatibility: Round shape works seamlessly with all winding machines (horizontal, vertical, automatic), making it ideal for diverse production lines.
Cost-Effective Production: Simple cylindrical design reduces manufacturing complexity, lowering base costs by 15-20% compared to specialty wires.
Proven Reliability: Decades of industry use in standard applications, with well-documented performance in motors, transformers, and coils.
Material Flexibility: Copper provides 98% IACS conductivity for high-efficiency needs; aluminum offers 61% IACS with 30% weight savings.
Insulation Versatility: Multiple enamel options (e.g., polyurethane for solderability, polyimide for high temps) let users match wire to specific needs.
Product Features
Smooth Surface: Enamel coating forms a glossy, uniform finish that reduces friction during winding, minimizing insulation wear.
Consistent Diameter: Tight tolerance (±0.002mm for small wires) ensures even winding tension and predictable performance.
Flexible Handling: Easily bent and shaped (minimum bend radius: 2× diameter for copper, 3× for aluminum) without insulation cracking.
Thermal Shock Resistance: Withstands rapid temperature changes (e.g., -40°C to 180°C) common in industrial environments.
Moisture Resistance: Enamel formulation resists water absorption, maintaining dielectric strength in humid conditions.
Product Process
Wire Drawing: Copper/aluminum rods are drawn through dies to achieve precise round diameters, with intermediate annealing for ductility.
Surface Cleaning: Chemical degreasing and pickling remove impurities, ensuring strong enamel adhesion.
Enamel Application: Liquid enamel is applied via die coating (for small diameters) or dipping (for larger sizes), with each layer cured at 300-450°C.
Curing & Cooling: Controlled oven curing forms a hard, flexible insulation layer; air cooling prevents thermal stress.
Quality Testing: Includes diameter checks, breakdown voltage testing, and adhesion tests (enamel must withstand 180° bending without peeling).
Spooling: Wound onto plastic or metal spools (1kg to 50kg capacity) for easy integration into winding processes.
Main Application Fields
Household Appliances: Motors in refrigerators, washing machines, and fans, where standard performance meets cost needs.
Automotive Electricals: Starter motors, window regulators, and sensor coils, using copper for conductivity or aluminum for weight savings.
Electronics: Transformers, inductors, and solenoids in TVs, computers, and power supplies.
Industrial Equipment: Small to medium motors, pumps, and control systems requiring reliable, affordable winding wire.
Renewable Energy: Solar panel inverters and small wind turbine generators, leveraging cost-effective aluminum options.
Consumer Electronics: Voice coils in speakers, micro-motors in cameras, and charging coils in wireless devices.
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