Product Parameters
Conductor Material: 99.95% pure copper (ETP grade) or 99.7% aluminum (1060/1350 series)
Dimensions:
Width: 2.0mm – 30.0mm
Thickness: 0.6mm – 10.0mm
Polyester Film Thickness: 0.02mm – 0.05mm (1 – 2 layers)
Non-woven Fabric Thickness: 0.05mm – 0.1mm (1 – 2 layers)
Insulation Class: Class 155 (F) (continuous operating temperature up to 155°C)
Tensile Strength: Copper core ≥ 210 MPa; Aluminum core ≥ 95 MPa
Elongation: ≥ 16% (copper); ≥ 13% (aluminum)
Breakdown Voltage: ≥ 6kV (single film + single fabric); ≥ 12kV (double film + double fabric)
Standards Compliance: IEC 60317-42. NEMA MW 1000. GB/T 6109.21
Product Advantages
Dual Insulation Protection: Polyester film provides excellent dielectric strength, while non-woven fabric adds mechanical toughness—resisting cuts and abrasion 30% better than single-layer insulation.
Space Efficiency: Rectangular profile allows 25-35% higher packing density than round wire, reducing equipment size in transformers and motors.
Moisture Resistance: Polyester film acts as a barrier to moisture, while non-woven fabric absorbs minimal water (< 5% by weight), maintaining performance in humid environments.
Cost-Effective Performance: Balances high insulation quality with moderate material costs, offering 20% savings over fully film-insulated wire without sacrificing reliability.
Material Versatility: Copper (98% IACS conductivity) suits high-efficiency applications; aluminum (62% IACS) cuts weight by 30% for less demanding uses.
Product Features
Secure Bonding: Polyester film is heat-laminated to the conductor, while non-woven fabric is tightly wrapped with 10-15% overlap, preventing delamination.
Rounded Corners: Conductor edges (radius ≥ 0.2mm) protect insulation from punctures during bending and winding.
Flexible Handling: Easily formed into complex shapes (minimum bend radius: 3× thickness for copper, 4× for aluminum) without insulation cracking.
Chemical Compatibility: Resists mineral oils, mild acids, and industrial cleaning agents common in manufacturing settings.
Uniform Insulation: Automated wrapping ensures consistent layer thickness (±0.003mm), guaranteeing predictable dielectric performance.
Product Process
Conductor Rolling: Copper/aluminum rods are rolled into rectangular strips, annealed to optimize ductility for wrapping.
Surface Preparation: Ultrasonic cleaning removes oxides and contaminants, ensuring strong adhesion with polyester film.
Polyester Film Lamination: Film is applied via hot rolling (120-150°C) to bond directly to the conductor, forming a smooth base layer.
Non-woven Fabric Wrapping: Automated machines wrap fabric around the film-laminated conductor with controlled tension to avoid wrinkles.
Curing: Final heat treatment (80-100°C) sets the wrapping, enhancing adhesion between layers.
Quality Validation: Includes breakdown voltage testing, insulation thickness checks, and bend tests to verify flexibility.
Main Application Fields
Industrial Transformers: Medium-voltage transformers in manufacturing plants, where dual insulation withstands thermal cycling.
Motors & Generators: Large AC motors and synchronous generators, using rectangular shape for efficient winding.
Renewable Energy Systems: Inverters and power conditioning units in wind and solar installations, resisting outdoor moisture.
Railway Equipment: Traction motors and control transformers, where mechanical durability handles vibration.
Marine Electricals: Shipboard motors and transformers, leveraging moisture resistance in humid, salt-air environments.
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