Product Parameters
Conductor Material: 99.95% pure copper (ETP grade) or 99.7% aluminum (1060/1350 series)
Dimensions:
Width: 0.8mm – 12.0mm
Thickness: 0.15mm – 4.0mm
Insulation Thickness: 0.02mm – 0.15mm (standard); 0.03mm – 0.2mm (self-adhesive)
Insulation Class: Class 155 (F) for standard polyacetal; Class 180 (H) for heat-resistant formulations
Adhesive Activation: 120°C – 180°C (self-adhesive variant, pressure-assisted)
Tensile Strength: Copper core ≥ 210 MPa; Aluminum core ≥ 95 MPa
Breakdown Voltage: ≥ 2kV (standard); ≥ 3kV (double-layer insulation)
Standards Compliance: IEC 60317-28. NEMA MW 1000. GB/T 6109.12
Product Advantages
Enhanced Chemical Resistance: Polyacetal insulation resists oils, greases, and weak acids, outperforming traditional enamel in industrial environments.
Form Stability: Self-adhesive coating bonds windings permanently when heated, maintaining shape under vibration—critical for automotive and aerospace applications.
Space Efficiency: Rectangular profile reduces winding volume by 25-35% compared to round wire, enabling smaller, more powerful devices.
Cost-Effective Bonding: Self-adhesive variants cut assembly time by 40% by eliminating glue or tape, lowering labor costs.
Material Flexibility: Aluminum options offer 30% weight savings over copper, while copper provides superior conductivity (97% IACS vs. 62% for aluminum).
Product Features
Consistent Insulation: Precision extrusion ensures uniform polyacetal coating (±0.003mm) for reliable dielectric performance.
Adhesive Uniformity: Self-adhesive layer (when specified) covers 100% of the wire surface, preventing weak bonding points.
Low Friction: Smooth insulation reduces winding friction, minimizing damage during automated coiling processes.
Temperature Tolerance: Withstands short-term overloads up to 200°C without insulation degradation.
Moisture Resistance: Polyacetal’s low water absorption (<0.2% in 24hrs) prevents insulation swelling in humid environments.
Product Process
Conductor Forming: Copper/aluminum rods are rolled into rectangular strips, annealed to achieve target ductility.
Surface Preparation: Ultrasonic cleaning removes oxides and contaminants, ensuring strong insulation adhesion.
Base Insulation Coating: Polyacetal resin is extruded or dipped onto the conductor, cured at 200-250°C to form a hard, smooth layer.
Adhesive Application (If Specified): A thin layer of heat-activated polymer is applied over the base insulation, dried at 100-120°C.
Precision Sizing: Cold drawing or rolling calibrates dimensions to tight tolerances (±0.01mm for width/thickness).
Quality Validation: Each batch undergoes adhesion testing, breakdown voltage checks, and adhesive activation trials.
Main Application Fields
Automotive Electronics: Starter motors, alternators, and EPS (electric power steering) coils—self-adhesive variants resist vibration-induced loosening.
Household Appliances: Compressor windings in refrigerators and air conditioners, where chemical resistance to refrigerants is key.
Industrial Motors: High-torque servo motors and drives, leveraging space efficiency for compact designs.
Transformers: Low-profile planar transformers in power supplies, using rectangular shape for efficient heat dissipation.
Aerospace Components: Lightweight aluminum versions in avionics cooling fans and actuator motors.
Renewable Energy Systems: Coils in small wind turbine generators and solar inverter inductors.
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