Product Parameters
Conductor Material: 99.95% pure copper (ETP grade) or 99.7% aluminum (1060/1350 series)
Dimensions:
Width: 1.2mm – 16.0mm
Thickness: 0.2mm – 5.0mm
Insulation Thickness: 0.03mm – 0.25mm (single layer); 0.06mm – 0.5mm (double layer)
Insulation Class: Class 220 (R) with short-term overload capability up to 250°C
Tensile Strength: Copper core ≥ 220 MPa; Aluminum core ≥ 100 MPa
Elongation: ≥ 18% (copper); ≥ 15% (aluminum)
Breakdown Voltage: ≥ 3kV (single layer); ≥ 5kV (double layer)
Vertical Winding Compatibility: Optimized for automated vertical coilers with winding speeds up to 60m/min
Standards Compliance: IEC 60317-30. NEMA MW 1000. GB/T 6109.15
Product Advantages
Extreme Temperature Resistance: PAI insulation maintains integrity at continuous operating temperatures of 220°C, ideal for high-power devices prone to heat buildup.
Vertical Winding Efficiency: Rigid yet flexible design reduces jamming in vertical winding machines by 40%, cutting production downtime.
Space Optimization: Flat shape allows 30% higher conductor packing density than round wire, boosting coil efficiency by 5-8%.
Mechanical Toughness: Insulation resists abrasion during winding and withstands 10.000+ thermal cycles without cracking.
Material Versatility: Copper options deliver 98% IACS conductivity for high-efficiency applications; aluminum variants offer 63% IACS with 35% weight reduction.
Product Features
Smooth Edges: Precision-machined rounded corners (radius ≥ 0.1mm) prevent insulation damage during vertical winding.
Uniform Insulation: Advanced extrusion ensures consistent PAI thickness (±0.005mm) for reliable dielectric performance.
Adhesion Strength: Insulation bonds securely to conductor, resisting delamination even under extreme bending (minimum bend radius: 3× thickness).
Chemical Resistance: Withstands oils, fuels, and industrial solvents, suitable for automotive and aerospace environments.
Low Outgassing: PAI formulation emits minimal volatile compounds, making it safe for sealed electrical enclosures.
Product Process
Conductor Rolling: Copper/aluminum rods are rolled into flat strips, then annealed to achieve optimal ductility for vertical winding.
Surface Treatment: Electrolytic cleaning removes oxides, ensuring strong insulation adhesion.
PAI Insulation Coating: Liquid PAI resin is applied via vertical dip coating (optimized for flat profiles), cured at 400-450°C in a nitrogen atmosphere to prevent oxidation.
Precision Calibration: Cold drawing ensures tight dimensional tolerances (±0.01mm for width/thickness) critical for vertical winding alignment.
Winding Compatibility Testing: Each batch is tested on vertical winding machines to verify feedability and reduce production line issues.
Quality Assurance: Includes dielectric strength testing, thermal shock trials (-55°C to 220°C), and adhesion checks.
Main Application Fields
Electric Vehicle Motors: High-power traction motors using vertical-wound stator coils, where thermal resistance and efficiency are critical.
Industrial Generators: Large-scale alternators and synchronous generators requiring compact, high-temperature coils.
Renewable Energy Systems: Wind turbine generators and solar inverter transformers with vertical-wound components.
Aerospace Electricals: Avionics motors and actuators, leveraging aluminum variants for weight savings.
High-Voltage Transformers: Compact power transformers in grid systems, using flat wire for efficient heat dissipation.
Marine Propulsion: Electric ship motors, where PAI insulation resists moisture and chemical exposure.
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