Product Introduction
Enamelled Fully Insulated Wire is a composite multi-grade insulated winding wire combining high-performance enamel coating and spiral composite tape outer wrapping. Conductors can select high-purity electrolytic copper or self-produced 1350 high-purity aluminum bare wire.
Single monofilament goes through standardized enamelling processes to form uniform, bubble-free, pinhole-free enamel insulation as primary dielectric barrier. After stranding and compacting into round or flat shapes, the entire conductor assembly is wrapped with polyester, polyimide or composite paper tape as secondary full insulation layer, realizing dual insulation protection for high-voltage, high-frequency transformer and reactor windings.
Multiple enamel formulas are available (polyurethane, polyesterimide, polyimide) covering temperature grades from 130℃ up to 240℃. The integrated enamel+tape insulation system balances thin wall thickness for high slot fill factor and outstanding voltage-withstand performance, widely adopted in new energy transformers, medium-high voltage reactors and high-frequency inductors. All enamel coating processes adopt closed-loop temperature control to guarantee consistent paint thickness across every wire.
Core Technical Parameter Table
|
Parameter |
Standard Specification Data |
|
Conductor Options |
High-purity electrolytic copper / Self-produced 1350 aluminum bare wire |
|
Single Wire Diameter (Round) |
0.1mm – 5.0mm customizable |
|
Flat Conductor Thickness/Width |
Thickness 0.1–2.0mm; Width 2–16mm |
|
Primary Enamel Insulation |
PU(130℃), PEI(155℃), PI(180/240℃); Single/Double/Heavy Build Coating |
|
Secondary Outer Wrapping Tape |
Polyester Film, Polyimide Film, DK/DM Composite Paper |
|
Thermal Grade Coverage |
B(130) / F(155) / H(180) / C(240) |
|
Conductor Resistivity (20℃) |
Copper ≤0.01724 Ω·mm²/m; Aluminum ≤0.0280 Ω·mm²/m |
|
Enamel Thickness Tolerance |
±0.003mm, no pinhole defects |
|
Executive Standards |
GB/T 6109, IEC 60317, NEMA MW1000 |
|
Joint-Free Length |
Max 4000m per production spool |
Material & Bonding Construction
1. Conductor Raw Materials
- Copper: ≥99.99% electrolytic copper, ultra-low resistance for high-efficiency power equipment
- Aluminum: Self-manufactured 1350 bare wire, lightweight cost reduction for medium-voltage devices
2. Dual Insulation Structure
- Primary Enamel Layer: Uniform cured enamel tightly bonded to each monofilament, excellent flexibility against repeated winding bending without cracking;
- Secondary Full Wrapping Layer: Multi-layer staggered spiral tape wrapping over the whole stranded bundle, boosting overall dielectric strength and anti-abrasion performance during coil assembly.
3. Stranding Form
Supports single round wire, multi-strand round bundle and compact flat rectangular forms according to winding slot design requirements.
Core Competitive Advantages
1. Flawless Uniform Enamel Coating
Controlled baking curve eliminates bubbles, pinholes and uneven paint thickness; enamel adhesion strength passes mandatory thermal shock and scratch testing.
2. Two-Stage Insulation Reinforcement
Enamel inner insulation + tape outer wrapping double barrier greatly improves partial discharge resistance under ultra-high voltage working conditions.
3. Wide Temperature & Frequency Adaptability
Multiple enamel grades cover low-frequency power transformers to MHz high-frequency charging inductors, compatible with oil-immersed and dry-type equipment environments.
4. Excellent Mechanical Flexibility
Enamel film maintains ductility under small bending radii; outer tape wrapping prevents enamel scratching during automated winding.
5. Full Customization Support
Adjust conductor material, cross-section shape, enamel build thickness, tape type and wrapping overlap rate to match customer coil design parameters.
Complete Production Flow
- Raw copper/aluminum wire feeding & precision drawing to target dimension
- Continuous annealing to eliminate processing internal stress
- Automated full-process enamelling & closed-loop oven curing
- Online enamel thickness & pinhole defect inspection
- Multi-strand stranding / flat pressing (as required)
- Multi-layer insulating tape constant-tension spiral outer wrapping
- Full electrical test: withstand voltage, insulation resistance, DC resistance
- Meter counting, spool winding and moisture-proof export packaging
Main Application Fields
- New energy vehicle charging transformers & high-frequency inductors
- 35kV–1100kV oil/dry-type power reactors
- Solar & wind power inverter magnetic components
- Industrial high-efficiency motor stator windings
- Medical high-voltage electromagnetic equipment coils
Packing & Global Shipping
Packaging
- Inner: Cylindrical wooden / plastic / tapered plastic spools
- Outer: IPPC export wooden cases, domestic Euro pallets with waterproof film wrapping
- Separate foam padding to avoid enamel scratch during transit
Logistics Terms
- MOQ: 1 Ton; Standard Lead Time: 2–3 weeks; Urgent order: 7–10 days
- Global transport: Ocean, air, full-truck land and combined container door-to-door delivery
FAQ
Q1: What is the advantage of enamelled fully insulated wire vs single enamel wire?
A: Single enamel wire lacks outer protective tape; our double insulation system enhances high voltage resistance and prevents enamel abrasion during winding.
Q2: Can self-adhesive enamel coating be added?
A: Yes, we supply self-bond enamel variant that forms rigid integrated coils after heating curing for automated mass winding.
Q3: Is aluminum version available for lightweight projects?
A: Both copper and aluminum conductor versions are fully customizable.
Q4: Do you provide enamel material COA certification?
A: Each batch can supply enamel raw material certificates and third-party SGS/TUV performance test reports.
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