Fully Insulated Flat Aluminum Stranded Wire

Fully Insulated Flat Aluminum Stranded Wire is a dedicated compact flat winding conductor for oil-immersed power transformers, grid shunt reactors and medium-voltage electrical equipment. All aluminum core strands are self-manufactured bare aluminum wire from our supporting workshop, made of ≥99.7% 1350 high-purity electrical aluminum.

Every single aluminum round strand is wrapped with PET or PI film for independent inter-strand insulation first. After multi-strand uniform stranding and precision cold pressing into neat flat rectangular bundles, the whole assembly is spirally wrapped with multi-layer DK/DM composite insulation paper to form a closed full insulation structure. Compared with single-layer insulated flat stranded wire without outer wrapping, this double insulation system thoroughly avoids inter-strand short circuit risks caused by winding friction, long-term vibration and transformer oil impurity erosion during decades of operation.

The aluminum conductor cuts total winding weight by nearly 70% versus copper equivalents and greatly reduces raw material expenditure. The flat profile raises coil slot utilization rate by 20%–28%, supporting miniaturized transformer design. This product has passed full eddy current flaw detection for raw aluminum and batch electrical performance testing, stable for mass production of 35kV to 1100kV distribution equipment.

1. Self-Produced Bare Aluminum Base Wire

All aluminum monofilaments are fully self-supplied. The bare aluminum production line includes extrusion, multi-stage tungsten die drawing, 360–400℃ recrystallization annealing and full eddy current non-destructive testing, eliminating internal pores, inclusions and surface scratches before entering stranding processes.

2. Stranding & Compacting Process

• Insulated aluminum strands are arranged in parallel uniform rows with fixed lay pitch to guarantee balanced current distribution;
• Precision flat pressing removes gaps between strands without damaging inner film insulation;
• Tight bundled structure improves mechanical shock resistance during coil winding and long-term equipment vibration.

1. Double Full Insulation Safety Barrier

Independent film on each strand + full composite paper outer wrapping forms dual protection. Even partial outer wrapping is scratched during assembly, internal strands cannot contact each other, drastically lowering transformer fault probability.

2. Optimized Flat Profile for High Fill Factor

Smooth rectangular outline fits iron core slots tightly, reducing coil radial thickness and allowing smaller transformer tank size under equal power output.

3. Excellent Oil Immersion Aging Resistance

PET+DK insulation system shows no hydrolysis, swelling or dielectric attenuation after long-term mineral transformer oil immersion, with stable service life exceeding 20 years.

4. Low High-Frequency Eddy Loss

Uniform strand transposition inside the flat bundle balances magnetic flux linkage for every aluminum wire, suppressing skin and proximity effect loss in variable-frequency reactors.

5. Lightweight Economic Edge

Aluminum density is only 1/3 of copper, slashing transportation load and raw material costs for large-volume transformer projects.

Stage 1: Bare Aluminum Wire Manufacturing

• Aluminum rod pay-off → Straightening → Iron brushing cleaning → Washing & rinsing
• 400–500℃ high-temperature extrusion → Multi-stage drawing to target diameter
• 360–400℃ continuous annealing → Eddy current full inspection → Bare wire take-up

Stage 2: Fully Insulated Flat Stranded Wire Processing

• Insulated aluminum strand feeding
• Uniform parallel stranding with controlled lay length
• Precision square pressing into flat rectangular bundle
• Multi-layer constant-tension composite paper full wrapping
• Online inspection: dimension, insulation breakdown voltage, DC resistance
• Digital metering, wooden spool winding & moisture-proof export packing

• 35kV / 110kV / 220kV oil-immersed distribution power transformers
• 1100kV ultra-high voltage grid shunt & series reactors
• Metallurgical rectifier transformers and industrial furnace power equipment
• Lightweight mobile power station transformer windings

Packaging Scheme

• Inner spools: Heavy-duty solid wooden spools / thickened plastic tapered spools
• Outer export packing: IPPC fumigated wooden cases, Euro standard pallets
• Protection: Full anti-static moisture PE film + foam anti-collision separators

Shipping & Order Terms

• MOQ: 1 Ton
• Standard Lead Time: 2–3 weeks; Urgent Priority: 7 working days
• Transport: Sea, air, full-truck land, combined container global door-to-door delivery

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