Product Overview
Film wrapped wire, also known as film insulated magnet wire, is a premium-grade conductor manufactured by tightly wrapping polyester, polyimide (Kapton), or polypropylene film around a high-purity copper or aluminum core. After precise high-temperature curing, it forms a seamless, void-free insulation layer with exceptional electrical strength, mechanical toughness, and environmental stability.
Designed for high-voltage, high-frequency, and extreme working conditions, film wrapped wire is widely used in dry-type reactors, inverters, wind power generators, EV charging systems, and aerospace-grade coils.
As a listed magnet wire manufacturer with 86 years of expertise, JWHK ensures strict quality control, consistent batch performance, and global delivery reliability.
Core Technical Specifications
|
Parameter |
Details |
|
Conductor Material |
≥99.97% Oxygen-Free Copper / High-Purity Aluminum |
|
Insulation Material |
Polyester (B) / Polyimide (F/H) / PTFE |
|
Temperature Class |
B(130°C) / F(155°C) / H(180°C) |
|
Shape |
Round: φ1.8mm – φ5.6mm |
|
Insulation Thickness |
25μm – 100μm (Customizable) |
|
Dielectric Strength |
≥15 kV/mm |
|
Corona Resistance |
Excellent (Partial Discharge Inception Voltage ≥1200V) |
|
Standards |
IEC 60317, NEMA MW1000, GB/T7672 |
Key Product Advantages
Film insulation delivers 3× higher dielectric strength than conventional enameled wire. The seamless structure eliminates air gaps, ensuring stable performance under high voltage and high-frequency pulses.
Ideal for high-frequency inverters and reactors. The dense film structure suppresses partial discharge, extending service life by 50%+ under severe electrical stress.
Withstands high winding tension, sharp bending, and thermal cycling (-40°C to 180°C). The film bonds tightly to the conductor, preventing delamination or cracking.
Polyimide/PTFE film resists humidity, oil, solvents, and chemicals, ensuring reliability in harsh industrial environments.
Thin insulation allows for 20–25% higher slot fill factor than thick enamel or paper insulation, enabling smaller, lighter coil designs.
Production Process & Quality Control
1. Precision Conductor Preparation: High-purity copper/aluminum rod drawing to strict tolerance (±1μm).
2. Ultra-Clean Surface Treatment: Removes oil and oxide for perfect film adhesion.
3. Multi-Layer Film Wrapping: Tension-controlled (±1%) lapping with precise overlap (50–70%).
4. High-Temperature Curing: 280–350°C oven for seamless bonding.
5. AI Visual Inspection: 100% surface scan for pinholes, wrinkles, and foreign matter.
6. Electrical Testing: Dielectric strength, partial discharge, and insulation resistance tests.
Primary Applications
- Dry-Type Air Core Reactors: High voltage, low loss
- EV & Industrial Inverters: High frequency, corona resistance
- Wind Power Generators: Long-term reliability
- Aerospace & Defense Coils: Extreme environment
- Medical Equipment: High precision, low noise
Packing & Logistics
- Spools: Wooden / Plastic / Anti-static
- Outer Packaging: IPPC Wooden Pallets / Export Crates
- Protection: Moisture-proof film + shock-absorbing foam
- MOQ: 1 Ton
- Lead Time: 2–4 Weeks (Standard) | 1–2 Weeks (Urgent)
Frequently Asked Questions
Q: Can you customize insulation thickness?
A: Yes, 25μm to 100μm available per request.
Q: What is the maximum voltage rating?
A: Up to 20kV depending on insulation thickness.
Q: Do you provide corona-resistant grades?
A: Yes, specially treated film for high-frequency inverter use.
Q: Are free samples available?
A: Yes, standard samples free (customer pays freight).
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