What is Enamelled Wire
Enamelled wire has a very thin layer of
insulation or enamel. The wire is typically copper or aluminum, while the
insulation is either a thin varnish or a polyester or fiberglass yarn.
Applications
Enamelled wire is used in applications
which require tight coils of wire, in applications such as inductors, motors,
speakers, hard disk head actuators, or electromagnets.
Most enamelled
wire will be copper, but aluminum is also used in certain applications, such as
large transformers and loudspeaker coils.
There are
numerous reasons that copper is the most widely used metal in enameled wire.
Copper is the
highest electrical conductivity of all non-precious metals. Because it has a
lower conductivity than copper, aluminum wire requires a cross section that is
1.6 times larger for it to create the same current capability as a copper wire,
making copper wire more energy efficient aluminum wire.
Copper is also
300% stronger than aluminum, allowing it to withstand more extreme conditions.
Shape
Common
shapes for enameled wire are square, round or rectangular.
The shape
of the wire will determine how tightly the wire can be coiled. Square copper
wires, for example, will be wound tighter since they have less space between
the turns when they are formed in a coil. For this reason, they are often used
in confined spaces and in applications where higher power is required.
Rectangular
copper wires can be wound even tighter. They are arranged in a plane and then
laminated into a flat ribbon. Rectangular copper wire is used on edge-wound
spring coils.
Round
wire, on the other hand, will have more space between the wires and cannot be
wound as tightly due to its shape.
There are
also hexagonal wires available; they are used in voice coils.
Color
The color
of enameled wire has no bearing on the wire itself. It is purely aesthetic, and
neither the insulation, nor any other element of how the wire will function,
will be impacted. Wires can come in a variety of colors, including red, green
and amber.
In cases
where a certain wire color is preferred, some manufacturers will provide
customers with a wire in that specific color.
Insulation
Insulation
serves to enhance the thermal endurance of the wire and is used to protect the
wire from shorting out by coming in contact with itself. Insulation is
especially important for coils that requires hundreds, possibly thousands, of
wire turns.
Square or
rectangular wires that have insulations that are thicker than average can
sometimes come with an additional high-temperature polyimide or fiberglass
tape. The strength and long-term reliability of the winded wire are improved by
an extra insulating varnish.
Different
insulation types will have different thermal capacity, diameter (which can be
measured in millimeters or inches), AWG wire size and application.
Polyester
and polyurethane are popular insulations, but there are many different types of
insulation to chose from, including:
·
Polyester-imide has
high thermal endurance and solvent resistance. It also has good windability due
to a low friction.
·
Polyamideimide is
designed to be used in inverter duty applications and motors that may
experience voltage spikes.
·
Formvar: is
very flexiable and has high resistance to abrasion.
·
Polyester Nylon is
a dual coat insulation, with a polyester basecoat and a nylon topcoat. The
polyester has high thermal properties and the nylon provides high mechanical
properties.
·
Polyester-amide-imide is
a dual coat insulation, which has a polyester basecoat and an amide-imide outer
coating. This insulation provides the wire with increased windability, heat
shock resistance and increased overload capacity. Polyester-amide-imide also
has an increased chemical resistance to most solvents and insulating varnishes.
·
Dacron glass a
served filament that is available either unvarnished or varnished with silicon
or organic material. Dacron glass is a combination of glass and polyester
fibers. It has improved flexibility and is abrasion resistant.
·
Polyamide-ML is
made of polyimide resins. Good resistance to chemical solvents and burnout.
Typically used in extreme conditions given its high ability to withstand
overload and ability to not be affected by exposure to varnish solvents.
Older
insulation materials used to be made of things like cotton, paper, or silk.
These are only useful for low-temperature applications with a thermal rating of
105°C.
Large
power transformers that operate at high voltages may be insulated by
oil-impregnated paper or pressboard, examples of electrical insulation paper.
The wires
offered by Double Feather come with a polyurethane insulation.It will have a
thermal rating of 155°C.180 °C, Double Feather also offers wires with a
polyester-imide insulation that comes overcoated with polyamide-imide. This
wire has a thermal rating of 200°C.
Wire Gauge
The
American wire gauge (AWG) rating of the wire, used in the U.S. and Canada,
represents specific characteristics of round wire, such as diameter, resistance
and current.
As the
wire diameter decreases, the AWG number will increase. For instance, wire with
a diameter of 5.827 millimeters will have an AWG size of 3, while a wire with a
diameter that measures 0.101 millimeters will have an AWG size of 38.
There are
44 standard wire gauges in total, that range from 0000 to 40. The 0000 gauge
wire will have a diameter of 11.684 mm, while the 40 gauge wire has a diameter
of 0.0799 mm.
Weight
Wire
weight will also be based on AWG standards and will have an inverse
relationship with the gauge, meaning as the gauge becomes greater, the weight
of the wire will decrease.
The 0000
gauge wire will have a weight of 640.5005 lbs per 1000 feet, while the 40 gauge
wire has a weight is 0.0299 lbs per 1000 feet.
Temperature Rating/Thermal Class
The
temperature of the wire at which it will have a 20,000 hour service life is
called the thermal class, or temperature rating. The service life of the wire
can be extended by using the wire at a lower temperature.
Thermal
class is measured in degrees celsius. 130°, 155°, 180° and 200° are some common
temperatures found in different types of insulation.
Bondable Enamelled Wire
Wire that
contains an extra adhesive film, which can be epoxy, polyester or polyamide, on
top of the usual insulation that activates when heated up is called bondable
wire. The turn to turn windings of the wire will bond into a coil that is
self-supporting, eliminating the need for the spindles around which the wire is
wound, called bobbins.
There are
three main types of bonding: solvent, oven and resistance.
A solvent
bonding coat will be applied while the wire is winding, or else the completed
coil will be dipped in a solvent once the winding has completed.
During
oven bonding, the wire is fully wound and then put into an oven. Depending on
the size of the coiled wire, oven bonding time can range from 10 to 30 minutes.
Resistance
bonding uses an electric current to bond the completed windings. The size of
the wire and the design of the coil will determine how long it will take to
complete the process. Resistance bonding is used for wire sizes 34 gauge or
higher.
Soldering Process
The
enamelled wire will eventually need to be soldered, which is the process in
which two metals are fused together by a third metal. The third metal will be
melted down and then resolidify to join the other two metals together.
Older
wire might require the insulation to be removed first before the wire can be
soldered, but the majority of wire being made now will not require its enamel
to be removed before being soldered, as the insulation will act as a flux when
burnt.
Breakdown Voltage
The
dielectric strength of the enamel insulation of the wire is also known as the
breakdown voltage.
There are
three types of breakdown voltage: Grade 1, Grade 2 and Grade 3. The breakdown
voltage grade will increase with thicker insulations. Breakdown voltage is
based on AWG standards, with smaller gauges having higher breakdown voltages.
The
insulation thickness, or build, is the measurement of the enamel, which can be
calculated by subtracting the total diameter of the wire from the total
diameter of the insulation and wire together.
Insulation
build can be single, heavy, triple or quadruple. Single and heavy are the most
common.
Where can I buy Enameled Wire?
View the
enameled wire selection from double feather cable by clicking the links below.
We have wires in numerous different gauges, temperature ratings and
insulations. Find your enameled wire at double feather today!
Enameled
Round Aluminum Wire
Diameter
Range(mm):0.13-5
Temprature
Class:130,155,180,200,220
Standard:IEC,NEMA,GB,JIS
Color:natural
color,red,blue,green and so on
UL NO:E320132
Package:
PT15 PT-25 PT-30 PT-60 PT-200 .
Bobbin/Spool
also according to customer requirements
Introduce of
Enameled Round Aluminum Wire:
Enamelled
aluminum magnet wire is mainly used as an electrical conductor wherever coils
are in motion.
Enamelled
aluminum magnet wires are available in diameters from 0.13 mm to 5mm(SWG4-39;AWG4-35),
with all
insulation and self-bonding enamel types.
In addition,
our enameled aluminum magnet wire also reached many Production Standards, such
as IEC/NEMA/IIS/GB.
We also can
provide many more certification,such as UL,SGS,ISO14001,ROHS and soon.
Features of
Enameled Round Aluminum Wire:
Low density
allows coil weight reduction
Rapid heat
dissipation
High cut
through
Excellent
heat shock
Perfect
breakdown voltage
High heat
resistance
Good solvent
resistance
Application
of Enameled Round Aluminum Wire:
Transformers/Heat-resistant
motors/UPS Power source/Generators/Refruigerating system; Other electrical
devices in the coil windings
Specifications
of Enameled Round Aluminum Wire:
Enameled:Polyester
| Modified Polyester | Polyester-imide /Polyamide-imide
Type:PEW/130 PEW/155
EIW/180 EI/AIW/200/220
Degree class
:130 155 180 200 220
Insulation
Grade1/Grade2/Grade3
Standard:IEC,NEMA,JIS,GB
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