Core Indicators of Magnet Wire: Why is insulation so important?

The insulation of magnet wire is one of its core performances, which is directly related to the safety and working efficiency of the equipment. As an important material for transmitting electrical energy, the insulation performance of magnet wire must not only meet the needs of ordinary use, but also cope with complex working environments. The insulation of magnet wire mainly comes from the insulating paint film on its surface.

The following are several core elements to achieve high insulation performance:

High-quality insulating paint materials

Common insulating paint materials such as polyester and polyamide-imide have high resistivity and excellent breakdown resistance.

The insulation performance of the paint film can be further improved by improving the molecular structure and adding functional fillers.

Uniform paint film thickness

The paint film thickness needs to be uniform during the coating process to avoid electrical weaknesses caused by insufficient thickness.

The integrity of the paint film can be ensured through multiple coatings and precise curing processes.

Stable adhesion

The paint film must be firmly attached to the conductor surface to prevent the paint film from falling off due to mechanical vibration or thermal expansion and contraction.

The use of surface treatment techniques (such as cleaning and annealing) can enhance the adhesion of the paint film.

Test methods for insulation of magnet wire

Dielectric strength test:

Test the breakdown resistance of magnet wire under high voltage to ensure that it does not fail in insulation within the working voltage range.

Generally, the breakdown voltage value of the paint film is determined by gradually increasing the voltage.

Insulation resistance test:

Measure the insulation resistance at both ends of the magnet wire to reflect the resistivity of the paint film.

High insulation resistance value indicates that the paint film has excellent insulation performance.

Thermal shock test:

Put the magnet wire in a high temperature environment and observe whether the paint film cracks or peels off.

This test is used to evaluate the stability of the insulating paint film in temperature changes.

Aging test:

Continuously operate in a high temperature, high humidity or high voltage environment to simulate long-term use conditions and detect changes in the insulation performance of the paint film.

Technical measures to improve insulation

Optimize coating process:

Use multi-layer coating technology to ensure that each layer of paint film is evenly distributed and free of bubbles.

Introduce automated equipment to improve coating accuracy and efficiency.

Develop new insulating materials:

Develop nano-composite paint to improve the electrical properties and mechanical strength of the paint film by adding nanoparticles.

Use environmentally friendly solvent-free paint to reduce the impact of volatile organic compounds on the environment.

Strengthen quality inspection:

Introduce online inspection technology on the production line to monitor the thickness and uniformity of the paint film in real time.

Use advanced testing equipment to quickly screen out magnet wires with insulation defects.