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Enameled wire, or enameled wire, is a kind of insulated electromagnetic wire with a metal conductor as the core, coated with multiple layers of polymer insulating varnish and cured at high temperature. It is the core raw material of winding electrical components, mainly used to realize current conduction and electromagnetic induction energy conversion. Unlike ordinary insulated wires, enameled wire has a very thin, uniform, strong adhesion, high pressure resistance, high heat resistance, high flexibility, and can meet the stringent requirements of precision winding, dense arrangement, and high-speed alternating work.
The overall structure of Enameled wire is divided into two layers: the internal metal conductor assumes the function of electrical conductivity, and the external varnish assumes the function of electrical insulation, short-circuit-proof, oxidation-proof and corrosion-proof protection. In the working process of motors, transformers and all kinds of electromagnetic equipment, enameled wire needs to continuously withstand multiple stresses such as energized heat, high-frequency electric field, mechanical pulling, vibration and friction, and temperature alternation, etc. Therefore, the material formula of enameled film, the precision of coating, and the curing process directly determines the stability, efficiency, and service life of the electrical equipment.
According to the conductor material, insulation system, temperature resistance level and cross-section form, enameled wire can be divided into a number of sub-categories, of which the most widely used industrial applications, the highest technical value for the enameled copper wire, enameled aluminum wire, high-temperature-resistant special enameled wires and new energy special rectangular enameled wire.
| Classification Category | Types | Characteristics & Applications | Common Standards (IEC 60317) |
|---|---|---|---|
| Conductor Shape | Round | Most common, easy to wind | – |
| Conductor Shape | Rectangular / Flat | High fill factor, better heat dissipation | 60317-0-2 |
| Insulation Thickness | Grade 1 (Thin) | Highest copper fill, lower breakdown voltage | – |
| Insulation Thickness | Grade 2 (Medium) | Best balance, most commonly used | – |
| Insulation Thickness | Grade 3 (Heavy) | Highest breakdown voltage | – |
| Thermal Class | 155°C (Class F) | General industrial | – |
| Thermal Class | 180°C (Class H) | Standard motors & transformers | – |
| Thermal Class | 200°C (Class N) | Modern EV motors, high reliability | – |
| Thermal Class | 220–240°C+ | Extreme high-temperature applications | – |
| Insulation Material | Polyurethane (PU) | Solderable, lower temperature | 60317-13 etc. |
| Insulation Material | Polyesterimide (PEI) | Good cost-performance, 180°C | 60317-25/26 |
| Insulation Material | PEI + PAI | Excellent overall performance, 200–220°C | 60317-27/29 |
| Insulation Material | Polyimide (PI) | Highest temperature rating | 60317-40/44 |
| Special Types | Litz Wire | High-frequency, reduces skin effect | – |
| Special Types | Self-Bonding Wire | Coils can be heat-bonded | – |
| Special Types | Paper Covered / Fiberglass Covered | High-voltage, large transformers | – |
High temperature enameled wire is a special enameled wire specially developed for equipment with high temperature accumulation, frequent temperature rise and poor heat dissipation. Ordinary conventional enameled wire temperature resistance level of 130 ℃, 155 ℃, only for room temperature, frequency, low load conditions. The high temperature enameled wire can reach 180℃, 200℃, 220℃ and above, which belongs to H class and above ultra-high heat-resistant insulated wire.
Temperature-resistant grade is optional: 180℃/200℃/220℃ full gradient products to meet the temperature rise requirements of different equipment;
Extra-long thermal life: insulation does not deteriorate or chalk under high temperature environment, suitable for long-term continuous work equipment;
Multi-environmental resistance: resistant to refrigerant, oil immersion, heat and humidity, vibration resistance, suitable for closed, water-cooled, oil-cooled conditions;
Suitable for frequency conversion working conditions: resistant to high-frequency thermal shock, effectively reducing the risk of insulation failure of frequency conversion equipment.
High temperature enameled wire adopts high temperature resistant resin system, which has excellent thermal aging resistance, thermal shock resistance and high temperature insulation stability, and can maintain the integrity of the paint film and stable insulation performance under high temperature environment for a long time, and will not be degraded due to temperature alternation.
In addition to the basic heat resistance, the high-end high temperature enameled wire is also resistant to oil, hydrolysis, vibration and high frequency pulse, suitable for automotive oil-cooled motors, industrial high-temperature motors, hermetic transformers, high-power inverter equipment and other demanding scenarios, is the core of high-end industrial and new energy equipment supporting wire.
Enameled wire, as a basic core material for electromagnetic equipment, has formed a complete product system from general civil, general industrial to high-end new energy. Among them, enameled copper wire has become the mainstream base material in the industry with its excellent comprehensive performance, enameled aluminum wire realizes lightweight and low-cost support, polyesterimide enameled wire assumes the high-end general scene in the industry and rectangular flat enameled wire takes the lead in new energy EE. enameled wire is leading the technological upgrading of new energy EV motors. Different types of enameled wires are accurately adapted to the different working conditions of motors, transformers, vehicle electric drives, etc., which provide a solid guarantee for the efficient, stable and long-lasting operation of electrical equipment, and at the same time, continue to promote the iterative upgrading of the new energy automobile, electric power transmission, and high-end equipment manufacturing industries.
