HB-AIW/220 is a polyamide-imide (AIW) base with a thermosetting bond coat that holds bond strength at the full 220 °C thermal class. Class 220 thermoset self-bonding - engineered for oil-cooled rotors and high-speed servo motors that have to keep their bond strength at full operating temperature.
Description
HB-AIW/220 is built on a pure polyamide-imide (PAI) base - the same AIW chemistry that has powered industrial traction motors for years - finished with a thermoset bond coat. Where thermoplastic self-bonding wires soften and lose integrity above 180 °C, HB-AIW/220's cross-linked bond retains strength through the full Class 220 thermal index.
Its class 220 endurance and outstanding refrigerant and scrape resistance made it the workhorse of premium magnet wire.The product is positioned squarely in the 'high-temperature + self-supporting' quadrant that is now driving every new EV traction platform: the hairpin-ization and oil-cooling directly pull its demand; the low-altitude economy (eVTOL propulsion, drone motors) and humanoid joint motors (concentrated windings of frameless torque motors) open further headroom. Technology directions include faster-setting bond coats at lower temperature (reducing thermal shock to the base film), hybrid insulation systems combining bonding with targeted impregnation, and ultra-fine self-bonding flat wire (0.02-0.10 mm).
Use HB-AIW/220 when your application cannot rely on a varnish dip-bond process: high-performance EV traction motors, oil-cooled rotor and stator windings, high-temperature solenoids and ignition coils operating at 180–220 °C, aerospace and automotive actuators subject to sustained centrifugal force, and premium industrial servo and spindle motors.
The wire is SGS- and UL-certified; dimensions follow NEMA MW1000, the IEC 60317 series and GB/T 7095; custom specifications on request.
Features
- 220 °C thermoset bond strength - Class 220 base + thermoset cross-linking bond; far higher bond strength at temperature than thermoplastic self-bonding wires; suitable for 180–200 °C long-term duty.
- Hairpin-grade rectangular profile - flat cross-section maximises slot-fill; width 0.50–7.00 mm, thickness 0.08–1.60 mm; minimum insulation 0.01 mm single-side.
- It exhibits good adhesion to the underlying PAI insulating layer while maintaining the full 220°C thermal class rating, with no softening observed at high temperatures after bonding.
- Vibration reliability for high-speed rotors - turn-to-turn bonding withstands strong vibration and centrifugal force; reduces NVH complaints in high-speed EV rotors.
- High mechanical strength at temperature - thermoset bond does not soften; coil geometry stays precise under continuous high load.
- Refrigerant + oil + chemical compatibility - stable in R134a and R1234yf refrigerant immersion; survives 200 °C continuous oil contact in rotor cooling.
- Primarily used in high-performance new energy traction motors, oil-cooled motors, as well as industrial motors and transformers operating in high-temperature environments
- Standards coverage - GB/T 7095.5–7, IEC 60317 series, NEMA MW1000, JIS, or custom.
Specifications
Product Dimensions and performance standards
Products Size Range: Wide: 0.50-7.00mm Thickness: 0.08-1.60mm Minimum Insulation Thickness: 0.01mm(Single Side)
| HB-AIW (Class 220) | |||||
| Base insulation | Polyamide-imide | ||||
| Thermal Class | 220 | ||||
| Thermal Shock Temperature | ≥240℃ | ||||
| Breakdown Voltage | ≥700V | ||||
| Elongation | ≥30% | ||||
| Bond strength | ≥0.3 N | ||||
| Bondability | Self-bonding | ||||
| Solderability | Non-solderable | ||||
| Compliance | NEMA MW1000 / IEC 60317 series / GB/T 7095 | ||||
| Certification | SGS- and UL-certified | ||||
Manufacturing Scope of Flat Wire
Certificate
The product has been certificated by SGS and UL
Application
Telison's HB-AIW/220 is primary used in high-performance new energy traction motors, oil-cooled motors, high-speed motor rotor windings：
- EV traction motors.
- Oil-cooled EV rotor & stator - bond strength stable after continuous 200 °C oil immersion; preserves rotor balance.
- eVTOL / drone propulsion motors - low-altitude economy segment.
- Humanoid robot joint motors - concentrated windings in frameless torque motors.
- High-temperature solenoids & ignition coils (180–220 °C) - replaces traditional Class H wire with self-bonding advantage.
- Downhole-tool electromagnetic coils, aerospace and automotive actuators.
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