Class 240 Self Bonding Enamelled Flat Wire

From cryogenic lows to 400°C peaks - HB-PIW is our Class 240 polyimide self-bonding flat wire, the only series member that holds dielectric strength under radiation, vacuum and thermal shock together.From cryogenic lows to 400°C peaks - HB-PIW is our Class 240 polyimide self-bonding flat wire, the only series member that holds dielectric strength under radiation, vacuum and thermal shock together.

HB-PIW sits at the top of Telison's self-bonding pyramid. Its base is a polyimide enamel film - long called the 'king of synthetic materials' - finished with an additional high-temperature thermosetting bond coat. The combined system delivers a thermal index of 240 °C (Class C in IEC 60085), short-term thermal-shock tolerance above 260 °C, and dielectric strength retained across the full temperature spectrum from cryogenic to ultra-high.

For more than three decades, designers needing a self-supporting coil above Class 220 had no commercial option. HB-PIW was developed to close that gap. It is the only magnet wire in our catalog that meets three harsh-environment stresses at the same time: radiation dose, vacuum outgassing, and cryogenic-to-400 °C thermal cycling. Polyimide's radiation resistance is documented in insulation-engineering literature as far superior to polyester / polyurethane equivalents; combined with the impregnation-free self-supporting construction, the result is a coil that needs no varnish bake, no bobbins, and no tie-wraps.

Telison's HB-PIW is primarily designed for the aerospace and military industries, as well as applications in particularly harsh environments. Use HB-PIW when the application fails if any of the following fails: a satellite's attitude-control reaction-wheel motor, a reusable-rocket electromechanical actuator, an eVTOL propulsion motor at high altitude, a fusion-reactor electromagnetic winding in intense radiation, or a semiconductor-equipment heating coil operating in clean-room vacuum.

The wire is SGS- and UL-certified; dimensions follow NEMA MW1000, the IEC 60317 series and GB/T 7095; custom specifications on request.

• Ultimate Thermal Resistance: Temperature index as high as 240°C (Class C), the only series member to reach IEC 60085 Class C, with breakdown voltage ≥700 V and thermal-shock ≥260 °C.
• Outstanding cryogenic performance: Covering applications across the full temperature spectrum from deep cryogenic to ultra-high temperature,film and bonding remain stable
• Superior Radiation Resistance: Under equivalent irradiation doses, the electric strength retention of polyimide insulation is far superior to conventional insulation materials such as polyester and polyurethane. 
• Three-dimensional cross-linked bond coat - thermosetting resin forms a 3D network after cure, enhancing solvent / oil resistance on top of the already chemically stable base.
• Eliminating the impregnation process means no solvent baking stage, shortening production cycles and reducing energy consumption

• Impregnation-free, bobbin-free - self-supporting coil architecture removes bobbins, formers, clamps and tie-wraps; shorter cycle, lower energy, no VOCs.

• Primarily designed for the aerospace and military industries, as well as applications in particularly harsh environments involving high temperature, high humidity, chemical corrosion, and severe vibration
• Standards coverage - GB/T 7095.5–7, the IEC 60317-27/28/29 family, NEMA MW1000, JIS, or custom.

Products Size Range: Wide: 0.50-7.00mm Thickness: 0.08-1.60mm Minimum Insulation Thickness: 0.01mm(Single Side)

Manufacturing Scope of Flat Wire

The product has been certificated by SGS and UL

Telison's HB-PIW is primarily designed for the aerospace and military industries, as well as applications in particularly harsh environments：

• Space economy: satellite attitude-control & reaction-wheel motors, probe flywheel windings, antenna drives.
• Aerospace: reusable-rocket electromechanical actuators, TWT / magnetron magnet windings.
• eVTOL / electric aircraft: high-power-density propulsion motors requiring low-pressure, lightweight, impregnation-free coils.
  Frontier tech: humanoid-robot joints under extreme duty cycles; fusion / Gen-IV nuclear electromagnetic components.
  Premium industrial: semiconductor-equipment heating coils in clean-room vacuum, high-speed high-temperature spindle motors.

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