Rectangular Magnet Wire
Rectangular Magnet Wire | Enamelled Rectangular Copper Wire
Enamelled rectangular copper wire is a specialized winding conductor designed for high-density electrical coils. It features an oxygen-free copper conductor coated with thin, high-dielectric enamel insulation. This flat configuration is engineered for power transformers, electric motors, generators, and heavy-duty inductors requiring optimal space utilization and thermal management.
Specifications of Rectangular Magnet Wire
|
Parameter |
Specification |
|
Conductor Material |
High-conductivity oxygen-free copper (OFC / ETP) |
|
Conductor Shape |
Rectangular with controlled corner radius |
|
Width Range |
2.00 mm – 16.00 mm |
|
Thickness Range |
0.80 mm – 5.60 mm |
|
Width-to-Thickness Ratio |
1.5:1 to 8:1 |
|
Conductor Tolerance |
According to IEC 60317-0-2 / NEMA MW 1000 |
|
Insulation Type |
Polyurethane, Polyesterimide, Polyamide-imide (PAI) |
|
Thermal Class |
Class 155°C (F), 180°C (H), 200°C (C), 220°C |
|
Insulation Thickness |
Grade 1 (Thin), Grade 2 (Thick), or Custom Build |
|
Breakdown Voltage |
Up to 5,000V (subject to insulation grade & size) |
|
Elongation |
≥ 30 % (size dependent) |
|
Flexibility / Adhesion |
Mandrel bend & stretch test per IEC standards |
|
Surface Finish |
Smooth, uniform coating free of pinholes or streaks |
|
Standard / Test Method |
IEC 60317, NEMA MW 1000, JIS C 3202 |
Conductor Materials and Sizes
Oxygen-Free Copper Conductors
High-purity ETP/OFC copper provides maximum electrical conductivity, minimizing resistance losses and thermal dissipation issues in tight winding layouts.
High-Density Cross Section
Flat copper profiles eliminate the dead air space inherent to round wires, substantially increasing the slot fill factor in transformer slots and motor stators.
Custom Dimensioning
Conductor dimensions, aspect ratios, and edge radii are produced to precise customer drawings to prevent insulation damage during automated coil winding.
Enamel Insulation Options
Thermal Class Flexibility
Insulation systems range from Class 155°C to 220°C, matching distinct operational temperature demands across standard transformers and traction motors.
Insulation Build Selection
Single, dual, or composite layers (such as Polyesterimide overcoated with Polyamide-imide) offer tuned dielectric strength and chemical oil resistance.
Electrical Dielectric Integrity
Uniform film application provides high voltage breakdown strength and prevents inter-turn short circuits under peak surge loads.
Mechanical & Abrasion Resistance
The outer enamel coating resists cracking, peeling, and mechanical scraping during high-tension, fast-paced coil-forming operations.
Manufacturing Process
Conductor Forming & Precision Drawing
Continuous drawing and precision rolling shape raw copper into exact rectangular profiles with uniform corner radii and tight dimensional tolerances.
In-Line Annealing
Controlled thermal annealing relieves mechanical stress, achieving high elongation values and soft copper properties necessary for smooth bending.
Multi-Pass Enamelling
The rectangular profile passes through precision enamel applicators multiple times, building up thin, defect-free dielectric layers.
Thermal Curing & Polymerization
Vertical curing ovens precisely control temperature profiles to fully polymerize the enamel, establishing permanent mechanical adhesion and thermal durability.
Spool Rewinding & Packaging
Finished wire passes inline pinhole detection before automated rewinding onto spools with controlled tension to prevent surface friction damage.
Quality Control & Testing
Dimensional Inspection
Laser micrometers continuously monitor width, thickness, and aspect consistency to maintain compliance with tight tolerance limits.
Electrical Continuity & Dielectric Testing
In-line spark testing and batch breakdown voltage checks verify insulation continuity and eliminate pinhole defects across the spool length.
Mechanical Integrity Testing
Mandrel wrapping, spring-back evaluation, and elongation tests verify that the copper conductor and enamel coating withstand extreme bending stress.
Thermal & Chemical Testing
Heat shock testing and solvent resistance assays confirm long-term stability when exposed to high operating temperatures and transformer oils.
Electric Motors & Traction Drives
Used in stators and rotors where flat wire maximize power density and heat dissipation within compact motor housings.
Power & Distribution Transformers
Applied in heavy-duty low-voltage and high-voltage transformer coils to handle mechanical short-circuit forces and high electrical currents.
Industrial Inductors & Reactors
Integrated into high-power inductors and choke coils requiring minimum copper losses at elevated operational frequencies.
Power Generators
Essential for utility-scale and industrial generator windings that require high dielectric reliability and structural rigidity.
Advantage of Rectangular Configuration
Maximized Slot Fill Factor
Flat wires eliminate vacant voids between turns, boosting the overall conductor mass inside the coil slot by up to 30% compared to round wire.
Superior Thermal Conduction
Flat surface-to-surface contact between adjacent turns allows heat to transfer efficiently out of the coil structure, reducing hot-spot temperatures.
Enhanced Structural Rigidity
Rectangular windings form a solid, compact block that resists physical deformation caused by electromagnetic forces during power surges.
Custom Rectangular Magnet Wire
Tailored Cross-Section Ratios
Custom width, thickness, and edge corner radii produced to exact technical drawings and winding geometries.
Specific Insulation Coatings
Choice of single or multi-layer enamel chemistry paired with exact thermal class ratings for specialized operating environments.
Custom Spooling & Packaging
Flexible delivery options, including varied spool types, continuous lengths, and protective moisture-proof packaging.
Packaging, Delivery and Supply
Precision Spool Packaging
Wound on plastic or wooden spools with controlled tension to prevent tangling or surface damage during high-speed unwinding.
Environmental Protection
Each spool is wrapped in protective plastic film with desiccant and secured in wooden crates to prevent moisture exposure and transit impacts.
Traceable Batch Marking
Clear labeling includes conductor size, insulation grade, thermal class, tare weight, net weight, and production batch numbers for full traceability.
Technical Information Buyers Should Provide
Conductor dimensions (Width × Thickness) and acceptable tolerance ranges
Required enamel material and dielectric thermal class rating
Insulation build thickness (Grade 1 or Grade 2)
Minimum required breakdown voltage
Preferred spool sizes, maximum reel weight, and packaging specifications
Total required order quantity and delivery schedule
FAQ
As one of the leading rectangular magnet wire manufacturers and suppliers in China, we warmly welcome you to buy advanced rectangular magnet wire made in China here from our factory. All customized products are with high quality and competitive price. Contact us for quotation.
