Self-Bonding Enamelled Flat Wire

Self-Bonding Enamelled Flat Wire for Motor, Transformer and Inductor Windings

Self-bonding enamelled flat wire combines a rectangular copper conductor with an insulated enamel system and a bondable outer coating. After winding, the bondable layer activates to hold adjacent turns together and form a mechanically stable coil structure.

Product Range by Thermal Class

Class 180 (Polyurethane System)

Suitable for standard thermal requirements with versatile heat or solvent activation options.

Class 200 (Composite System)

Balances high thermal resistance with superior mechanical flexibility and dielectric strength.

Class 220 (Thermoplastic System)

Designed for heavy-duty coils requiring precise structural integrity after thermal bonding.

Class 240 (Polyimide System)

Provides maximum heat resistance for severe operating environments.

Technical Specifications

Parameter	Available Specification
Conductor Shape	Rectangular / Flat Copper
Width Range	0.50 – 7.00 mm
Thickness Range	0.08 – 1.60 mm
Thermal Class	180°C / 200°C / 220°C / 240°C
Breakdown Voltage	>= 700 V (Class 200)
Thermal Shock	>= 220°C (Class 200)
Elongation	>= 30%
Minimum Insulation	0.01 mm (Single side)
Compliance	NEMA / IEC / JIS / Standard Specifications

Conductor and Insulation Architecture

Flat Geometry

Maximizes surface area within tight slot designs, significantly improving fill factor compared to round wire.

Multi-Layer Insulation

Offers UEW, EI-AIW, AIW, and PIW configurations to meet specific dielectric strength targets.

Bondable Overcoat

Eliminates secondary varnishing or mechanical bracing by self-fusing adjacent turns.

Bonding Activation Methods

Heat Bonding

Uses precise temperature exposure during or after winding to soften the outer layer, forming a solid structure upon cooling.

Solvent Activation

Utilizes compatible liquid agents on Class 180 wires to activate the adhesive coating without thermal exposure.

Coil Stabilization

Prevents turn displacement under high dynamic shock, vibrational loads, or magnetic stress.

Key Industrial Applications

EV Traction Motors

Provides rigid, high-density stator windings capable of enduring rapid acceleration forces.

Servo & Spindle Motors

Maintains tight spatial tolerances and dimensional consistency for precision rotational equipment.

OBC Transformers

Integrates high thermal resistance with compact geometry in vehicle charging modules.

High-Frequency Inductors

Delivers stable magnetic properties and lower power loss in compact designs.

Quality Control and Testing Standards

Electrical Verification

Every production batch undergoes dielectric breakdown voltage and insulation continuity tests.

Mechanical Validation

Strict limits on elongation percentages and bend performance protect enamel during high-speed winding.

Thermal Endurance

Accelerated aging and thermal shock testing confirm insulation stability across operational ranges.

Custom Manufacturing Capabilities

Dimensional Customization

Precision cross-sections tailored to specific slot fill requirements.

Insulation Build

Single or multi-pass enamel thickness optimized for distinct voltage stress.

Packaging Solutions

Delivered on standard bobbins (P-5, P-10, P-30) or specialized reels for smooth dereeling.

FAQ

Q: How does self-bonding wire simplify the manufacturing process?

A: It eliminates secondary liquid varnishing and curing steps by bonding adjacent turns through heat or solvent post-winding.

Q: Which activation method is best for rectangular magnet wire?

A: Heat activation is standard for high-temperature classes (200°C–240°C), while solvent activation suits specific Class 180 applications.

Q: Why choose flat enamelled wire over traditional round wire?

A: Flat conductors maximize space utilization in winding slots, increasing current density and heat dissipation while reducing component size.

Q: What insulation systems can be combined with self-bonding overcoats?

A: Base coats include Polyurethane (UEW), Polyesterimide (EI-AIW), Polyamide-imide (AIW), and Polyimide (PIW).

Q: What dimensions can be specified for high-density coil designs?

A: Conductor widths range from 0.50 to 7.00 mm and thicknesses from 0.08 to 1.60 mm, with custom insulation starting at 0.01 mm per side.

Q: What international standards do these products meet?

A: All configurations conform to standard IEC, NEMA, and JIS requirements for electrical insulation and mechanical tolerances.

Request Custom Specifications and Engineering Support

Upgrade your coil efficiency with high-precision self-bonding magnet wire. Contact our technical engineering team today to receive detailed technical datasheets, request samples, or obtain a tailored quotation for your custom dimensional requirements.

Request a Technical Quote

As one of the leading self-bonding enamelled flat wire manufacturers and suppliers in China, we warmly welcome you to buy advanced self-bonding enamelled flat wire made in China here from our factory. All customized products are with high quality and competitive price. Contact us for quotation.