Enameled micro flat wire

In connection with the miniaturization with enameled micro flat wires we could prove:

• Weight savings of up to 10%
• Installation space savings in the range of 8%
• Increases in the copper filling factor by 8%
• Significant improvement of the heat conduction properties were shown in various customer applications.

 

Bruker-Spaleck production technology enables highly accurate cross-section geometry over long wire lengths:

• Particularly when compared to the wires available on the market with large cross sections
• This is associated with major advantages in the further processing of the wire (positioning and handling)
• Measurements have shown that only 5% of the cross-sectional area is lost due to the corner radius
• In addition to copper as the base material, the alternative material aluminum can also be produced at a lower material price

 

Wire materials

• Copper and aluminium, as well as your specific alloys

 

Enameled micro wire

• Market innovation
  - Originally used in stationary transformer construction
  - In e-mobility, this wire is relevant for hairpin motors for traction drives
  - Dimensions from dmin∙bmin  = (0.80∙2.00) mm² are available on the market
• Dimensions in the range t = 0,030 ... 1,500 mm / w = 0,500 ... 5,000 mm possible
• All common coating types are available

Dimension range

• Thicknesses between 0,030 – 1,500 mm
• Widths between 0,500 – 5,000 mm

 

Enamel versions and characteristics

Coating type1		Temperature index / operating temperature	Thermal shock in °C	Comments
Polyurethane	V155	≤ 157	190	Excellent tinning, high thermal strength
	V180 / V190	≤ 180 / 200°C	220 / 230	Good tinning, high heat resistance, pinhole resistant
Polyesterimide	W180V	≤ 194°C	230	Tinning possible, high thermal resistance
	W200	≤ 205°C	240	Very high thermal resistance
Polyersterimide with polyamide top layer	W210	≤ 210°C	250	Very good mechanical, chemical and thermal properties
Polyamideimide	W220	≤ 220°C	270	Thermal and chemical resistance even higher than W210
	W240PAI	≤ 240°C	280	Ultimate thermal resistance with series wires
Polyimide	W240	≤ 240°C	300	Special product with highest thermal and chemical resistance
1All wires also available with baked enamel coating

 

Further properties:

• Low number of high voltage defects
• Discharge voltages: V to kV range (→ Depending on coating thickness and coating selection)
• Normalized breakdown voltage due to coating thickness in the range 80…140°V/µm → measured against a cylindrical coil
• Functional layer construction

 

Flat wire with natural edge

Conventional roll stands deliver a natural edge on the wire (cross sectional view)

 

Rectangular cross section

Four roller stand enables production of an almost rectangular cross section

 

 

Projects

In numerous samplings from various customers, the following added value could be achieved in the applications:

• Installation space savings through higher copper filling factor
• Defined winding pattern enables new product features such as direct cooling
• Enameled micro flat wire minimizes losses due to current electrical displacement

Quality meets automotive standards:

• Highest dielectric strength
• Minimized number of errors

We are happy to assist you as a competent partner in the product development of your customer-specific flat wire dimensions, enamel versions or layer thicknesses.

 

Form of delivery

• Merchantable standard spools/coils or special requirements after consultation on customer request