Enameled Rectangular Aluminum Wire for transformer winding
Summary
Enameled rectangular aluminum wire is a specialized conductor designed for transformer winding applications, offering excellent electrical insulation, high thermal resistance, and lightweight characteristics. With its flat profile and enamel coating, this wire enhances transformer efficiency by optimizing space utilization and improving thermal dissipation. It is widely used in dry and oil-immersed transformers, power generators, and electrical machinery.
Introduction
Enameled rectangular aluminum wire is a crucial component in transformer winding, combining the cost-effectiveness and low weight of aluminum with the superior insulating properties of enamel. Compared to traditional round wires, the flat rectangular profile allows for more efficient coil arrangements, reducing air gaps and enhancing electrical performance. This wire type is designed to withstand high temperatures, transformer oils, and various industrial solvents, making it an ideal choice for demanding electrical applications.
Key Features and Specifications
Dimensional and Thermal Properties
The enameled rectangular aluminum wire is available in a wide range of dimensions and thermal classifications to meet different transformer requirements.
| Property | Specification |
|---|---|
| Thickness (a) | 0.8 – 8.0 mm |
| Width (b) | 2.0 – 22.0 mm |
| Thermal Class (°C) | 120, 180, 200, 220, 240 |
| Insulation Type | Polyester, polyester-imide, polyamide-imide |
| Standard Compliance | IEC 60317, NEMA, GB, JIS |
| Packing Options | 30kg-150kg plywood spool |
Enamel Insulation and Heat Resistance
The enamel coating provides excellent electrical insulation and mechanical protection. Depending on the thermal class, different insulation materials are used:
- Polyester (130°C – 150°C): Suitable for moderate thermal applications
- Modified Polyester (155°C – 175°C): Enhanced durability for high-performance transformers
- Polyester-imide (180°C – 200°C): Improved heat shock resistance for industrial applications
- Polyester-imide + Polyamide-imide (220°C and above): Superior insulation for high-temperature environments
Advantages of Enameled Rectangular Aluminum Wire in Transformer Winding
1. High Space Utilization and Winding Efficiency
The rectangular shape allows for tighter coil packing, reducing gaps in windings and enhancing the efficiency of magnetic flux distribution. This results in:
- Reduced energy losses
- Improved transformer performance
- Lower resistance and optimized electrical conductivity
2. Lightweight and Cost-Effective Alternative to Copper
Compared to enameled copper wire, aluminum wire offers:
- Significantly lower weight, reducing the overall weight of transformers
- Lower cost, making it a budget-friendly solution without compromising performance
3. Superior Thermal and Chemical Resistance
Enameled rectangular aluminum wire is engineered to withstand:
- High operating temperatures, maintaining insulation integrity under heavy loads
- Exposure to transformer oils and solvents, preventing degradation over time
4. Excellent Mechanical Strength and Durability
Despite being lightweight, aluminum wire exhibits excellent tensile strength, reducing the risk of breakage during winding. The enamel coating further enhances:
- Abrasion resistance
- Protection against moisture and environmental factors
Applications in Transformer Winding and Electrical Equipment
1. Dry-Type and Oil-Immersed Transformers
Enameled rectangular aluminum wire is widely used in:
- Power transformers
- Instrument transformers
- Distribution transformers
2. High-Efficiency Electrical Motors and Generators
Its lightweight properties make it ideal for:
- Large and medium-sized electrical machinery
- High-frequency and high-efficiency motors
3. Industrial and Household Appliances
Enameled aluminum wire is also applied in:
- Compressors
- Washing machine motors
- Welding equipment
Conclusion
Enameled rectangular aluminum wire is an essential material for transformer winding, offering a perfect balance of efficiency, insulation reliability, and cost-effectiveness. Its optimized design enables improved thermal dissipation, reduced weight, and enhanced electrical performance, making it a preferred choice for modern transformer manufacturing. Whether in high-voltage power distribution or industrial applications, this wire ensures long-lasting performance with minimal energy losses.
Frequently Asked Questions (FAQ)
1. Why is enameled rectangular aluminum wire preferred in transformer winding?
The flat profile allows for better space utilization, reduced energy losses, and improved efficiency, making it ideal for transformers.
2. How does aluminum compare to copper in transformer applications?
Aluminum is lighter and more cost-effective than copper, while still providing excellent electrical and thermal properties.
3. What are the key standards for enameled rectangular aluminum wire?
The wire complies with IEC 60317, NEMA, GB, and JIS standards, ensuring high-quality insulation and durability.
4. What are the temperature ratings of enameled rectangular aluminum wire?
Thermal classes range from 120°C to 240°C, depending on the insulation type used.
Why Choose Us
Enamelled Wires Factory Directly
As an established leader in the production of enamelled wires, we provide top-quality enamelled copper and aluminium wires from the largest and most advanced facility in China. Our patented system ensures seamless monitoring of production processes, guaranteeing the exceptional quality of our enamelled wires.
Many Years of Know-how as a Producer of Enamelled Wires
Leverage our extensive experience as a leading producer of enamelled wires. Operating from the largest and most advanced facility in China, we provide enamelled wires of superior quality. Our commitment to continuous investment in cutting-edge machinery and ongoing innovation in our research and development department ensures that we deliver products that enhance your processes and drive inspiration.
Individual Enamelled Wires Matching Your Requirements
As a producer of enamelled copper and aluminium wires, we tailor our products to meet your specific project needs. For suitable volumes, we offer customized enamelled wires from our extensive range. Our production process involves close collaboration between our sales team, application technology experts, and you, ensuring optimal results for your requirements.
Frequently Asked Question
We have ISO9001,ISO14001,IATF16949 and UL certificates.
We are a factory.
We have a special QC department with 15 inspection personnel. Quality inspection team including incoming material, process and finished product inspection
Enamelled wires are available in insulation classes F-155, H-180, and C-200, which indicate their maximum operating temperatures in degrees Celsius
The temperature ratings typically range from 130°C to 220°C, depending on the insulation class and specific application requirements.
Enamelled aluminium wires are lighter and less expensive than copper wires but have slightly lower conductivity. Copper wires, on the other hand, offer higher conductivity and better mechanical strength but are heavier and more costly
Enamelled aluminium wires are ideal for use in large motors, transformers, and other applications where weight reduction is crucial without significantly compromising conductivity.
Enamelled copper wire is preferred in industries requiring high conductivity, such as in electronics, small motors, and applications where space is limited due to copper’s superior conductivity and strength.
Yes, we can customize enamelled wires to meet project-specific requirements, including different sizes, insulation types, and performance specifications.
Enamelled CCA Wire, Enamelled Aluminum Wire, Enamelled Copper Wire
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