CU Wire Test Data

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Soft Copper Wire for Enameled Wire

Dimension Table of Self-bonding Enameled Copper Wire(Class 1, 2)

Dimension Table of Enameled Copper Wire(Class 2, 3), KS / JIS

Dimension Table of Enameled Copper Wire(Class 0, 1), (KS/JIS)

Enameled Copper Wires of PU/PE/PEI

Self-bonding Enameled Wire

Self-Lubricating Enameled Wire

Special Enameled Litz Wire

Tension Table for Coiling

Crazing and Cure Effect of Various Enameled Wires

Critical Properties of Various Enameled Wires

Copper Wire : Bare & Insulation

The soft copper wire should be tested by several methods such as its diameter(mm), tolerance(mm), cross section area(mm), weight(kg) per kilometer, conductivity(%) at 20℃, electric resistance(Ω) per kilometer at 20℃, tensile load(kg), tensile strength(kg) per ㎟, elongation(Standard distance, 250mm) for manufacturing enameled copper wire before litz wire fabrication.

Regarding the below table(class 1 & 2), (i) the data shows that the base coating(=BC) minimum thickness(mm) means 1st enameled insulation(1~2 times coating). (ii) the outer coating(=TP, Top Coating) minimum thickness(mm) means 2nd enameled insulation with 1~3 times coating and then the self bonding varnish is coated on TP and (iii) the maximum overall diameter(mm) is bare copper conductor + 1st, 2nd enameled insulation + self bonding varnish coating (iv) the maximum conductor resistance(Ω) is tested by per kilometer and at 20℃.

Regarding the below table(class 2 & 3), (i) maximum film thickness(mm) would be the Top Coating(TP), 2nd enameled insulation with 1~3 times coating after base coating(=BC) with 1~2 times coating, (ii) the maximum overall diameter(mm) is bare copper conductor + 1st, 2nd enameled insulation and (iii) the maximum conductor resistance(Ω) is tested by per kilometer & at 20℃. FYR, the diameter ranges are from 0.020mm(bare conductor) ~ 1.0mm.

The following table(class 0 & 1) shows that
(i) the conductor means bare state before enamel coated,
(ii) max. film thickness of class 0 & 1 means the thick of thickest enamel coating,
(iii) max. overall diameter means a bare copper conductor + enamel coating.
(iv) the maximum conductor resistance(Ω) is tested by per kilometer & at 20℃. FYR, the diameter ranges are from 0.10mm(bare conductor) ~ 3.20mm and the enamel coating thickness is as following, class 0 > class 1 > class 2 > class 3.

1. Polyurethane Enameled Wire

Designation UEW
Thermal Class B (130℃) F (155℃)
Specification NEMA MW 75 C, KSC-3107(6), JISC-3202(6)
Characteristics – Solderable and self-fluxing easily without stripping off the film.
– Good electrical properties even at high frequencies.
– Good mechanical properties, moisture and chemical resistance.
– Colorable in red, green, etc.

 

 

2. Polyester Enameled Wire

Designation PEW
Thermal Class F (155℃)
Specification NEMA MW 5 C, KSC-3107(5), JISC-3202(5)
Characteristics – Modified polyester resin.
– Good heat resistance.
– Flexibility and adhesion comparable to P.V.F
– Tends to hydrolyze in moisture environments.

 

 

3. Polyester-imide Enameled Wire

Designation EIW
Thermal Class H (180℃)
Specification NEMA MW 30 C, KSC-3107(8), JISC-3202(8)
Characteristics – Modified polyester resin.
– Class H modified polyester resin.
– Excellent electrical properties and thermal aging resistance.
– Good refrigerants(Freon) resistance and chemical resistance.

 

 

4. Solderable Polyesterimide Enamelled Wire

Designation EIW UL
Thermal Class H (180℃)
Specification NEMA MW 77 C
Characteristics – Solderable without removing the film
– Excellent electrical properties and thermal aging resistance.

1. Polyurethane + Poly-amide Wire

Designation SB-UE-YW
Thermal Class B(130℃), F(155℃)
Specification NEMA MW 80 C, KSC-3107(7), JISC-3202(7)
Characteristics – Base coating-Polyurethane Top coating-Polyamide Resin
– To bond adjoining coils or layers with thermal plastic overcoat.
– Retains the solderable characteristic.
– Bonding is accomplished by the use of solvent(Alcohol)

 

 

2. Polyester + Poly-amide Wire

Designation SB-PE-YW
Thermal Class F(155℃)
Specification
Characteristics – Base coating-Polyester Top coating-Polyamide Resin
– To bond adjoining coils or layers with thermal plastic overcoat.
– Bonding is accomplished by the use of solvent(Alcohol) and heating.

 

 

3. Polyester-imide + Poly-amide Wire

Designation SB-EI-NYW
Thermal Class H(180℃)
Specification
Characteristics   – Base coating-Polyesterimide Top coating-Polyamide Resin
– To bond adjoining coils or layers with thermal plastic overcoat.
– High temperature characteristics, dielectric breakdown voltage, heat shock resistance and lubricity.
– Bonding is accomplished by heating and pressing.

1. Polyurethane + Nylon Wire

Designation UE-NYW
Thermal Class B(130℃), F(155℃)
Specification NEMA MW 28 C
Characteristics – Base coating-Polyurethane Top coating-Polyamide Resin(Nylon)
– High temperature characteristics.
– Good abrasion resistance, windability because of the nylon overcoat
– Increased solvent resistance and ther thermal rating of the insulation.)

 

 

2. Polyester + Nylon Wire

Designation PEW-NYW
Thermal Class F(155℃)
Specification NEMA MW 24 C
Characteristics – Base coating-Polyester Top coating-Polyamide Resin(Nylon)
– High temperature characteristics.
– Good abrasion resistance, windability and flexibility.
– Good solvent resistance.

 

 

3. Polyester-imide + Nylon Wire

Designation PEI-NYW
Thermal Class H(180℃)
Specification NEMA MW 76 C
Characteristics – Base coating-Polyesterimide Top coating-Polyamide Resin(Nylon)
– High temperature characteristics.
– Good abrasion resistance, windability and flexibility.
– Good solvent resistance.

1. Polyester-imide + Poly-amide enameled Wire

Designation EI-AIW
Thermal Class H(200℃)
Specification NEMA MW 35 C, UL Listed
Characteristics – Base coating-Polyesterimide Top coating-Polyamidemide
– Excellent thermal, electrical, mechanical and chemical properties.
– Especially good resistance to Freon 22.

 

 

2. Litz Wire(Self-Bonding, Solderable polyester-imide + poly-amide litz wire)

Designation LITZ-SEI-SB
Thermal Class H(180℃)
Specification
Characteristics – Woven wire constructed of individually film insulated wires
– Self-Solderable.
– Minimize the power losses due to the “Skin Effect”.
– Good high frequency Characteristic

 

 

3. Nylon Enameled Wire

Designation NEW or NCW
Thermal Class A(105’C)
Specification NEMA MW 6 C
Characteristics – Base coating-Polyesterimide Top coating-Polyamide Resin(Nylon)
– Composed of Poly-amid resin.(Nylon 12)
– Comparable to UEW
– The film will short circuit at a fixed temperature.(substitute for the thermal fuse)

The following table(Tension table for coiling) shows the coil tension based on gram as per the size of copper conductor from 0.020mm~2.0mm. Therefore, you may expect the bending radius of the wound coil’s size and various winding condition of copper wire before fabrication or production.

The below table explains various enameled wires'(PVF, EIW, UEW, PEW = enamel insulation type as per temperature) crazing and cure effect as well as it shows the case of sample winding and immersion after wound and heating for 30 minutes at 120℃. You should get some data and information from this table before producing self-bonding type litz-wire or general type.

Regarding the below table, copper wire or aluminum wire shows to be able to be tolerated under test condition as per each insulation type
– UEW: Polyurethane Enameled copper wire
– PEW : Polyester Enameled copper wire
– EIW : Polyesterimide Enameled copper wire
– AIW : Polyamideimide Enameled copper wire
– EI-AIW : Polyesterimide-Polyamideimide Enameled copper wire
– UEW/N, PEW/N, EIW/N : Lubricating Enameled copper wire
– SL-EI/AIW : Self-Lubricating Polyesterimide-Polyamideimide Enameled copper wire

On the following table, in case of copper wire, if the conductor’s diameter is 0.34mm, the tolerance of the diameter should be ±0.006mm and the overall diameter should be 0.385mm(tolerance +0.005, -0.004mm). On similar case, the max. conductor resistance should be 322.6Ω/km at 20℃. The others are same as 0.34mm.