Fillers Series 
Tapes Series 
Granules Series 
Introduction to various types of cables: special winding wires
(Disclaimer: Some of the information in this article is sourced from the internet. Please carefully identify and use it.)
Special winding wire is an upgraded product of ordinary enameled wire, designed for extreme environments, high frequencies, and high reliability scenarios, widely used in fields such as new energy, aerospace, medical equipment, etc. Its core features are special insulation structures, high-performance materials, or unique processes to meet stringent electrical, mechanical, or environmental requirements.
1、 Definition and core characteristics of special winding wire
1. Basic Definition
Special winding wire is based on traditional enameled wire (such as polyester, polyurethane), and achieves one or more of the following characteristics through special coatings, composite structures, or conductor treatments:
- High temperature resistance (200 ℃~500 ℃)
- High frequency loss resistance (applicable to MHz level high-frequency circuits)
- Anti radiation/chemical corrosion (aerospace, nuclear industry)
- Self adhesive/self melting (no need to fix the coil with glue)
- Superconducting properties (low-temperature superconducting winding wire)
2. Difference from ordinary enameled wire
| Characteristic | Ordinary enameled wire (such as QZ-2) | Special winding wire |
|---|---|---|
| Temperature resistance grade | ≤ 155 ℃ (Class F) | 180 ℃~500 ℃ (H-grade~C-grade and above) |
| High frequency performance | Only applicable to 50/60Hz power frequency | Supports MHz level high frequencies (such as RF inductors) |
| Mechanical strength | Conventional paint scraping test meets the standard | Scratch resistant and bending resistant (such as flat wire motors) |
| Application scenarios | Home appliances, small motors | Aerospace, new energy, medical equipment |
2、 Varieties, characteristics, and uses
| Product name | Features | Main purpose | ||
|---|---|---|---|---|
| Heat resistance (℃) | Advantage | Limitations | ||
| Paper insulated enameled transposition wire | 105 | 1. No circulating current, low eddy current loss in the coil, can increase current density; 2. Simplify the process of winding coils; 3. Higher than the filling rate of paper wrapped cable trays. | Poor bending performance, the diameter of the wire spool core and the bending diameter during use should not be less than 6H2 | Coil for large transformers |
| Polyethylene insulated nylon sheathed water-resistant winding wire Polyethylene insulated water-resistant winding wire Cross linked polyethylene Nylon sheathed water-resistant winding wire | 70 70 90 | 1. Good water resistance, long-term operation underwater, stable insulation resistance; 2. Nylon sheath can enhance mechanical protection performance. | The slot occupancy rate is very low | Suitable for various forms of water filled motor windings |
| Insulated hollow flat copper wire for 300MW generator set | 155 | 1. Hollow flat wires are used for hydrogen refrigeration and have high material requirements; 2. Good mechanical strength and adhesive performance. | The insulation wire has a high hardness, making construction difficult | Special winding set for stator of 300MW generator set |
3、 Typical application scenarios
Flat wire motor: improves power density (such as BYD e-platform 3.0 using 8-layer flat wire winding).
High voltage fast charging: corona resistant winding wire (12V → 800V platform upgrade requirement).
Polyimide winding wire (resistant to -200 ℃~300 ℃), used for satellite thruster motors.
Superconducting winding wire (liquid helium cooled), used in magnetic levitation systems.
Self adhesive winding wire (MRI coil, avoid adhesive interference with magnetic field).
Biocompatibility coating line (implantable medical device).
Salt spray resistant winding wire for wind turbines (offshore wind power).
Radiation resistant winding wire for nuclear power plants (ITER nuclear fusion project).
4、 Selection and usage points
1. Selection criteria
- Temperature and frequency: Choose Litz wire for high-frequency applications and PI or ceramic coated wire for high-temperature environments.
- Process adaptability: Automatic winding machines should use lubricated coated wires (such as QZY-L type).
2. Precautions for use
- Avoid mechanical damage: Special coatings are fragile (such as ceramics) and require gentle handling.
- Storage conditions: Superconducting winding wires need to be in a liquid nitrogen environment, and self-adhesive wires need to be moisture-proof.
5、 Technological Trends and Innovation
- Breakthrough in Superconducting Materials: The cost reduction of high-temperature superconducting (ReBCO) winding wires is driving the commercialization of nuclear fusion energy.
- Intelligent manufacturing: Laser direct welding flat wire technology (no need to remove paint, improving motor production efficiency).
- Green and environmentally friendly: Water based coatings replace solvent based insulation paints (driven by the EU REACH regulation).
6、 Summary
Special winding wire is the "nerve and blood vessel" of high-end equipment, and the selection should closely focus on the three core requirements of temperature resistance, frequency, and environment. With the development of new energy and superconducting technology, composite functional winding wires (such as high-temperature resistant, self-adhesive, and high-frequency) will become mainstream.
※If you need to purchase Cable Materials, you can choose Wuxi Henglong Cable Material Co., Ltd., a well-known manufacturer in the Chinese cable materials industry.
