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What does enameled wire do?

Enameled wire is a kind of cable used for electrical insulation, and its main function is to transmit electrical signals from one part to another, while maintaining stable and reliable transmission of electrical signals inside the cable. The main feature of enameled wire is the use of enameled insulating materials, which can maintain good insulation properties at high temperatures and high voltage environments.

Enameled wires usually consist of copper wires as the conductor, covered with an enameled insulating layer. The enameled insulation usually consists of several layers of special varnish, which melts at high temperatures and forms a uniform insulating layer that ensures the stable transmission of electrical signals inside the cable. In addition, enameled wire also has the characteristics of small size, light weight, good flexibility, abrasion resistance, corrosion resistance, etc. Therefore, it is widely used in various electrical equipment and electronic products, such as electric motors, transformers, generators, televisions, audio equipment, computers and so on.

In short, enameled wire is a kind of cable used for electrical insulation, with good insulation performance and stable electrical signal transmission ability, it is widely used in various electrical and electronic equipment.

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Enameled wire production line for manufacturing and packaging

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Continuous shift conductor, if you need it, please contact me, comment or message

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Insulated conductors

Insulated conductors are used in power transmission and distribution systems, in which a layer of non-conductive materials, such as: resin, plastic, silicone rubber, PVC, etc., is uniformly and sealingly wrapped around the periphery of the conductor to form an insulating layer to prevent the conductor from contacting the outside world causing leakage, short circuit, electric shock and other accidents, the inside of the insulated conductor is composed of a metal conductor, usually copper or aluminum, while the outer layer is a layer of insulating material.

Compared with ordinary wires, insulated wires have better electrical insulation properties, which can prevent current leakage and interference, thus improving the safety and reliability of the power system. Insulated conductors are commonly used in high-voltage lines in power transmission and distribution systems, such as transmission lines and cables in substations. R stands for soft copper wire, V stands for polyvinyl chloride insulation, S stands for double twisted, B stands for flat, and P stands for shielded. 1, RV - polyvinyl chloride insulated single-core flexible wire, maximum operating temperature 65℃, minimum operating temperature -15℃, working voltage AC 250V, DC 500V, used as internal wiring of instruments and equipment. 2, RVB: parallel multi-stranded flexible wire (flat), like the phone line often used at home bare wire, but the core and RVV core consistent, the two cores are wrapped in parallel in the sheath, usually a sheath of two 3, RVS: twisted multi-stranded flexible wire, that is, the soft core of RVB torn, twisted. Usually two twisted pairs. 4、RVSP: twisted shielded wire. 5、RVVB: polyvinyl chloride sheathed flexible wire (flat type), standard GB/T 5023.5-2008/IEC 60227-5:2003. 6, RVV: multi-stranded flexible wire, that is, the core consists of multiple strands of copper wire, RVV wire is the most commonly used cable for weak electrical systems, the number of cores is variable, there are single, there are multiple, there is also a sheath outside. But there are no special requirements for the arrangement between the cores. 7, RVVP: copper-core PVC insulated shielded PVC sheathed flexible cable, also called electrical connection anti-interference flexible cable, rated voltage 250V/450V. 8, BVVR is a copper-core PVC insulated PVC sheathed flexible wire, with an outer sheath; BVR is a copper-core PVC insulated flexible wire, only the insulation layer, no outer sheath. Usually said double plastic wire refers to the BVV series, the first V refers to polyvinyl chloride insulation, the second V refers to polyvinyl chloride sheathing, if the BV series refers to the single plastic wire.

Commonly used insulated wires are as follows: 1: 1 rubber-insulated wire Model: BLX - aluminum-core rubber-insulated wire, BX - copper-core rubber-insulated wire. 2 polyvinyl chloride insulated wire (plastic wire) Model: BLV - aluminum-core plastic wire, BV - copper-core plastic wire.

Rubber cable Model: YHC - heavy-duty rubber cable, NYHF - agricultural neoprene dragging cable. Rubber insulated wire has copper core, aluminum core, single core, double core and multi-core. Used for house wiring, working voltage generally does not exceed 5OO volts.

Insulated conductors come in various forms, including overhead insulated conductors and underground insulated cables. Overhead insulated conductors are transmitted through overhead power poles or cable bridges, while underground insulated cables are buried in underground pipes or tunnels to transmit power signals. Different insulated conductors are suitable for different power transmission and distribution scenarios and are selected as needed.

Le fil émaillé est aussi appelé fil de bobinage, conducteur gainé, fil d'aimant, fil de solénoïde, fil verni, fil laqué. LP Industry est l'u

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Abrasion-resistant wire

Abrasion-resistant wire is wire that can maintain electrical properties and mechanical strength under harsh conditions such as mechanical wear and tear and friction. These wires are usually used in situations where they need to move frequently or go through harsher environments, such as machinery and equipment, automated production lines, etc.

Abrasion-resistant wires need to have the following characteristics:

good mechanical strength: wear-resistant performance wire needs to have good mechanical strength, able to withstand various forms of mechanical wear and friction.

good wear resistance: wear-resistant performance wire covered with wear-resistant materials to maintain the electrical properties and mechanical strength of the wire under severe friction, extrusion and other harsh conditions.

good insulation performance: wear-resistant performance wire needs to have good insulation performance to avoid wire failure and safety accidents caused by insulation breakage.

good corrosion resistance: wear-resistant performance wire will usually pass through the wet, corrosive environment, need to have good corrosion resistance, to avoid corrosion of the wire leading to safety accidents.

appropriate flexibility: wear-resistant performance wire needs to have a certain degree of flexibility, in order to move or bend is not easy to break or damaged.

Wear-resistant performance wire needs to have better mechanical strength, wear resistance, insulation, corrosion resistance and appropriate flexibility to ensure that the wire can work stably and safely in harsh environments.

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Enameled Wire Enamels

Wire enamels are mainly used to coat the insulation of enameled wire cores. Since the wire will be subjected to heat, chemical and various mechanical forces in the process of winding the coil and inlaying the wire, the enameled wire enamel is required to have good coating (i.e., it can be evenly coated), strong adhesion of the enamel film, smooth and soft surface with toughness, a certain degree of wear resistance and elasticity, good electrical properties, heat resistance, solubility resistance, no corrosion of the conductor and other characteristics. Specifically divided into the following nine types. 1, acetal varnish main component is polyvinyl acetal, used in the production of enameled wire for oil-containing transformers. 2, polyurethane varnish main component is polyurethane methylene, widely used in electronic transformers, electronic coils, relays, micro motors, high frequency electrical instruments and other electronic requirements for the production of enameled wire for winding. 3、Solderability polyesterimide lacquer has the general performance of polyesterimide lacquer, 475° can be directly welded. 4, polyester imide lacquer is the most widely used class of enameled wire with excellent thermal performance, usually higher than 180 level, can be single coated, can also be used as a primer and polyamideimide or nylon lacquer composite production of composite lines. A large number of refrigerators and air conditioning compressors, explosion-proof motors, power tools, ballasts, dry-type transformers and other occasions with high insulation level. 5, polyester lacquer with polyester as the main component, good overall performance, used for washing machine motors, micro motors, instruments and telecommunications equipment, electric tools and general motors with enameled wire production. Heat-resistant polyester modified with Seck, also a large number of primers and polyamide imide composite for cold media resistant enameled wire production. 6, polyamide imide is the most widely used high heat-resistant grade (220 grade) enameled wire enamel, mostly used as a top coat to produce composite lines, used to improve the overall performance of the enameled wire. A large number of sealed motors, cold media resistant enameled wire production. Some products can also be single coated. To improve the performance of the enameled wire, it can also be made into self-lubricating type and filler. In the heavy motor and automotive industry has great application. 7、Polyester imide enamel heat grade 240, superior performance, its enameled wire is resistant to radiation. 8, nylon varnish using its lubricity, generally used in the enameled wire surface layer. For other performance also has improved. 9, self-adhesive varnish very according to the use of different components, mainly polyamide, epoxy (phenoxy) and aromatic polyamide and other different types of self-adhesive varnish. Generally do enameled wire top coat. Used for deflection coil, transposition wire, voice coil and anisotropic coil bonding molding.

Insulating varnishes can be divided into seven categories according to the insulation class Y, A, E, B, F, H and C [2] . The details are described as follows: Heat resistance grade: Maximum allowable working temperature (℃) Y grade: 90℃ Insulation structure made of unimpregnated cotton yarn, silk and paper materials or their combinations Class A: 105℃ Insulation structure made of impregnated or immersed in liquid dielectric (such as transformer oil, cotton yarn, silk and paper materials or their combinations) Grade E: 120℃ Insulation structure composed of synthetic organic film, synthetic organic enamel and other materials or their combinations B grade: 130℃ Class F：155℃ H grade: 180℃ Insulation structure made of mica, glass fiber, asbestos and other materials or their combinations after bonding or impregnation and coating with suitable resin (such as silicone resin) Class C：180℃ or more Insulation structure composed of mica, glass fiber, and unimpregnated mica, ceramic, quartz and other materials or their combinations after bonding or impregnation or coating with suitable resins

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Types of enamelled copper wire

Enameled wire is the main variety of winding wire. It consists of a conductor and an insulation layer. After the bare wire is annealed and softened, it is painted and baked several times. However, it is not easy to produce a product that meets both standard requirements and customer requirements. It is influenced by the quality of raw materials, process parameters, production equipment, environment and other factors. Therefore, the quality characteristics of various enameled wires differ, but they all have four properties: mechanical, chemical, electrical and thermal.

According to the shape of the copper conductor, it can be divided into enameled square copper wire, enameled round copper wire, enameled flat copper wire and ultra-fine enameled flat copper wire. Different types of enameled wire can be selected according to the shape and size of different use spaces.

For example, enameled round copper wire is generally used in transformers, heat-resistant motors and generators; ultra-fine enameled flat copper wire is mostly used in high-temperature voltage devices, instruments and various electronic component windings.

Enameled copper wire now occupies an important market in the field of industrial machinery, and you are welcome to learn more about various enameled wires.

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LP Industry fournit principalement le fil émaillé et le fil magnétique, y compris le fil d'aluminium émaillé et le fil de cuivre émaillé.

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MAGNETIC INSULATED WINDING WIRE

Magnetic inuslated winding wire, also referred to as magnet wire, is used in a multitude of electrical devices that require the development of electrical and/or magnetic fields to perform electromechanical work. Examples of such devices include electric motors, generators, transformers, actuator coils, and so on. 

Typically, magnet wire is constructed by applying electrical insulation to a metallic conductor, such as a copper, aluminum, or alloy conductor. The conductor typically is drawn or formed to have a rectangular or round cross-section. The electrical insulation is typically formed as a coating that provides for electrical integrity and prevents shorts in the magnet wire. Conventional insulations include polymeric enamel films, polymeric tapes, paper insulation, and certain combinations thereof.

Traditional magnet wire is formed with polymeric enamel insulation that is applied in successive layers and baked in a furnace. In order to achieve higher dielectric and partial discharge performance, it is typically necessary to apply a greater number of layers and, therefore, thicken the enamel. 

The magnet wire may have a thermal classification of at least 220° C. in accordance with the American Society for Testing and Materials (“ASTM”) standard 2307. The magnet wire may also be resistant to various oils, liquids, and/or chemicals, such as transmission fluid. Additionally, the magnet wire may be capable of withstanding significant mechanical forces during a coil formation process.

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What are common enameled wire conductors

Enameled wire is also a common type of wire conductor, usually made of copper or aluminum. It gets its name from the fact that it is coated with an insulating varnish, usually polyurethane or polyimide. This insulating varnish prevents short circuits between the enameled wires and protects the conductor from corrosion and oxidation.

Winding machine winding coil enameled wire is a necessary processing material, different types of electrical coils used in the enameled wire is also different, different types of enameled wire used in the winding machine is also different, the classification of enameled wire can probably be divided from the shape, material and insulation level.

We commonly used enameled wire is mainly divided into round and flat wire, these two types of enameled wire cross-sectional shape is different, the application is also completely different, the most extensive application areas of round wire, common electromagnetic coils, inductor coils, motor stator coils are using round wire as a conductor, flat wire is commonly used in reactor coils, transformer coil conductor.

Enameled wire material is mainly divided into two categories, copper and aluminum wire is our most commonly used two conductors, copper wire compared to aluminum wire can pass a larger current, with a lower temperature rise, the material also compared to aluminum wire to be more hard and tough, aluminum wire has a high cost performance, easier to wind and other advantages.

Commonly used enameled wire conductors include

thin enameled copper wire (Bare-enameled copper wire): this copper wire is a high purity copper wire with an extremely thin layer of insulating varnish and is commonly used in electronic, electrical and communication equipment.

2. Heavy-enameled copper wire: This copper wire is thicker than thin enameled copper wire and has a thicker insulating varnish and is typically used in high power equipment such as motors, transformers and generators.

3.Enameled aluminum wire (Enameled aluminum wire): This conductor is similar to copper enameled wire, but uses aluminum material and is typically used in low-power equipment and light applications.

All three of these enameled wire conductors have good insulation, electrical conductivity and corrosion resistance, and are among the common conductor materials used in the electronic, electrical and communications fields.

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This article studies the sales volume and sales revenue of round enameled wire in the global market, major regions and major countries, and also focuses on the analysis of the competition situation of major manufacturers (brands) around the world, the sales volume, price, revenue and market share of round enameled wire.

According to the historical situation in the past five years (2017-2021), the overall scale of global circular enameled wire, the scale of major regions, the scale and share of major enterprises, the scale of major product categories, and the scale of major downstream applications in the past few years are analyzed. The sizing analysis includes volume, price, revenue, and market share, among others. In view of the development prospects of round enameled wire in the next few years, this paper predicts that to 2028, it mainly includes the forecast of global and major regional sales and revenue, the forecast of classified sales and revenue, and the sales and revenue forecast of main application of round enameled wire, etc.

According to the research of 168 Report Network, in terms of revenue, the global circular enameled wire revenue in 2021 will be about one million US dollars, and it is expected to reach one million US dollars in 2028. During the period from 2022 to 2028, the compound annual growth rate (CAGR) is %. At the same time, the global sales of circular enameled wires in 2020 will be approximately, and it is expected to reach 2028. In 2021, the market size of China will be about US$ million, accounting for about % of the global market, while the North American and European markets will account for % and %, respectively. In the next few years, the CAGR of China will be %, while the CAGR of the United States and Europe will be % and %, respectively. The Asia-Pacific region will play a more important role. In addition to China, the United States and Europe, Japan, South Korea, India and Southeast Asia will still play an important role that cannot be ignored. market.

Major circular enameled wire manufacturers in the global market include Dahrén (Liljedahl Group), Hi-Wire (Superior Essex), Essex Furukawa, Precision Wires India Limited (PWIL) and Sam Dong, etc. In terms of revenue, the top four global manufacturers will occupy approximately % market share.

In terms of product type, copper conductors occupy an important position, with a market share of % in 2021 and expected to reach 5% in 2028. At the same time, in terms of application, the share of electric motors in 2028 will be about %, and the CAGR will be about % in the next few years.

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Enameled wire welding and paint stripping

The first one: The paint stripping method of aluminum enameled wire is of course scraping the paint with a blade. The wire has not become brittle, but the efficiency is too low, and it is only suitable for the stripping of large wires, and the wire with a diameter of less than 0.5mm is not suitable, because the thin wire is very easy to be scratched, and it is constantly damaged by the scraper, and the toughness is greatly changed. Poor, not suitable for large-scale operations, in addition, after the aluminum enameled wire is scraped, the surface will have burrs, which is not conducive to welding.

The second type: paint stripping of aluminum enameled wire, let's talk about centrifugal knife, this is said to be a kind of paint stripping equipment first introduced in Germany, it uses 3 high-speed rotating knives to peel off the paint of aluminum enameled wire directly, the efficiency is good . This paint stripping method is the same as hand scraping paint, and it is only suitable for stripping paint of large lines. We all know that the physical properties of aluminum are soft and poor in toughness. It is only half that of copper. When using a centrifugal knife, it is easy to be twisted into a rope and broken directly. If the diameter of the aluminum enameled wire you use is 1.5 Below MM, the centrifugal knife is not suitable for you. Even if it is not directly broken, it will be twisted almost ten times. If you use aluminum enameled wire with a smaller diameter, basically don't consider this kind of removal. The paint removal method is not suitable for most motor manufacturers, because the diameter of the aluminum enameled wires used by motor manufacturers is relatively small. In addition, the centrifugal knife will also peel off a layer of aluminum wire when stripping the paint, and the diameter of the aluminum enameled wire will generally become smaller by dozens of wires or larger. This method may not be used for customers with higher requirements.

The third type: the grinding wheel of the aluminum enameled wire, whether you use a steel wire wheel or a fiber wheel, during the process of the paint on the aluminum enameled wire being worn off, the temperature of the aluminum wire will increase rapidly with the high-speed friction, accompanied by With the high-speed air flow, the surface of the aluminum wire is rapidly oxidized, and it is difficult to handle after being oxidized. In addition, due to the different materials of the grinding wheels, generally speaking, the aluminum enameled wire polished by the steel wire wheel turns yellow, and the aluminum enameled wire polished by the fiber wheel turns gray or black. It is not the silvery white of aluminum itself. After the thick wire is ground by the grinding wheel, the degree of oxidation is small, and the silvery white can still be seen. So, if the wire your company is using now is relatively thick, you can choose this method, if it is a thin wire, this method is not suitable.

Fourth: The paint stripping method of aluminum enameled wire is to use paint stripper. I believe many people have used this product. I also believe that many people can't stand its paint stripping efficiency for a long time. The speed of stripping 130 lines is acceptable. , in about a minute, you have to wait for the 150 line, you have to wait hard for the 180 line, and you don't have to wait for the 220 line, this product is more harmful to the aluminum of the aluminum enameled wire Small, in general, it is a better way to use paint stripping powder to strip paint. Many factories make special molds, and a large number of aluminum enameled wires soaked in paint stripper are placed on a fixed shelf to wait for the paint stripper to react, and the efficiency is OK. . But for high-temperature lines, the paint stripping of various manufacturers is basically useless now, and the paint will not come off no matter how long it takes, so this method is not suitable for high-temperature lines. In addition, by the way, paint strippers are generally alkaline, aluminum is an amphoteric metal, acid can corrode it, and alkali can also, so remind friends who are using paint strippers now to use after you have finished stripping paint Be sure to rinse with clean water (or alcohol) (preferably using an ultrasonic cleaning machine). The paint remover is easier to dissolve in water or alcohol. Just rinse it a little. Be careful that your solder joint is corroded by the paint remover.

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The development trend of new products of enameled wire

The development trend of new products of enameled wire

The development and innovation of new products of enameled wire has shifted from researching new products with higher heat resistance to the direction of product structure and coating structure innovation, in order to improve the performance level of enameled wire, develop new functions and improve processing characteristics. The scope of product application, so as to adapt to the needs and changes of the market more quickly.

The innovation of new varieties of enameled wires in the future will focus on four themes of "environmental protection, energy saving, frequency conversion, and high efficiency". Special-shaped enameled wire, self-adhesive, Ritz wire, fluorine-resistant enameled wire, anti-corona enameled wire, aluminum core enameled wire, etc. are all the directions for the development and research of new products in the future. Among them, the anti-corona enameled wire used for variable frequency motors and frequency converters has the most development prospects, and it is a new growth point of the enameled wire market in the future.

1. Anti-corona composite enameled wire is the main trend of new product development and the main new growth point of the future market

     According to the country's industrial policy of developing products with "low consumption and high efficiency" in the future, variable frequency motors are the key products developed by the country in the future. Anti-corona enameled wires are used in variable frequency motors, which can improve the insulation performance under variable frequency conditions and meet the requirements of anti-corona. , Anti-high frequency pulse current requirements, especially with high partial discharge voltage (corona resistance) performance. Compared with ordinary enameled wires, the pulse resistance life of insulation in the same thick enamel layer is increased by more than 100 times.

The frequency conversion motor is the key development direction of the motor industry. Because it is 30-40% more energy efficient than the general motor, it is a new product that will be promoted and popularized before 2020. After 10 years, the output of variable frequency motors will account for more than 50-70% of all motors, which is a major innovation for the enameled wire industry. According to the forecast, the application of enameled wire in the motor industry will reach 190,000 tons in 2010, 250,000 tons in 2015, and 300,000 tons in 2020. According to the 50-70% frequency conversion motor, the demand for anti-corona enameled wire is 100,000 tons and 150,000 tons respectively. Tons, 200,000 tons, any variety of enameled wire can not reach this development speed. However, the current variable frequency motor is still under development and has not been widely used in industrialization. At present, the national demand for anti-corona enameled wire is less than 10,000 tons, and the domestic supply is less than 5,000 tons, and most of them still rely on imports. It can be seen that the anti-corona enameled wire has a large space for future development and is a new variety with the most development potential. my country's market is huge, and we must catch up and develop vigorously.

2. Technical development direction and market trend of medium, small size and micro enameled wire

    According to the analysis of relevant professionals and industry survey data, the current demand for enameled wire in my country is about 600,000 tons, and it is expected to reach 1.1 million tons by the end of the "Eleventh Five-Year Plan", of which medium and small enameled wires account for about 45%. The main application areas are small household appliances, automotive motors, power tools, communications, electronic information and micro-motors and other industries. With the increase of product categories in these industries and the continuous upgrading of products, many electronic component products have put forward higher requirements for the variety and quality of enameled wires used. In addition to further improvement in the four major performance indicators of general enameled wires, many special properties have been added to meet specific functional requirements, or to improve the applicability of enameled wires during use, and reduce enameled wire production or use costs. Such as: diameter reduction, light weight, high self-adhesion, tension characteristics, consistency of winding parameters, high frequency and high pressure resistance, high Q value characteristics, thermal fuse, heat resistance, refrigerant resistance, direct welding, Shaped, non-magnetic, high conductivity, etc. The development of enameled wire technology also puts forward higher requirements for the management of enameled wire production process, such as production technology, production equipment, personnel quality, production environment, testing methods and material application.

  Small and medium-sized enameled wire will become the mainstream market in the future. According to preliminary statistical analysis, the total domestic market demand for small and medium-sized enameled wire is about 300,000 tons per year, accounting for 45% of the total demand. The future demand will continue to grow and will become the future In the mainstream market, the number of industry demands is roughly divided as shown in Table 3.

     The small and medium-sized enameled wire market has a large market capacity and a wide market distribution, covering almost all special varieties and electrical and electronic control systems in all industries. At present, most companies are focusing on the special enameled wire market, the contradiction between supply and demand is very prominent, and the market competition is intensifying. However, in some varieties and specifications, domestic products still cannot meet the requirements for use. In the fierce market competition, how to seize the opportunity, correct positioning, grasp the market, and obtain benefits is the direction we face and choose.