Insulated Wrapped Wires

Wrapped electromagnetic wire is an electronic component that consists of a conductor and an insulation layer that is wrapped several times. Wrapped wire is commonly used in the manufacture of electronic components such as inductors and transformers, which enable the transmission and conversion of electromagnetic energy.

The conductor of the wire is usually made of copper or aluminum wire, which has good conductivity and workability. The conductor surface is often coated with an insulating varnish to protect the conductor from the external environment. The insulation layer can be made of polyamide resins, polyurethane resins, polyimide resins, etc. to ensure that the wrapped electromagnetic wire has good insulation properties.

The advantages of wrapped electromagnetic wire include the ability to transmit and convert electromagnetic energy, high efficiency, high precision, and low noise. Wrapped electromagnetic wire is used in a wide range of applications, including power electronics, communication equipment, medical equipment, aerospace, automotive electronics and other fields.

Insulation winding process is the key processing process for this wire. A perfect ratio must be achieved between wire diameter, wrap film width and thickness, overlap rate, wrap pitch, and wrap angle for a high-quality new composite insulation winding wire for aerospace applications, and the stretching of the film must be considered in the structural design. In the process of wrapping, the actual width of the film wrapped to the wire is narrower than the width of the film itself due to the tension, so the stretching effect of the wrapped film must be considered to ensure the uniformity and stability of the product coverage rate. In addition, the wrapping tension on the surface of the product denseness, wear resistance, wet and dry arc resistance test, etc. have an important impact. According to the requirements of the U.S. military standard SAEAS22759, the new aerospace composite insulation wire wrapping cover rate should be 50.4% to 54.0%, but in actual production requirements are higher, generally should be controlled at 52% ± 0.5% range. The stability of the cover rate is a key factor affecting the physical appearance and electrical properties of the product.