Why Electric Vehicles Use Flat Enameled Wire?

Enameled wire, as a type of magnet wire, also called electromagnetic wire, is generally composed of conductor and insulation and made after annealed and softened, and enamelling and bake process many times. Properties of enameled wires are affected by raw material, process, equipment, environment and other factors and varies.

Cross section of enameled wire is usually round, resulting in low filling factor after winding. Development of technology calls for conventional enamel wire to change towards flat shape, light weight, low power consumption, and good properties. There flat enameled wire came into market. Flat enameled wire is made of an oxygen-free copper rod or an electrical aluminum rod that is drawn, extruded or rolled through mold and then coated with insulation. Its thickness ranges from 0.025mm to 2mm and width is usually less than 5mm. Width and thickness ratio 2:1 to 50:1. They are mostly applied to various products, such as EV, telecommunication, transformers, motors, generators, etc.

So what are the characteristics of flat enameled wire? Let’ s find out.

Compared with ordinary round enameled wires, flat enameled wires have better softness and flexibility, and have excellent performance in terms of current carrying capacity, transmission speed, heat dissipation performance and occupied space, and are especially suitable for electrical and electronic equipment. In general, flat enameled wire has the following characteristics:
(1) save space
Flat enameled wire takes up less space than round enameled wire and saves 9-12% of space so that smaller and lighter electronic and electrical products will be less affected by the volume of the coil, obviously saving other material;
(2)High filling ratio
Given the same space, filling ratio of flat enameled wire can reach more than 95%, which gives a vital solution to reduce resistance and increase capacitance and fits for high-capacity and high-load operating environment
(3)large cross section
Flat enameled wire has a larger cross-sectional area than round one, which is good for heat getting out. Meanwhile, it can also improve “skin effect” and reduce loss for high-frequency motor.

Flat enamel wire plays such a vital role in EV. There are many electromagnetic wires in drive motor of EV which requires to withstand high voltage, temperature, and voltage change during operation and don’ t easily break down and have long service life. To suit the demands of EV, Tianjin Ruiyuan makes high-end flat enamel wire, our anti-corona electromagnetic wire, ATF oil-resistant electromagnetic wire, high PDIV electromagnetic wire, high temperature use electromagnetic wire, etc. ranks among the best in the industry of EV. Most flat enameled wires at Tianjin Ruiyuan are made of copper for good conductivity performance. For specific demands for wire design, we can adjust and make the wire achieve customers’ desirable performance as well.
Click our product page or contact us if you’ d like to learn more and get a custom flat wire design!


Post time: Apr-10-2023