This comprehensive guide will introduce you to the different types of copper winding wire used in various applications.
Types of Copper Winding Wire based on Shape
Enamelled Round Copper Winding Wires
Copper is a very ductile metal and can be drawn into round wires with different diameters. Based on the diameter, the current carrying capacity of copper winding wire varies. For example, thinner wires are used in headphones, charging cables etc. Whereas, thicker copper wires are used in transformers, motors etc.
At GEEKAY, we manufacture round enamelled copper wires of diameters ranging from 0.07 mm to 4.0 mm.
Enamelled Rectangular Copper Winding Wires
Copper can be drawn into flat shapes to form rectangular winding wires. Rectangular winding wires are integral components in compact and high-performance applications like electric vehicle motors, EV power trains etc.
Apart from the shape, enamelled copper wire can be classified based on the type of enamel coating used.
Types of Copper Winding Wire based on Enamel Used
Based on the type of enamel coat and the number of coats, the properties of copper winding wire vary. Here are the most common classifications:
1. Polyester Coated Copper Winding Wires (PE)
a. PEW Polyester Enamelled Copper Wire
Polyester Copper Winding Wires have good electrical characteristics, good heat and solvent resistance. They have mediocre thermal shock resistance and poor resistance to hydrolytic degradation. Hence care must be taken when used in sealed equipment.
They come with a polyester enamel coating and have a temperature index of 130°C and 155°C (B Class). They are widely suited for usage in magnet coils and general-purpose motors in auto electricals, fans, home appliances, motors and transformers.
| Type | Enamel Used | Temperature Index | Standard (Cu) | Advantages | Operational Precautions | Applications |
| PEW | Polyester Enamelled Wire | 130°C | Good electrical characteristics.
Good heat resistance. Good solvent resistance. |
Mediocre resistance to thermal shock
Poor resistance to hydrolytic degradation; care must be taken when used in sealed equipment. |
1. General purpose motors
2. Magnet coils |
|
| PEW | Polyester Enamelled Wire | 155°C | IEC 60317-3, NEMA MW 5C
JIS-3202 |
b. NY-PEW Enamelled Copper Wire
These are nylon coated polyester copper winding wires with good surface slip characteristics. These wires have good thermal shock resistance with temperature index of 155°C (F Class). It has an enamel coating of Polyester and PolyAmide (Nylon) making them suitable for high-speed machine winding. They find their application in motors and home appliances.
| Type | Enamel Used | Temperature Index | Standard (Cu) | Advantages | Operational Precautions | Applications |
| NY-PEW | Polyester
+ Nylon wire |
155°C | MW 24-C | Good surface slip characteristics; suited for high-speed machine winding.
Good thermal shock resistance. Similar advantages to PEW. |
Poor resistance to hydrolytic degradation; care must be taken when used in sealed equipment. | 1. General purpose motors
2. Small motors |
2. Hermetic Copper Winding Wires
a. AIW Enamelled Copper Wire
AIW Enamelled Copper Wire is ideal for application where mechanical strength is of paramount importance. This hermetic wire has a PolyAmideImide enamel coating and has a temperature index of 220°C and 240°C (M Class). These copper winding wires have benefits like good heat resistance and good overload characteristics. This makes them suitable for applications in auto electricals, industrial motors and home appliances.
| Type | Enamel Used | Temperature Index | Standard (Cu) | Advantages | Operational Precautions | Applications |
| AIW | Polyamideimide
Enamelled wire |
200°C
220°C |
IEC 60317-26, IEC 60317-57, MW 81-C,
JIS-3202 |
Mechanically strong coating.
Good heat resistance. Good overload characteristics |
Coating flexibility is slightly inferior to PEW. | 1. Transformers for heat-resistance equipment.
2. Motors for electric tools. 3. Hermetic motors. 4. Motors for electrical equipment. |
b. EIW Enamelled Copper Wire
EIW Enamelled Copper Wire is best suited for application that demands good heat resistance and thermal shock resistance. It also offers excellent resistance to hydrolytic degradation and refrigerants. These hermetic wires are coated with PolyEsterImide to give strong mechanical properties. They have a temperature index of 180°C (H Class) and is suitable for applications in auto electricals, fans, home appliances, transformers and industrial motors.
| Type | Enamel Used | Temperature Index | Standard (Cu) | Advantages | Operational Precautions | Applications |
| EIW | Polyesterimide Enamelled Wire | 180°C | IEC 60317-8
NEMA-MW30C NEMA-MW72-C JIS-3202 |
Good heat resistance.
Good thermal shock resistance. Mechanically strong coating. Excellent resistance to hydrolytic degradation. Excellent resistance to refrigerants. |
Film detachment is difficult. | 1. Class-F motors
2. Freon motors 3. Microwave oven transformers 4. Magnet coils for heat resistant components 5. Motors for electrical equipment. |
c. NY-EIW Enamelled Copper Wire
Nylon EIW copper winding wires have good surface slip characteristics supporting high speed machine winding. They have good thermal shock resistance and can withstand temperatures upto 180°C (H Class). These characteristics are imparted by using an enamel coating of PolyEsterlmide and PolyAmide (Nylon). These nylon coated copper wires are suited for applications in motors, home appliances and auto electricals.
| Type | Enamel Used | Temperature Index | Standard (Cu) | Advantages | Operational Precautions | Applications |
| NY-EIW | Polyesterimide + Nylon Wire | 180°C | IEC 60317-22 | Good surface slip characteristics; suited for high – speed machine winding.
Good thermal shock resistance. Similar advantages to EIW. |
Poor resistance to hydrolytic degradation; care must be taken when used in sealed equipment. | 1.General purpose motors 2.Small motors. |
d. EIW-AIW Enamelled Copper Wire
EIW-AIW Enamelled Copper Wire has a very high thermal resistance. They have a temperature index of 200°C and 220°C (H+ Class or K Class). An enamel coating of Polyesterimide and Polyamideimide imparts these hermetic wires strong mechanical properties making them resistance to hydrolytic degradation and refrigerants. EIW-AIW copper winding wires find their application in industries like Refrigeration & Air Conditioning, Railways, Defence Equipment, Fans, Home Appliances, Industrial Motors, Pumps and Auto Electricals.
| Type | Enamel Used | Temperature Index | Standard (Cu) | Advantages | Operational Precautions | Applications |
| EIW-AIW | Polyesterimide + Polyamideimide | 200°C
220°C |
IEC 60317-13, MW 35-C, MW 73 C, MW 36-C, MW 38-C, JIS-3202 | Good heat resistance.
Good thermal shock resistance. Mechanically strong coating. Excellent resistance to hydrolytic degradation. Excellent resistance to refrigerants. |
Film detachment is difficult | 1.Class-F motors
2.Freon motors 3.Microwave oven transformers 4.Magnet coils for heat-resistance components 5.Motors for electrical equipment |
e. Corona Resistant Enamelled Copper Wire
Corona Resistant copper winding wires are high performance winding wires that can withstand discharge induced deterioration. They have an insulation coating made of PolyEsterImide and PolyAmideImide infused with special nano materials to resist corona discharges due to surge voltages. Corona resistant wires are used in high voltage transformers, electric vehicle motors and inverter drive motors.
3. Self Bonding Copper Winding Wires
4. Poly Vinyl based Copper Winding Wires
5. Self Solderable or Polyurethane based copper winding wires
6. Self Lubricating Copper Winding Wires
Let us see them in detail in the next blog, Types of Enamelled Copper Wires – Part II.