Magnet Wire for EVs
Magnet wire, also known as enamel wire or winding wire, is a crucial material in the manufacturing of electric vehicles. It serves an irreplaceable role in various applications such as electric motor winding, battery connections, and electronic control systems in the production of new energy vehicles.
Signi has obtained various certifications, including IEC, IATF 16949, ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, and more. They are capable of producing magnet wires in temperature grades such as 130/155, 182, 200, 220, and 240, including round and flat enamelled wires. Signi has become a supplier to several well-known new energy vehicle companies, including BYD, Tesla, NIO, Xiaopeng, and others.
Signi magnet wire hot products for electric vehicles
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Class 200℃ enamelled copper round wire
Size: φ0.15-5.2mm
Temperature Resistance: 200°C, 220°C
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Class 180℃ enamelled aluminum round wire
Size: φ0.4-5.0mm
Temperature Resistance: 180°C
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Class 220℃ enamelled aluminum round wire
Size: φ0.4-5.0mm
Temperature Resistance: 220°C
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Class 200/220℃ copper rectangular wire
Size: a(0.27-3mm), b(0.8-5.2mm)
Temperature Resistance: 200°C, 220°C
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Class 180℃ aluminum rectangular wire
Size: a(1-5.6mm), b(2-16mm)
Temperature Resistance: 108°C
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Class 220℃ aluminum rectangular wire
Size: a(1-5.6mm), b(2-16mm)
Temperature Resistance: 220°C
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Self-Adhesive enamel wire
Alcohol-based heat bonding
Provides a more compact winding
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High-Temperature resistant wire
Voltage resistance: 5-12KV
The enamel film does not crack under 350℃ baking
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Copper-Clad enamelled flat Wire
Lightweight, excellent conductivity
High cost-performance ratio
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Solderable enamel wire
No need for paint removal
Can be directly soldered
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Corona-Resistant enamel wire
Excellent corona resistance
Outstanding dielectric performance
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Micro enamel wire
Minimum specification: 0.2*1mm
High slot filling rate
Product categories of enameled wires for wlectric vehicles
Enameled copper round wire for EVs
This wire, made of copper with insulating enamel, boasts excellent conductivity and a high-temperature resistance of up to 220℃—ideal for electric vehicle applications. Despite its simple manufacturing, it has limitations like a small surface area and lower heat dissipation, and a relatively low slot fill ratio.
Enameled copper flat wire for EVs
Enameled copper rectangular wire is a flat copper conductor coated with insulating enamel. It offers higher fill factor, improving motor winding slot fill ratio and heat dissipation compared to round wire. However, production costs and winding processes are more complex, requiring consideration based on project needs.
Copper-Clad aluminum enamel wire for EVs
Copper-clad aluminum enamel wire features an aluminum core coated with copper and insulated with enamel. This design combines copper's conductivity with aluminum's lightweight properties. It is used in diverse electrical applications, including electric motors, transformers, and generators.
Enameled aluminum round wire for EVs
Enameled aluminum round wire features an insulated circular aluminum conductor with a layer of enamel insulation. With its lightweight nature and cost-effectiveness, aluminum wire, boasting over 60% conductivity of pure copper, is an excellent choice for various winding needs. It is particularly suitable for low-power auxiliary components in electrical systems.
Enameled aluminum rectangular wire for EVs
Featuring a flat cross-section, enameled aluminum rectangular wire provides excellent slot fill and heat dissipation. Ideal for confined spaces and applications needing a larger conducting cross-section, its lightweight nature (one-third of copper) significantly reduces vehicle weight. Widely employed in electric vehicle auxiliary components like motors, batteries, and power window systems.
Characteristics of enameled wires for electric vehicles
Excellent conductive performance
The conductivity of enameled wires is one of its most crucial performance indicators, influencing the efficiency and performance of electric vehicles. Enameled wires for electric vehicles typically utilize highly conductive materials such as pure copper, pure aluminum, or copper-clad aluminum as conductors to ensure efficient current transmission.
High-temperature resistance
Enameled wires for electric vehicles often employ insulation enamels like polyimide or polyesterimide with good high-temperature resistance, allowing them to operate at temperatures up to 240°C. This ensures their suitability for the elevated temperature environments generated by the heat produced during the operation of electric vehicle motors.
Corrosion resistance
Electric vehicles often encounter corrosive environments such as humidity and unfavorable acid-base conditions, demanding high corrosion resistance from enameled wires. Enameled wires for electric vehicles typically utilize insulation enamels with excellent corrosion resistance to ensure long-term performance in harsh conditions.
Winding processability
The winding processability of enameled wires is a crucial performance indicator, directly impacting the production efficiency and quality of electric motors. Enameled wires for electric vehicles commonly exhibit good winding processability, facilitating the winding and shaping of complex wiring configurations.
Reliability
Enameled wires with a well-designed insulation coating and high-quality copper/aluminum conductors can meet the stability and reliability requirements of automotive electrical systems, enhancing system lifespan.
Lightweight design
The use of copper-clad aluminum or pure aluminum conductor enameled wires in electric vehicle auxiliary systems can effectively reduce overall weight, contributing to the realization of lightweight electric vehicle designs. Cost Reduction
Mature production processes and lower customized batch costs make enameled wire production cost-effective. With good winding processability, it enhances electric motor production efficiency and reduces overall production costs.
Application of enameled wire in the electric vehicle field
Generator
The electric motor is the core of a new energy vehicle's power, and the winding of the electric motor directly affects the vehicle's performance and efficiency. Enameled copper wire, as the primary material for motor windings, provides excellent conductivity, effectively reduces resistance, and thereby enhances the motor's efficiency.
Traction motor
The traction motor is a core component of an electric vehicle, responsible for propelling the vehicle forward. Enameled wire, used for motor windings, offers good conductivity, excellent heat resistance, and corrosion resistance, meeting the high-performance requirements of the motor.
Battery connections
The battery system serves as the power source for new energy vehicles, requiring reliable electromagnetic wires for connections between individual battery cells and the electric motor. Enameled copper wire, with outstanding conductivity and insulation properties, ensures the efficient operation of the battery system while preventing short circuits and energy losses.
Lane assistance systems
Lane assistance systems compile data actively from sensors in the rearview mirror and other vehicle sensors. They drive motors within the steering mechanism to help the vehicle avoid collisions through corrective measures.
Braking system
The braking system utilizes the enameled wire motor as a generator, converting kinetic energy lost during deceleration back into energy stored in the battery. Enameled wire, used for motor windings, provides good conductivity, high heat resistance, and corrosion resistance, meeting the high-performance requirements of the motor.
Charging stations
Charging stations provide charging services for electric vehicles. Enameled wire is used for the connection cables in charging stations, featuring good conductivity, high heat resistance, and corrosion resistance, meeting safety and reliability requirements for charging stations.
Why choose Signi enameled wire
- Signi offers a variety of enameled wires, including polyesterimide enameled wire, polyesterimide/polyamide-imide composite, polyamide-imide enameled wire, enameled aluminum round wire, enameled aluminum flat wire, copper-clad aluminum enameled wire, and more.
- Signi carefully selects high-quality aluminum rods, applying paint uniformly through molds to maximize the avoidance of factors such as uneven paint film, eccentricity, and pinholes that may affect the comprehensive performance of enameled wire during the production process.
- Signi has a rigorous testing system, ensuring that all enameled wires leaving the factory undergo thorough testing to meet standard levels in scratch resistance, softening breakdown performance, temperature resistance, and more.
- Signi has obtained various certifications, including IEC, IATF 16949, ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, demonstrating its commitment to quality. Customization of enameled wires according to different standards is available to meet specific requirements.
- As a manufacturer in the aluminum industry, Signi prioritizes quality and after-sales service, offering a comprehensive solution for your enameled wire needs.
