Why Magnet Flat Wires Are More Suitable for Electric Vehicles?

With the continuous advancement of electric vehicle technology, the requirements for the drive motor are increasing, and the selection of enameled wires has become crucial. Below, we will explore the advantages of using enameled flat wires instead of enameled round wires in electric vehicle drive motors and analyze the development trends of enameled wires.

The 5 advantages of choosing enameled flat wires for electric vehicle motors

Increased slot fill ratio

Enameled round wires exhibit a relatively lower packing factor within the same motor winding space, while the excellent design of enameled flat wires (flat wires) allows for a higher slot fill ratio. This means that more conductors can be arranged in the same space, thereby enhancing the efficiency and power of the motor.

Higher load current and motor output power

The design of enameled flat wires enables them to withstand higher load currents, achieving higher motor output power. This provides electric vehicles with more robust driving performance, improving the overall driving experience.

Better motor cooling, lower temperature rise

The rectangular cross-section of flat wires provides a larger surface area for heat dissipation compared to round wires, effectively reducing the motor's temperature rise. Lower temperature rise results in reduced motor losses, higher efficiency, and prolonged motor life.

Reduced manufacturing costs

The use of enameled flat wires can optimize motor design, reducing motor size and weight, thus lowering manufacturing costs. This aligns with the electric vehicle industry's pursuit of cost-effectiveness and increased competitiveness.

Additional advantages of using enameled flat wires for drive motors

In addressing the specific requirements of electric vehicle drive motors, enameled flat wires offer the following additional advantages:

• Excellent resistance to corona discharge, extending motor life.
• Increased initial voltage for partial discharges, reducing the likelihood of localized discharges.
• Good compatibility with cooling oil, adapting to complex working environments.
• Sufficient robustness to prevent motor short circuits, ensuring system reliability.

Specific applications of enameled flat wires in electric vehicles

Enameled flat wires, known for their space-saving design, high fill factor, large cross-section, and deformation resistance, find extensive applications in motor windings. In the design of next-generation traction motors, enameled flat wires offer higher packing density, improved cooling effects, and enhanced flexibility in motor design, particularly excelling in high-torque applications. The applications of enameled flat wires in electric vehicles include, but are not limited to, motor windings, battery connections, electronic control systems, braking systems, and charging stations.

Trends in the development of enameled wires for electric vehicles

The future development of enameled wires in the electric vehicle field shows clear trends. Firstly, there is a growing preference for rectangular wire designs to enhance motor efficiency and power output. Secondly, enameled wires will focus more on uniformity, insulation levels, and the application of multifunctional coatings to adapt to complex working environments.

Aluminum enameled wires are gradually becoming the mainstream in the market due to their high performance. The application of distributed windings and high-performance insulation materials will further optimize motor designs. The future development of enameled wires will emphasize improving motor performance, reducing costs, and adapting to high-voltage working environments, providing stronger power support for electric vehicles.

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.

Signi magnet wire hot products for electric vehicles