Ensuring Every Enamel Wire is Safe and Reliable
Raw Material Selection
Quality starts with source control. We select high-purity electrolytic copper (copper content ≥99.99%) as the conductor material to ensure excellent conductivity and ductility. The paint film is made from imported heat-resistant insulating coatings such as polyester and polyimide, meeting the requirements of high-temperature electrical applications (155°C–220°C).
Precision Drawing and Annealing Control
The dimensional accuracy of the enameled wire depends on the control of the wire drawing and annealing stages. We use CNC wire drawing equipment to strictly control the wire diameter tolerance (±0.002mm) and roundness. Annealing temperature is monitored online throughout the entire process to ensure conductor softness and uniform crystallization, avoiding oxidation, cracking, and internal stress concentrations.
Uniform and Defect-Free Coating
The coating process utilizes a multi-pass continuous dip coating followed by heat curing, ensuring consistent thickness of each coat, ensuring overall pressure resistance. The curing oven has a multi-stage temperature control system to ensure full polymerization of the paint film. Online optical inspection and eccentricity monitoring systems can detect coating thickness and defects in real time, preventing defects such as bubbles, exposed copper, and cracked coatings.
Comprehensive Electrical and Mechanical Testing
Dielectric Strength Testing
Ensures that the insulating paint film withstands high voltage without breakdown and complies with IEC and NEMA insulation grade standards.
Paint Adhesion Testing
Verifies that the insulation layer is firmly bonded to the copper conductor and resists peeling through scratching, tensile, and torsion tests.
Solvent Resistance Testing
Evaluates the chemical resistance of the paint film by immersion in solvents such as alcohol and acetone to ensure it can withstand subsequent processing steps such as dipping and cleaning.
Mechanical Performance Testing
Examines tensile strength, elongation, and elastic recovery to ensure product suitability for high-speed automatic winding equipment.
Environmental and Aging Reliability Testing
To ensure long-term stability in complex electrical environments, we perform multiple simulated life tests:
Heat Aging Testing
Continuously heats the film at high temperatures for 168 hours to detect insulation degradation.
Damp Heat Testing
Tests paint film adhesion and electrical performance changes under high temperature and humidity conditions.
Abrasion Resistance Test
Simulates high-speed winding conditions to verify the paint film's wear resistance.
Short-Term Overload Test
Simulates current surges to evaluate the product's thermal stability and insulation integrity in high-temperature environments.