Enameled aluminum flat wire is a magnetic wire product with a flat rectangular cross-section. It is suitable for high power density winding design and is widely used in motors, transformers and electric drive systems of new energy vehicles.
By combining a flat wire structure with aluminum conductors, this product improves slot fill factor while achieving lightweighting and cost optimization, and has been widely used in the fields of new energy and high-efficiency motors.
Product Overview
Temperature rating: Class 155 / 180 / 200 / 220
Insulation system: PE / PEI / PAI (optional)
Supply capacity: Supports size customization and bulk delivery
Chalco Enameled Aluminum Flat Wire Product Form Factors and Specifications
The enameled aluminum flat wire adopts a flat rectangular cross-section structure, and some specifications can be provided with a cross-section form with a near-equilateral ratio (square). The corners are rounded (R-corner) and are suitable for the engineering design needs of motors and power windings. It supports a variety of specifications and mass production.
-
Cross-sectional dimension range
Standard size range : Thickness 1.0 – 5.6 mm ; Width 2.0 – 16.0 mm
Maximum available dimensions: Thickness 2.0 – 10.0 mm ; Width: 16.0 – 35.0 mm
-
Conductor corner radius (R-angle design)
Enameled aluminum flat wire features a rounded corner (R-angle) conductor, typically ranging from 0.5 × thickness to 1.0 mm, supporting winding forming and insulation protection. The R-angle can be adjusted based on specifications and application requirements.
The specific R-angle size can be matched and adjusted according to specifications and application conditions.
-
Enamelled insulation layer configuration
Coating grade: Grade 1 / Grade 2 / Grade 3 (optional)
Coating thickness (double-sided): Level 1 coating 0.05 – 0.08 mm; Level 2 coating approximately 0.12 mm ;
Thickened coating: up to 0.45 mm
Chalco Enameled Aluminum Flat Wire Cooperation Areas
Based on its comprehensive capabilities in aluminum conductor materials, enameled insulation systems, and bulk delivery, Chalco enameled aluminum flat wire has established long-term partnerships with many motor and power equipment manufacturers, and its products are widely used in the following fields:
New energy vehicles and electric drive systems
Suitable for electric drive applications requiring high fill factor, thermal stability, and batch consistency.
Widely used in new energy vehicle drive motors, hairpin motor windings, and electric drive systems.
Industrial motors and high-efficiency motors
Designed for continuous operation and stable performance under high-load conditions.
Applicable to servo motors, variable frequency motors, and high-efficiency industrial motors (IE3 / IE4 / IE5).
Transformers and power equipment
Suitable for medium to large cross-section conductors with high requirements for dimensional consistency and insulation reliability.
Used in dry-type transformers, reactors, and high-current, high-power winding systems.
Industrial and Energy Systems Project
Motors and winding systems for industrial equipment
New energy and power engineering supporting equipment
Project-based, batch conductor supply needs
If you have specific specifications or project requirements, please submit the parameter information to obtain the corresponding selection and supply solution.
Chalco's core advantages in enameled aluminum flat wire
In motor and power winding design, enameled aluminum flat wire, through its structural form and material combination, provides a more cost-effective conductor solution for high power density and large-scale applications.
- High slot fill factor flat wire structure, which increases winding power density in a limited space
- Aluminum conductor solution achieves lightweighting and optimizes overall material costs.
- The flat cross-section facilitates heat dissipation and is suitable for continuous operation and high-load conditions.
- The smooth and uniform coating surface reduces the risk of winding friction and scratches, making it suitable for automated winding production.
- Mature applications in project-based and mass production scenarios, adaptable to long-term stable supply needs.
Typical technical performance reference
Enameled aluminum flat wire meets the conventional engineering application requirements for windings in motors, transformers, and power equipment in terms of mechanical properties, electrical insulation properties, and chemical stability.
The following data are reference performance indicators under typical specifications and test conditions; specific parameters can be adjusted according to conductor size, temperature rating, and enamel film structure.
Coating system and temperature resistance rating
Coating type (optional): PE / PEI / PAI
Paint film grade: Grade 1 / Grade 2 / Grade 3
Temperature rating: Class 155 / 180 / 200 (configurable upon request)
Different coating systems and grade combinations can meet different temperature rise, voltage and usage environment requirements.
Mechanical properties (flexibility and adhesion)
| Project | Class 120 | Class 180 | Class 200 |
| Bending along the edge (b ≤ 10 mm) | 2 × b | 4 × b | 4 × b |
| Bending along the edge (b > 10 mm) | 3 × b | 5 × b | 5 × b |
| Bending along a plane (all sizes) | 2 × a | 4 × a | 4 × a |
| Elongation at break | ≥32% | ≥32% | ≥32% |
| Note: b is the conductor width, and a is the conductor thickness. | |||
Electrical performance (breakdown voltage)
| Test conditions | Class 120 | Class 180 | Class 200 |
| Room temperature, Grade 1 paint film | ≥1500 V | ≥1500 V | ≥1500 V |
| Room temperature, Grade 2 paint film | ≥2500 V | ≥2500 V | ≥2500 V |
| High temperature, Grade 1 paint film | ≥750 V | ≥750 V | ≥750 V |
| High temperature, Grade 2 paint film | ≥1500 V | ≥1500 V | ≥1500 V |
Chemical properties (media compatibility)
| Project | Class 120 | Class 180 | Class 200 |
| Resin resistance | 5H | 3H | 4H |
| Solvent resistance | 2 h | 3 h | 4 h |
| Transformer oil | Excellent | Very Good | Very Good |
| refrigerant | — | Good | Very Good |
Production capacity and supply methods
To meet the application needs of enameled aluminum flat wire in motors and power windings, production covers two process routes: flattening and extrusion molding. This supports mass production of different cross-sectional specifications and application scenarios, ensuring consistency in dimensions, coating, and delivery.
Production Route 1: Precision Flattening (Rolling)
Enameled round aluminum wire → Multi-stage flattening → Online inspection → Coil delivery
- Suitable for motor and new energy vehicle windings
- Maintain paint film integrity and edge quality
- Supports parallel production and mass production of multiple specifications.
- Commonly used in continuous operation conditions such as hairpin motors and high-efficiency motors.
Production Route 2: Extrusion
Aluminum billet → Extruded flat conductor → Enameled insulation → Finished product inspection → Coil delivery
- Covering medium and large cross-section specifications
- Suitable for transformers, reactors and high-power winding systems
- Meeting project-based and long-term stable supply scenarios
Supply form
Spool types: PT25 / PT30 / PT35 / PT60 / PT90 / PT200 / PT270
Single roll weight: up to 150 kg/spool
Supports tapered and custom spools; specifications can be matched to equipment requirements.
It is suitable for automatic winding, mass production and continuous feeding conditions.
Enameled aluminum flat wire vs. enameled copper flat wire selection comparison
In motor and power winding design, both enameled aluminum flat wire and enameled copper flat wire are widely used. The two materials differ in conductivity, weight, cost, and application focus; therefore, selection should be based on specific application conditions.
| Comparison Dimensions | Enameled aluminum flat wire | Enameled copper flat wire |
| Conductor density | Lower levels are beneficial for overall weight loss. | higher |
| conductivity | Below copper, it is usually achieved through cross-sectional compensation design. | higher |
| Winding slot full rate | A higher slot fill factor can be achieved with a flat wire structure. | Also suitable for flat wire high-slot fill rate design |
| Cost structure | Material costs are relatively controllable, making it suitable for mass production. | High material costs |
| Heat and continuous operation | Applicable to continuous operation under reasonable design conditions | Suitable for high power density and compact design |
| Typical application focus points | Lightweight, cost control, and large-scale application | High conductivity, compact structural design |
Selection Reference Guide
In new energy, motor and power equipment projects, enameled aluminum flat wire and enameled copper flat wire are not simply substitutes, but rather material choices based on different design goals and application focuses.
- When applications prioritize system weight control, material costs, and mass production, enameled aluminum flat wire is typically included in the selection criteria.
- When the design focuses more on extreme conductivity or installation space is limited, enameled copper flat wire remains a common choice.
- In flat wire winding structures, both materials can meet engineering application requirements through reasonable cross-sectional design and insulation configuration.
Actual selection should be based on specific application conditions. If you require a comparison of the compatibility between enameled aluminum flat wire and enameled copper flat wire, please provide parameters to confirm the appropriate selection and supply plan.
Project Selection and Cooperation Guidelines
Enameled aluminum flat wire is suitable for motor and power winding projects with specific requirements for weight control, cost structure, and bulk supply.
After clarifying the application conditions, specification range, and operating conditions, the material solution and supply method can be further confirmed.
Common Project Focus
Q1: Is enameled aluminum flat wire suitable for mass production projects of new energy motors?
A: Under reasonable current density and structural design conditions, enameled aluminum flat wire has been widely used in new energy and high-efficiency motor projects, and is suitable for mass production and long-term supply needs.
Q2: Does the project support customization based on project specifications?
A: We can match the specifications according to the cross-sectional dimensions, temperature resistance rating, paint film type, and delivery schedule to support project progress in the sample, trial production, and mass production stages.
Q3: How can we determine whether an aluminum or copper solution is more suitable for the current application?
A: After providing the application parameters, the selection and solution confirmation of enameled aluminum flat wire and enameled copper flat wire can be carried out in combination with performance requirements and supply conditions.
If you are currently selecting materials for a motor or power winding project, please submit your application parameters. Chalco can assist in material selection and supply solution confirmation.
Chalco can provide you the most comprehensive inventory of aluminum products and can also supply you customized products. Precise quotation will be provided within 24 hours.
Get a quote
