Double Fiberglass Covered Flat Copper Wire – Custom Sizes Available

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Conductor Dimensions

Our double fiberglass covered flat copper wire is available in a comprehensive range of sizes to accommodate diverse application requirements. The conductor dimensions follow industry-standard specifications, with typical ranges covering most motor and transformer designs.

The flat copper conductor thickness typically ranges from 0.80 mm to 8.00 mm, while the width ranges from 2.00 mm to 35.00 mm depending on the specific product configuration . For standard double fiberglass covered rectangular copper wire, the narrow side dimension typically ranges from 0.80 mm to 5.60 mm, with the wide side ranging from 2.00 mm to 16.00 mm . Aluminium conductor options are also available with slightly different dimensional ranges.

Insulation Thickness

The total insulation thickness for double fiberglass covered wire typically falls into standard levels, with common specifications of 0.20 mm, 0.30 mm, 0.40 mm, and 0.50 mm . The tolerance on insulation thickness is typically -20% as specified in GB/T 7672-2008 standards. For applications requiring enhanced dielectric strength, additional insulation layers or combination constructions with film materials can be specified.

Thermal and Electrical Performance

Temperature Ratings

Double fiberglass covered wire is available in multiple thermal classes to suit different operating environments. The temperature indices offered include 130°C (Class B), 155°C (Class F), 180°C (Class H), and 200°C (Class C) . The 200°C thermal class is achieved using impregnating varnishes such as polyesterimide or silicone resins, as specified in GB/T 7672.24-2008 .

Breakdown Voltage

The dielectric strength of double fiberglass covered wire is specified according to the insulation configuration. For double fiberglass covered wire, the minimum breakdown voltage requirement is 560V as specified in industry standards . This provides adequate electrical protection for the majority of medium-voltage motor and transformer applications. For applications requiring higher voltage withstand capability, additional insulation layers or combination with film insulation can be specified.

Technical Standards Compliance

International and National Standards

Our double fiberglass covered flat copper wire is manufactured in compliance with multiple international and national standards to ensure product quality and compatibility with global equipment designs:

• IEC 60317-0-6:2020: The international standard specifying general requirements for glass-fibre wound resin or varnish impregnated winding wires . The standard includes provisions for appearance requirements, maximum overall diameters for single and double glass-fibre coverings, and minimum elongation testing .

• GB/T 7672.1-2008: The Chinese national standard for glass-fiber wound winding wires, which is equivalent to IEC 60317-0-4:2006 . This standard provides general requirements for glass-fiber wound rectangular copper wire and forms the foundation for the GB/T 7672 series.

• GB/T 7672.3-2008: The standard for 155°C (Class F) glass-fiber wound rectangular copper wire, specifying requirements for varnish impregnated and enamel-coated variants.

• GB/T 7672.4-2008: The standard for 180°C (Class H) glass-fiber wound rectangular copper wire, providing specifications for higher temperature applications.

• GB/T 7672.5-2008: The standard for 200°C glass-fiber wound rectangular copper wire, suitable for extreme thermal environments .

Quality Management

Our manufacturing facility maintains quality management systems certified to international standards, ensuring consistent product quality across all production batches. This includes dimensional verification, electrical testing, and visual inspection at multiple stages throughout the manufacturing process.

Manufacturing Process

Conductor Preparation

The manufacturing of double fiberglass covered flat copper wire begins with the careful selection of high-purity electrolytic copper. The copper undergoes a drawing process to achieve the required conductor dimensions, followed by annealing to achieve optimal flexibility and electrical conductivity . For flat conductors, the round copper wire is cold-drawn and deformed through professional forming equipment to achieve the rectangular cross-section .

Precision size control is maintained throughout the forming process, with dimensional accuracy typically held to within 0.001mm . This level of precision is essential for ensuring consistent electrical performance and uniform fiberglass covering.

Surface Preparation

Following the forming operations, the copper conductor undergoes ultrasonic cleaning using pure water to remove surface contaminants, oxides, and processing residues . This cleaning step is critical for ensuring proper adhesion of the impregnating varnish and long-term reliability of the insulation system.

Fiberglass Winding

The defining operation in manufacturing double fiberglass covered wire is the application of the fiberglass covering. The process involves wrapping two layers of alkali-free fiberglass yarn around the copper conductor in a spiral pattern . The two layers are typically wound in opposite directions (right-hand and left-hand lay) to ensure complete coverage and enhanced mechanical strength .

The winding process is performed on specialized machinery with precise tension control to ensure uniform coverage and consistent insulation thickness. The winding directions and tension must be carefully controlled to prevent gaps or overlaps that could compromise insulation integrity.

Impregnation and Curing

After the fiberglass winding is complete, the wire passes through an impregnation and curing process. The wire is coated with insulating varnish of the required temperature resistance index, then passed through a curing oven where the varnish is baked to bond the fiberglass layers and the fiberglass to the conductor into a unified insulation system .

The impregnating varnish selection depends on the required thermal class, with options including polyester resins for 130°C (Class B), polyesterimide or silicone resins for 200°C (Class C), and other varnish formulations for intermediate temperature ratings .

Final Processing

Following impregnation and curing, the finished wire undergoes final processing including cooling, dimensional verification, and testing. The wire is then wound onto spools for shipment using permanent tension winding equipment to ensure proper packaging and prevent damage during transit.

Packaging

Standard Packaging Options

Our double fiberglass covered flat copper wire is packaged to ensure product protection during transit and convenient handling at the customer’s facility. Standard packaging options include:

• Poly-wood spools: Available in sizes such as PT-25, PT-30, PT-60, PT-90, PT-200, PT-270, with typical weights of 30kg to 150kg per spool .

• Wooden spools: Available in dimensions such as 250mm × 500mm and 250mm × 600mm, suitable for heavier wire gauges and larger order quantities .

• Wooden cases: Used for outer packaging to protect spools during international shipping and provide additional protection against handling damage .

Custom Packaging

We offer customized packaging solutions to meet specific customer requirements, including special spool sizes, pallet configurations, and shipping documentation. Our packaging is designed to prevent damage to the wire and ensure that it arrives at the customer’s facility in optimal condition for winding operations.

Applications

Double fiberglass covered flat copper wire finds extensive application in:

• High-voltage motors: Providing insulation reliability for motor windings operating at elevated temperatures.

• Generators: Offering thermal stability and dielectric strength for power generation equipment.

• Traction transformers: Meeting the demanding thermal and mechanical requirements of railway applications.

• Power substations: Providing insulation for transformer windings in utility and industrial installations.

• Electronics and instrumentation: Serving as high-temperature connection wire in specialized equipment