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Aluminium Conductor Material
The aluminium conductor used in Kapton round wire is manufactured from high-purity electrical grade aluminium, typically alloy grades 1350 or 1370, with an aluminium content of 99.7% or higher. The conductor material conforms to GB5584.3-85 specifications, with a conductivity resistance not exceeding 0.02801 Ω·mm²/m at 20°C.
Diameter Range
Kapton round aluminium wire is available in diameters ranging from 1.0 mm to 5.0 mm. This diameter range encompasses the most common sizes for high-performance motor, generator, and transformer applications requiring polyimide film insulation. The conductor surface must be smooth and clean, free from abrasions, burrs, oil, or metal foam.
Insulation System: F46+Polyimide Film
Material Composition
The insulation system utilises a multi-layer polyimide film with a fluoropolymer (F46/FEP) coating that functions as a heat-fusible layer for bonding to magnet wire conductors. The composite film combines the outstanding properties of polyimide—excellent thermal stability, dielectric strength, and mechanical toughness—with the heat-sealable characteristics of FEP fluoropolymer.
The polyimide F46 film performs successfully across a wide temperature range from -80°C to +260°C, with high radiation resistance, corrosion resistance, and superior dimensional stability.
Wrapping and Heat Sealing Process
The manufacturing process involves evenly wrapping the polyimide film around the aluminium conductor. During subsequent heating, the F46 layer on the composite film melts and flows, bonding the film and conductor into a unified insulation structure.
The wrapping configurations available include overlapped wrapping up to a maximum of 66%, single film construction, or two layers cross-lapped for enhanced dielectric protection. The heat sealing process ensures a continuous, void-free sheath that resists moisture penetration and maintains dielectric integrity under thermal cycling and mechanical stress.
Insulation Thickness
Standard insulation thickness options for polyimide film wrapped aluminium wire include 0.20 mm and 0.30 mm, with custom thicknesses available to meet specific customer requirements. Thinner insulation thicknesses provide a higher space factor compared to glass-fiber covered wires, enabling more compact equipment designs.
Performance Characteristics
Thermal Performance
Kapton insulated aluminium wire is rated for continuous operation at temperatures up to 220°C, with the insulation system capable of withstanding brief temperature excursions up to 260°C. The product is designed for use in temperature ranges from -75°C to 250°C, making it suitable for both cryogenic and high-temperature applications.
Dielectric Strength
The dielectric strength of polyimide film insulated aluminium wire significantly exceeds that of conventional enameled wires. Industry data indicates dielectric strengths of approximately 80 kV/mm for high-quality Kapton insulated constructions. For F46 polyimide film constructions, breakdown voltage exceeds 7,000V. The dielectric constant is 2.9, with a dissipation factor of 0.002 at 1 MHz.
Mechanical Properties
Kapton film provides excellent mechanical strength, flexibility, and scrape abrasion resistance. The material exhibits lower frictional properties than wire insulated with other commonly used polyimide materials, facilitating difficult winding operations. The tensile strength and elongation properties of the polyimide film ensure the insulation remains intact under mechanical stress and vibration.
Radiation and Chemical Resistance
Kapton insulated aluminium wire offers radiation resistance up to 10⁹ Rads, making it suitable for nuclear and aerospace applications. The material also exhibits excellent resistance to moisture absorption, with only 0.4% absorption at 50% relative humidity. The FEP coating provides additional chemical resistance against oils, solvents, and corrosive environments.
Advantages Over Glass-Fiber Covered Aluminium Wire
Aromatic polyimide tape-covered aluminium wire offers several advantages over glass-fiber covered aluminium wire. The polyimide film construction provides a higher space factor, enabling more compact equipment designs. The electrical characteristics and coating flexibility are far superior to those of glass-fiber covered aluminium wire. However, the polyimide film construction is more costly than glass-fiber covered alternatives, so it is recommended primarily for applications where space factor is particularly critical.
Key Applications
Submersible Motors and Submersible Pumps
Kapton round aluminium wire is widely used in submersible motors and submersible pumps, where the insulation system must withstand continuous water immersion and hydrostatic pressure.
High-Voltage Coils
The high dielectric strength of polyimide film insulation makes this wire suitable for high-voltage coil applications.
Wind Turbines
Wind power generation equipment benefits from the lightweight aluminium conductor and the thermal stability of polyimide film insulation.
Traction Motors
The combination of lightweight aluminium and high-temperature polyimide insulation is particularly valuable for railway traction motors, where weight reduction and thermal performance are essential.
Dry-Type Transformers
Polyimide film covered aluminium wire is used in dry-type transformer applications, where the insulation provides the necessary dielectric strength without liquid cooling.
Special Transformers and Reactors
Special transformers, including those requiring high-temperature operation or space-constrained designs, utilize polyimide film covered aluminium wire.
Standards Compliance
Kapton round aluminium wire with F46+polyimide film insulation is manufactured in compliance with multiple international standards:
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GB/T 7673: Chinese national standard for film-covered winding wires
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GB 5584.3-85: Standard for aluminium conductor materials
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GB/T 7673.1-87: Standard for flat conductor dimensions and corner radii
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IEC 60317-43: International standard for aromatic polyimide tape wrapped winding wires, class 240
When referencing the product according to IEC 60317-43, the following information should be provided: the standard reference, the nominal conductor diameter in millimetres, and the grade. Example: IEC 60317-43 – 2.000 mm – grade A2.
Packaging
Kapton round aluminium wire is typically supplied on wooden spools, with common spool dimensions of 600mm and coil weights of approximately 70kg. Custom packaging solutions are available to meet specific customer requirements.
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