| ELEKTRISOLA

Bondable Magnet Wire, Bondable Copper Magnet Wire

BondABLE MAGNET Wire

General

Our Product Line

General

Bondable magnet wire, also referred to as Selfbonding magnet wire, is film insulated wire ( Goto Magnet Wire Types ) which is coated with an additional bonding adhesive.

Backlight microscope picture of SB-wire

After activating the bondcoat, the individual turns of the coil are bonded together to produce self-supporting coils ("air coils" without bobbin) or special coils for later processing.

Use of bondable magnet wire offers advantages over conventional magnet wire in certain winding applications, eliminating the need for bobbins as well as taping or varnishing steps.

Cross section of wound coil
(Lighter colour = insulation, dark colour = bondcoat)

In many applications such as high-power speakers or small motors, bondable magnet wire can improve the performance and reliability. An important property of a bondable magnet wire is the thermal stability of the wound coil at higher temperatures. A thermoplastic bondcoat will become soft at higher temperatures and begin to lose its bond strength, but

could also be processed, for example, to form another shape of a coil and be rebonded at higher temperature. A thermoset bondcoat has higher heat resistant properties, so will lose its bond strength only at a temperature that will destroy the enamel.

Bondable magnet wire wound by hot-air and formed to rectangular shape

Because of the additional application of a bondcoat, selfbonding magnet wire is more expensive than normal wires, which is offset by the value added.

Activation of the bondcoat may be achieved with either heat, or in some cases a solvent, or a combination of the two ( Goto Bonding Processes ).

Our Product Line

Elektrisola produces bondable magnet wire with diameters of 0.010 - 0.50 mm ( Goto Technical Data by Size ). In addition to copper as a conductor material, other alloys are available, such as Aluminium or Copper Clad Aluminium for light weight coils or high tensile strength conductors for better durability ( Goto Metals ).

CCAW with bondcoat

Selfbonding magnet wire types can be differentiated by the chemical basis of their coatings, primarily by their thermal properties, by their technical properties and by the preferred bonding method.

The basic bondable magnet wire types offered around the world have differences mainly explained by the history of their development. Therefore Elektrisola offers selfbonding magnet wire types for the 3 major continents
( Goto Selfbonding Wire Types ). In Asia, special high performance bondcoats formulated for use in specific Asian applications are also offered ( Goto High Performance Selfbonding Wire Types ).

In addition to standard selfbonding enamel types, ELEKTRISOLA has its own certified selfbonding enamel development for special applications. For example, in fine wire sizes, specialized ultra-high temperature selfbonding enamel types are now available, which can be wound with automated hot-air winding machines for fast and cost effective processing providing a major advantage to Elektrisola customers.

Production Process

The production process of a selfbonding magnet wire is similar to a normal film insulated wire

( Goto Enamelling Process ), but needs 2 enamel applicators, one for the electrical insulation coating, and one for the bondcoat.

Bonding Process

The bondcoat adhesive on the outside of the bondable magnet wire can be activated by heat or with chemicals. These bonding methods are described below.

Heat/Thermal Bonding:

All Elektrisola bondcoats can be activated by heat, either by directing hot air on to the wire during winding, by oven-heating of the wound coil, or by applying electric current to the wound coil after the winding cycle is completed. In any of these examples, the principle is to heat the winding slightly above the bondcoat’s melting temperature in order to activate the bondcoat and bond the wires together.

Hot-air Bonding during winding has the advantage of eliminating the secondary bonding operation. This method is cost effective and primarily used for wire sizes thinner than 0.200 mm. This method became much more popular over the last few years following the development of ultra-high temperature selfbonding enamel types.

Hot air winding

Oven Bonding is accomplished by heating the wound coil, which still remains on a fixture or tooling, in an oven at a suitable temperature and time sufficient to obtain uniform heating throughout the winding followed by a cooling cycle. Heating time is generally 10 to 30 minutes, depending on the size of the coil. Disadvantages of oven bonding are the longer bonding time, additional process steps, as well as the potential need for many winding fixtures.

Resistance Bonding is accomplished by applying electric current to the finished coil to electrically heat it by resistance to the proper bond temperature. Bonding voltage and time are dependent upon wire size and coil design, and therefore will need to be developed experimentally for each specific application. This method has the advantages of being quick and generating a quite uniform heat distribution. It is typically used for wire sizes thicker than 0.200 mm.

Solvent Bonding:

Some bondcoats can be activated by applying specified solvents during the coil winding process. Application of the solvent, usually via a saturated felt during winding ("Wet Winding"), causes the bondcoat to become very soft. This process requires the use of a fixture to hold the coil in place while the solvent is drying and the wires stick together. Afterwards, the coil should be heated in an oven cycle to evaporate any residual solvent, which, if left within the coil, might cause long-term coil failure, as well as to complete the adhesive curing process for optimum bond strength.

Applications

Cellphone

Automotive

Industrial

Identification

Appliance

Consumer

Watches

Computer

Medical

Advantages OF BONDABLE MAGNET WIRE

The use of bondable magnet wire offers multiple advantages to customers:

Eliminates the need for bobbins
No need for taping or varnishing
Less handling in the process

Reduced total cycle times
Improved performance
Low environmental impact

Magnet wire, Magnet Copper Wire

Magnet Wire

General

Magnet wire is a metallic conductor insulated with a varnish and generally used for electrical applications. Most times magnet wire is wound in different shapes of coils to generate magnetic force for motors, transformers, magnets etc. Elektrisola produces over 30,000 different types of magnet wire with the most important differences of characteristics as follows:

Conductor Material for Magnet Wire

Copper is the standard used conductor material with excellent conductivity and very good windability. For low weight and larger diameters Aluminum sometimes can be used as a conductor material for magnet wire. Because of the difficult contacting of Aluminum wire with problems of oxidation Copper Clad Aluminum can help to compromise between Copper and Aluminum. For special applications a wide variety of conductor materials is offered, such as Brass, Silver, Nickel, Gold, Stainless Steel, or alloys of copper for special characteristics like higher mechanical strength or bending performance. In addition, the core conductors can be plated with different materials such as Silver or Nickel.

Metals

Bare Wire Diameter Range

Elektrisola specializes in fine magnet wire diameters, starting with 0.008 mm (8 microns), and going up to a diameter of 0.50 mm. Beside the standardized diameters a big variety of special diameters is produced according to customer’s specification. Bare wire tolerances are very important in magnet wire as they have direct impact on the resistance what again determines the variance of the final coil resistance.

Technical Data by Size for Magnet Wire

Comparison of 0.010 mm wire with human hair

Outer Diameter of Magnet Wire

International standards like IEC group magnet wires according to ranges of specific outer diameters. IEC groups the insulation in Grade 1, 2, or 3, NEMA in single, heavy, or triple, and JIS in class 0, 1, 2, or 3. The tolerances in these standards can be further restricted if necessary to design and optimize the wound coils and final products.

Technical Data by Size for Magnet Wire

Magnet wire outer diameter control by laser

Outer diameter control by usng a laser

Selfbonding Layer

In addition to the base coat insulations described separately, a selfbonding layer can be applied to the magnet wire, by which the wire will be bonded together for example for bobbinless coils, such as voice coils.

Selfbonding Wire Types

Transmitted light photo of selfbonding wire 0.09 mm AB15 green

V=200 X

Spool Types for Magnet Wire

Spool types have to fit to the wire size. Finer magnet wire sizes are wound on smaller spools, while for heavy sizes very large spools can be used. They are important for productivity as larger spools require less spool changes on the winding machines.

Spools & Packaging for Magnet Wire

The wire length on one spool can be very long:

0.018 mm on spool 99L: up to 417 km of magnet wire
0.05 mm on spool 199L: up to 1143 km of magnet wire
0.30 mm on spool 400/630: up to 277 km of magnet wire

Insulation Types for Magnet Wire

Elektrisola offers a wide range of different insulations. Polyurethane has the advantage of easy direct contacting by soldering, while Polyester insulations are more resistant against higher temperatures. Thin top coats as Nylon or Polyamidimide may improve certain desired characteristics like mechanical or chemical strength of the magnet wire.

Magnet Wire Types

Magnet Wire Colors

Colors may be used to differentiate magnet wire types or diameters, but have the disadvantage of lower technical properties and higher costs.

Lubrication for Magnet Wire

A defined very low amount of lubrication – mostly special types of paraffin – is applied to achieve excellent windability of the magnet wire in all winding processes without wire breaks.

Our Product Line of magnet wire

Elektrisola specializes in fine magnet wire diameter and offers a wide range of products from 0.008 mm (8 microns) to 0.50 mm with many different enamel types on different conductor materials.

Magnet Wire - Diameters

For copper: 0.008 mm – 0.50 mm
For other metals: Please inquire

Specifications for Magnet Wire

Elektrisola produces magnet wires according to many different specifications. The most important worldwide used specification is IEC, besides NEMA in North America and JIS in Asia.

Technical Data by Size for Magnet Wire

Enamel Types for Magnet Wire

Polyurethane
is a varnish which is easy for direct contacting by soldering, welding or crimping. Especially for fine magnet wire the easy soldering is the most advantage of this enamel type. Polyurethanes are available with Temperature Index 155 °C (Polysol^© 155) and Temperature Index of 180 °C (Polysol^© 180). This enamel is available from 0.008 to 0.50 mm on all of our conductor materials.

Polyesterimides
are more resistant against higher temperatures and beside the pure Polyesterimide (Estersol^© 180) not usable for direct soldering. Under this enamel type also Theic-modified Polyesterimide (Amidester^© 200) or (Amidester^© 210) are listed.

Polyamidimides and Polyimides
have the highest temperature and chemical resistance and you will find them as I220-magnet wire or ML240^©-magnet wire at ELEKTRISOLA product portfolio.

Enamel Wire Types

Based on the above mentioned enamel types, you can combine all these enamels with a self bonding coat such as Polyvinylbutyral, Polyamide or Polyester.

Selfbonding Wire Types

Selfbonding wire can be bonded by different methods

Bonding Methods

Production Process for magnet wire

Drawing process

For copper wires an 8 mm copper rod (5/16″ in USA) is used as raw material, which is drawn through drawing dies to the required bare wire dimension in several stages. The copper rod has to be of high purity and consistenly high quality to manufacture fine and ultrafine wires of sizes below 10 µm. ELEKTRISOLA uses only pure electrolytic copper ETP1 (copper content min. 99.99 %) from pre-approved high quality vendors.

The drawing process is carried out sequentially through several groups of machines producing specific diameter ranges. The wire is elongated in several stages through dies, so that the larger wire is permanently becoming thinner and longer during the drawing process while the volume remains unchanged.

Multiple drawing with cones

The quality of the copper, the fine tuning between the different drawing stages, and especially the quality of the drawing dies, are all of high importance to achieve a high quality final bare wire. The bearing surfxes of the wire drawing dies consist of natural or artificial diamonds or, for heavy wire production, of carbide.

Cross section of a drawing die

Enamelling Process for Magnet Wire

All magnet wires are magnet on special enamelling machines which are developed and produced by ELEKTRISOLA for our exclusive use. Enamelling is a continuous process, mainly consisting of the annealing process, enamel application, curing process, lubricant application, tension control and spooling.

1. Annealing Process
During the drawing process the bare wire’s grain structure has been changed through cold deformation. Annealing will re-crystalize the copper and make it soft again. This thermal stress relief process is carried out under protective atmosphere in order to avoid oxidizing the wire surface, which would interfere with good adherence of the initial coating of insulation later in the process. Softness of the magnet wire is an important criteria for good windability, in particular significantly reducing the number of wire breaks.

2. Enamel Application
There are 2 main application systems for enamelling of winding Magnet wires, i.e felt application and die application, whereas felt application is mainly used in fine magnet wire production, while die application is mainly used in heavy magnet wire production. The enamel coating should always be applied in as many single layers as possible rather than fewer and thicker layers to achieve better mechanical and electrical properties.

3. Curing Oven
Solvents contained in the liquid enamel are driven out in the curing oven at high Temperature and then are burnt catalytically by using the thermal energy in an environmentally friendly way. Temperature control is very important: if the temperature is too low, too many solvent residues will be left in the enamel layer, leading to poor adhesion and reduced mechanical and electrical properties of the magnet wire. If the temperature is too high, the enamel coating will be hard and brittle, leading to cracks in the insulation coating resulting from mechanical stress.

4. Lubrication
A defined amount of lubricant is precisely applied to the insulated magnet wires surface. Lubrication is necessary to achieve consistent winding properties and failure-free winding of the wire even at high winding speeds.

5. Diameter Control
ELEKTRISOLA continuously monitors the Outer Diameter of all magnet wires after the final pass by laser.

6. Tension Control
A continuous wire tension control during the enamelling process results in a consistently uniform spooling onto the spool. With effective tension control, elongation of the magnet wire is avoided and thus a change in resistance. Furthermore, good de-reeling properties for customer can be guaranteed.

7. Spooling
The wire pitch and the spool’s rotational speed are spooling process variables closely to be controlled. This results in consistently good magnet wire de-reeling performance and minimizes other problems like trapped and tangled wires.

8. Monitor
The monitor informs the operator about all important parameters of the process.

Magnet wire Applications

Automotive

Appliances

Industrial Electronics

Audio and Video

Computer

Watches

Mars Rover

Technical data

Magnet Wire

Magnet Wire Types

There are different enamels available worldwide at Elektrisola. In addition, there are a few types available in selected continents.

Technical Data by Size

The most important technical data of magnet copper wire are controlled by the resistance and outer diameter. These and other values are important as engineering support. Different standards specify these values differently, therefore the three major world standards are shown by size. IEC (International Electrical Commission) is the harmonized worldwide basic standard. NEMA and JIS still maintain additional elements of their older standards into their national standard.

Europe / Asia IEC 60317

Asia JIS C3202

America MW 1000C (inch)

America MW 1000C (metric)

Selfbonding Wire

Selfbonding Wire Types

For our self bonding wires there are typical enamel types available for the different markets, depending on the different standards and also on different main applications for the markets.

Europe

Asia (standard)

Asia (high performance)

America

Technical data by Size

The most important technical data of magnet copper wire are controlled by the resistance and outer diameter. These and other values are important as engineering suport. Different standards specify these values differently, therefore the three major world standards are shown by size. IEC (International Electrical Commission) is the harmonized worldwide basic standard. NEMA and JIS still maintain additional elements of their older standards into their national standard.

Europe / Asia IEC 60317

Asia JIS C3202

America MW 1000C (inch)

America MW 1000C (metric)

Conductor Materials for Magnet Wire

For most of the magnet wire applications copper is used as conductor material but for special applications like voice coils, actuator coils, or other special applications high performance metals are needed.

ELEKTRISOLA has a wide range of special conductor material, like low weight, high mechanical or bending performance metal. In addition, plated conductors are available which show superb characteristics for special applications.

Please contact us for metals not shown in the table.

Detail List of Elektrisola Conductor Materials for Magnet Wire

For most commonly used metals:

Metal Comparison

For detailed information of each metal group:

Copper

Oxygenfree Copper

High Performance Conductors

Aluminum

Copper Clad Aluminum

High Tension Aluminium

Nickel

Brass

Silver

Gold

Plated Conductors

Spools

Spool and Packaging for Litz Wire

Spool Types

Spool Types	Diagramm	Wire Sizes		Characteristics
Biconical	1	37 - 58 AWG	0.010 mm - 0.114 mm	Biconical spool for fine and ultrafine wire, superb de-reeling capability, ideal for high speed winding machines
Cylindrical	2	31 - 50 AWG	0.050 mm - 0.511 mm	Straight barrel spool, solid traditional design
Tapered	3	24 - 38 AWG	0.102 mm - 0.511 mm	Stable winding due to tapered barrel spool for heavier sizes
Container	Container for large spools

European Spools

Spool Type	d1 [mm]	d4 [mm]	I1 [mm]	I2 [mm]	Spool weight [g]	Filling weight unserved litz wire* [kg]	Filling weight served & taped litz wire* [kg]	Filling weight extruded litz wire* [kg]	Spools per box	Spools per pallet max
125K	125	16	125	100	200	2.0	1.3	**	4/6/9	216
160K	160	22	160	128	350	4.8	3.2	2.0	4	96
200K	200	22	200	160	600	8.9	5.9	3.9	2	42
250K	250	22	200	160	1050	16.6	11.0	7.3	1	36
355K	355	36	200	160	1850	32.4	-	**	-	12
VMV630	630	56	475	361	18500	214.0	178.0	**	-	1
VM 710	710	52	250	180	18000	-	81.0 (taped)	**	-	4
400/56-275	400	56	275	241	4590	81.0	67.5 (taped)	**	-	4

Dimensions of the spool

d1 ➡ Flange Diameter

d4 ➡ Core diameter

l1 ➡ Overall width

l2 ➡ Traverse

* Approximate values valid for copper, for other metals please inquire.

** The extrusion machines only work with spools bore diameter of 22 mm / 0.87 inch.

Other packages on demand.

American Spools

Spool Type	Flange diameter d1 [inch]	Bore diameter d4 [inch]	Overall width I1 [inch]	Traverse length I2 [inch]	Spool weight [lbs]	Filling weight unserved litz wire* [lbs]	Filling weight served & taped litz wire* [lbs]	Filling weight extruded litz wire* [lbs]	Spools per box max.	Boxes per pallet max.
3x3"	3.15	0.63	3.15	2.52	0.16	1.23	0.82	**	24	N/A
4x4"	3.94	0.63	3.94	3.15	0.28	2.21	1.43	**	6	N/A
5x5"	4.92	0.63	4.92	3.94	0.54	4.41	2.87	**	6	216
6x4"	6.00	0.63	4.33	4.32	0.75	7.06	4.63	**	6	125
6x6"	6.30	0.87	6.30	5.04	0.8	10.58	7.06	4.85	4	96
8x8"	7.87	0.87	7.87	6.30	1.35	19.62	13.01	8.60	2	42
250K	9.84	3.01	7.80	6.22	3	N/A	N/A	N/A	1	36
355K	13.98	1.42	7.87	6.30	4	71.44	59.54	**	N/A	12

Spool Type	Flange diameter d1 [mm]	Bore diamter d4 [mm]	Overall width I1 [mm]	Traverse length I2 [mm]	Spool weight [kg]	Filling weight unserved litz wire* [kg]	Filling weight served & taped litz wire* [kg]	Filling weight extruded litz wire* [kg]	Spools per box max.	Boxes per pallet max.
3x3"	80	16	80	64	0.07	0.56	0.37	**	24	N/A
4x4"	100	16	100	80	0.125	1.00	0.65	**	6	N/A
5x5"	125	16	125	100	0.245	2.00	1.30	**	6	216
6x4"	152.4	16	110	109.7	0.340	3.20	2.10	**	6	125
6x6"	160	22	160	128	0.35	4.80	3.20	2.20	4	96
8x8"	200	22	200	160	0.6	8.90	5.90	3.90	2	42
250K	250	76.5	198	158	1.461	N/A	N/A	N/A	1	36
355K	355	36	200	160	1.85	32.40	27.00	**	N/A	12

Dimensions of the spool

d1 ➡ Flange Diameter

d4 ➡ Core diameter

l1 ➡ Overall width

l2 ➡ Traverse

* Approximate values valid for copper, for other metals please inquire.

** The extrusion machines only work with spools bore diameter of 22 mm / 0.87 inch.

Other packages on demand.

Asian Spools

Spool Type	d1 (mm)	d4 (mm)	l1 (mm)	l2 (mm)	d14 (mm)	Spool Weight (g)	Filling Weight unserved litz wire* (Kg)	Spools per box	Boxes per pallet max
PT-4	124	22	200	170	140	270	6	4	24
PT-10	160	22	230	200	180	620/420	12	2	30/40
PT-15	180	22	230	200	200	550	18	1	45/36
PT-25	215	32	280	250	230	1000	28	1	24
P-30	300	30	160	130	300	1230	20	1	24
K200C	200	22	200	160	200	625	8	2	24

Dimensions of the spool

d1 ➡ Flange Diameter

d4 ➡ Core diameter

d14 ➡ Flange diameter

l1 ➡ Overall width

l2 ➡ Traverse

Product Range

Litz Wire

Litz Wire Types

Type

Type

Basic

Taped

Extruded

Profiled

Served

With strain relief

Diameter of Magnet Wire

0.010 - 0.500 mm

0.040 - 0.500 mm

0.032 - 0.500 mm

0.200 - 0.500 mm

0.020 - 0.300 mm

0.032 - 0.500 mm

0.030 - 0.300 mm

No. of wires

2 - 25.000 strands

max. 25.000 strands

max. 700 strands

max. 25.000 strands

2 - 23.000 strands

max. 500 strands

max. 23.000 strands

Total outer diameter

0.095 - 15.0 mm

1.0 - 10.0 mm

0.4 - 1.2 mm

max. 10.0 mm

Silk:	0.071 - 4.0 mm
Nylon:	0.071 - 10.0 mm

0.4 - 1.2 mm

0.5 - 5.0 mm

Total copper cross section

80 mm²

36 mm²

0.5 mm²

36 mm²

Silk: 6 mm²

Nylon: 36 mm²

0.38 mm²

up to 10.6 mm²

Outer coating

PET (Thermal class A-F)
PEN (Thermal class B-H)
PI (Thermal class H-C)

Polyamide
Polyester
Polyurethane

optional with/out serving

Serving:	Nylon
Taping:	PET,PEN,PI

Natural silk
Nylon
Polyester

optional with/out extrusion:	Polyamide
	Polyester
	Polyurethane

Taping:	PET
	PEN

Additional options

Overlapping of tape:	50 or 67 %
No. of tapes (max.)	2

Wallthickness overcoat: 0.1 - 0.4 mm

Min. construction(H x W):	1.2 x 1.2 mm
Ratio hight:width (H : W):	1 : 2 (1 : 3, where appropriate)
Tolerance (+/-):	0.1 mm

No. of layers (max.): 2

Multifilament:	optional:
PES	30 - 450 dtex
LCP	Fmax = 1.53 - 99.2 N
Aramide	Dension: 3.3 - 12.4 %

Taping construction: 3 layers (min.)

Characteristics

Flexible optimization of construction and conductor material possible acc.:

HF-performance, resistance
high flexibility, flexlife-performance
form stability

very high electric break down voltage
high mechanical robustness
optimal round form stability (e.g. for layered winding)

high mechanical robustness
high flexibility
good resistance against water, oils and grease
increased electric break down voltage

increase of copper filling factor up to 20 %
high flexibility and dimensional stability
good windability
optional with/out outer coating

optimal round form stability
(e.g. for layered winding)
specified distance between windings
resistance against splicing in combination with high flexibility
support for impregnation- & potting processes

very high tensile strength possible
smallest litz wire constructions with highest tensile strenght and flexlife performance
very good processability also for very small litz wires
combination of all conductor and coating materials possible

	VDE-certified acc.:	DIN EN 60950/U, 62378/J, 61558/K, 62368/J, 60601/L
	Max. working voltage:	1000 Vrms / 1414 Vpeak
	Max. frequency:	500 kHz
	Thermal class:	F/155 °C, H/180 °C

Typical applications

Transformers, Chokes, RF-tranducers, medical applications, sensors, electronic ballasts, switching power supplies, heating applications

Inverter, RF-transformers, RF-transducers, RF-chokes, Inductive charger

Heating applications, Smart Textiles, Patient Comfort

Induction cooking hobs, RF-transformers, RF-chokes, E-motors

Inverter, RF-transformers, RF-transducers, RF-chokes, Inductive charger

Automotive industry, industrial applications, medical applications, Smart Textiles, special applications for technical textiles, sports equipment

Inverter, RF-transformers, RF-transducers, RF-chokes, Inductive charger

See details

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Spools/Packaging

Spools and Packaging for MAGNET Wire

General

Magnet wire is wound on spools of different sizes and shapes. The wire diameter determines the spool size which can be used. Ultrafine wire typically is produced on smaller spools while heavy wire is wound on very large spools.

Different global standards specify different spool types which are typically associated with each continents standard.

Europe

Selection of Spool Type

Spool Types	Wire Sizes	Characteristics
Biconical	0.010 - 0.15 mm	Biconical spool for fine and ultrafine wire, superb de-reeling capability, ideal for high speed winding machines
Cylindrical	0.05 - 0.50 mm	Straight barrel spool, solid traditional design
Tapered	0.10 - 0.50 mm	Stable winding due to tapered barrel spool for heavier sizes
Container	Container for large spools

Biconical Spool

Spool Type	d1 [mm]	d4 [mm]	I1 [mm]	I2 [mm]	Spool weight [g]	nom. net wire weight [kg] *	recommended for wire sizes [mm]	spools per box	units per pallet
76/45	63.5	16	86	60	70	0.3	0.010 - 0.019	6	120
79/45	80	16	100	70	80	0.7	0.020 - 0.024	4	72
99L	100	16	125	96	150	1.0	0.016 - 0.032	6	20
124/45R	125	16	125	65	160	2.5	0.030 - 0.044	6	24/24
124L	125	22	200	140	290	4.5	0.030 - 0.060	4	24
159/45R	160	22	160	85	315	6.0	0.044 - 0.071	4	18
199/45R	200	22	200	106	600	11.0	0.050 - 0.100	2	21
199L	200	22	315	221	900	22.0	0.050 - 0.090	container	12
249/45R	250	22	250	132	1000	25.0	0.063 - 0.140	container	22

* valid for copper, for other metals please inquire

Cylindrical Spool

Spool Type	d1 [mm]	d4 [mm]	I1 [mm]	I2 [mm]	Spool weight [g]	nom. net wire weight [kg] *	recommended for wire sizes [mm]	spools per box	units per pallet
80K	80	16	80	64	70	0.7	0.025 - 0.030	9	60
100K	100	16	100	80	125	1.2	0.030 - 0.036	9	18
125K	125	16	125	100	200	2.5	0.050 - 0.060	6	24
160K	160	22	160	128	350	6.0	0.050 - 0.071	4	18
200K	200	22	200	160	600	11.0	0.060 - 0.120	2	21
250K	250	22	200	160	1050	22.0	0.100 - 0.500	container	22/22

* valid for copper, for other metals please inquire

Tapered Spool

spool type	d1 [mm]	d4 [mm]	l1 [mm]	l2 [mm]	d14 [mm]	spool weight [g]	nom. net wire weight [kg] *	recommended for wire sizes [mm]	spools per box	units per pallet
250KK	250	22	200	160	250	1050	22.0	0.100 - 0.500	container	22
250/400K	236	100	400	335	250	2250	45.0	0.125 - 0.500	container	9
315/500K	300	100	500	425	315	4350	90.0	0.250 - 0.500	container	6
400/630K	375	100	630	530	400	7300	180.0	0.250 - 0.500	container	3

* valid for copper, for other metals please inquire

Container

	Dimensions
Spool	h1 [mm]	d1 [mm]
199L	399	260
250	295	305
249/45R	351	306
250/400	500	315
315/500	630	400
400/630	800	500

America

Selection of Spool Type

Spool Types	Diagramm	Wire Sizes		Characteristics
Biconical	1	37 - 58 AWG	0.010 mm - 0.114 mm	Biconical spool for fine and ultrafine wire, superb de-reeling capability, ideal for high speed winding machines
Cylindrical	2	31 - 50 AWG	0.050 mm - 0.511 mm	Straight barrel spool, solid traditional design
Tapered	3	24 - 38 AWG	0.102 mm - 0.511 mm	Stable winding due to tapered barrel spool for heavier sizes
Container	Container for large spools

Biconical Spool

Spool Designation (inch)	d1 [inch]	d4 [inch]	I1 [inch]	I2 [inch]	Nominal Net Weight/Spool [pound] *	AWG Range	units per box
HK 76/45	2.50	0.63	3.40	2.36	0.66 lbs	46 to 58	6
3S	3.15	0.63	3.94	2.76	1.5 lbs	39 to 54	4
4S	3.94	0.63	3.94	1.85	3 lbs	39 to 52	6
5S	4.92	0.63	4.92	2.25	5 lbs	39 to 50	6
5SL	4.92	0.86	7.88	5.50	8 lbs	39 to 50	4
6S	6.30	0.63/0.86	6.30	2.88	12 lbs	38 to 46	4
8S	7.88	0.86	7.88	3.64	22 lbs	37 to 43	2
10S	9.84	0.86	9.84	4.45	55 lbs	37 to 42	1

* valid for copper, for other metals please inquire

Spool Designation (metric)	d1 [mm]	d4 [mm]	I1 [mm]	I2 [mm]	Nominal Net Weight/Spool [kg] *	mm Range	units per box
HK 76/45	63.5	16	86	60	0.30 kg	0.010 - 0.040	6
3S	80	16	100	70	0.68 kg	0.015 - 0.089	4
4S	100	16	100	49	1.36 kg	0.020 - 0.089	6
5S	125	16	125	65	2.27 kg	0.025 - 0.089	6
5SL	125	22	200	140	3.63 kg	0.025 - 0.089	4
6S	160	22	160	85	5.44 kg	0.045 - 0.102	4
8S	200	22	200	106	10 kg	0.056 - 0.114	1
8SL	200	22	315	221	20 kg	0.056 - 0.114	1
10S	250	22	250	132	25 kg	0.064 - 0.114	1

* valid for copper, for other metals please inquire

Cylindrical Spool

Spool Designation (inch)	d1 [inch]	d4 [inch]	I1 [inch]	I2 [inch]	Nominal Net Weight/Spool [pound] *	AWG Range	units per box
3x3	3.15	0.63	3.15	2.52	1.5 lbs	39 - 50	24
4x4	3.94	0.63	3.94	3.15	3 lbs	39 - 46	6
5x5	4.92	0.63	4.92	3.94	5 lbs	39 - 44	6
6x6	6.30	0.63/0.86	6.30	5.04	12 lbs	31 - 38	4

* valid for copper, for other metals please inquire

Spool Designation (metric)	d1 [mm]	d4 [mm]	I1 [mm]	I2 [mm]	Nominal Net Weight/Spool [kg]	mm Range	units per box
3x3	80	16	80	64	0.68 kg	0.025 - 0.089	24
4x4	100	16	100	80	1.36 kg	0.040 - 0.089	6
5x5	125	16	125	100	2.27 kg	0.050 - 0.089	6
6x6	160	16/22	160	128	5.44 kg	0.102 - 0.226	4

* valid for copper, for other metals please inquire

Tapered Spool

Spool Designation (inch)	d1 [inch]	d4 [inch]	I1 [inch]	I2 [inch]	dl4 [inch]	Nominal Net Weight/Spool [pound] *	AWG Range	units per box
V50	8.50	1.50	10.00	9.00	9.25	45 lbs	24 - 38	1
V100	10.00	1.50	13.25	12.00	11.00	85 lbs	24 - 36	1
250/400K	9.29	3.93	15.75	13.19	9.84	100 lbs	24 - 36	container
315/500K	11.81	3.93	19.70	16.70	12.40	200 lbs	24 - 30	container
400/630K	14.76	3.93	24.80	20.87	15.75	400 lbs	24 - 30	container

* valid for copper, for other metals please inquire

Spool Designation (metric)	d1 [mm]	d4 [mm]	I1 [mm]	I2 [mm]	dl4 [mm]	Nominal Net Weight/Spool[kg] *	mm Range	units per box
V50	216	38	253	227	235	20.0 kgs	0.102-0.551	1
V100	254	38	335	305	279.4	39.0 kgs	0.127-0.511	1
250/400K	236	100	400	335	250	45.0 kgs	0.124-0.513	container
315/500K	300	100	500	425	315	90.0 kgs	0.251-0.513	container
400/630K	375	100	630	530	400	180.0 kgs	0.250-0.500	container

* valid for copper, for other metals please inquire

Container

	Dimensions
Spool	h1 [mm]	d1 [mm]	h1 [inch]	d1 [inch]
199L	399	260	15.70	10.24
250	295	305	11.61	12.00
249/45R	351	306	13.81	12.05
250/400	500	315	19.69	12.40
315/500	630	400	24.80	15.75
400/630	800	500	31.50	19.69

Asia

Selection of Spool Type

Spool Types	Wire Sizes	Characteristics
Biconical	0.010 - 0.10 mm	Biconical spool for fine and ultrafine wire, superb de-reeling capability, ideal for high speed winding machines
Tapered	0.065 - 0.50 mm	Stable winding due to tapered barrel spool for heavier sizes
Container	Container for large spools

Biconical Spool

Spool Type	d1 [mm]	d4 [mm]	I1 [mm]	I2 [mm]	d14 [mm]	Spool weight [g]	nom. net wire weight [kg] *	recommended for wire sizes [mm]	spools per box	boxes per pallet
76/45	63.5	16	86	60	-	72.5	0.4	0.010 - 0.019	6	120
79/45	80	16	100	69.5	-	85	0.9	0.016 - 0.022	4/32	84/24
99L	100	16	125	96	-	150	1.2	0.020 - 0.030	4	30
124/45R	125	16	125	65	-	160	3	0.025 - 0.040	4/6	30
PL-4S	135	22	175	110	-	320/260	5	0.035 - 0.070	4	24
159/45R	160	22	160	85	-	315	6	0.035 - 0.070	4	30/24
199/45R	200	22	200	106	-	600	11	0.050 - 0.100	1/2	45/48/24

* valid for copper, for other metals please inquire

Tapered Spool

Spool Type	d1 [mm]	d4 [mm]	I1 [mm]	I2 [mm]	d14 [mm]	Spool weight [g]	nom. net wire weight [kg] *	recommended for wire sizes [mm]	spools per box	boxes per pallet
PT-4	124	22	200	170	140	270	6	0.065 - 0.120	4	24
PT-10	160	22	230	200	180	620/420	12	0.065 - 0.150	2	30/40
PT-15	180	22	230	200	200	550	18	0.110 - 0.300	1	45/36
PT-25	215	32	280	250	230	1000	28	0.120 - 0.500	1	24
PT-45	236	100	400	335	250	2150	45	0.120 - 0.500	container	8
PT-90	300	100	500	425	315	3900	90	0.200 - 0.500	container	6

* valid for copper, for other metals please inquire

Container

	Dimensions
Spool	h1 [mm]	d1 [mm]
PT-45	475	308
PT-90	630	400

Quality | UL | RoHS

Quality Systems and RoHS

General

Quality

RoHS

General

Elektrisola plants are certified according to several standards like ISO 9001, IATF 16949 etc. etc. and thus prove, that they meet customers requirements. Under Quality Certificates the most important of these certificates can be viewed.

Elektrisola products are approved by UL, too. The certificates or the link to the UL online certifications directory can be found under UL.

Additionally all plants certify, that our products meet environmental standards, emphasized by laboratory test results for most of our products. To view these, please go to RoHS and REACH.

Quality Certificates

Elektrisola Eckenhagen,

Germany

Elektrisola Atesina,

Italy

IATF 16949 Certificate

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UL

Elektrisola products are UL approved. See by Elektrisola plant below or check at www.ul.com.

RoHS and REACH

Environmental Compatibility

Elektrisola magnet copper wire products conform to the standards set forth in EU Directive 2002/95/EC, RoHS (Restriction of Hazardous Substances), EU Directive 2002/96/EC (Waste Electrical and Electronic Equipment) and EU Directive 2003/11/EC (Prohibition of PentaBDE & OctaBDE) and REACH (Registration, Evaluation and Authorization of Chemicals). Independent analysis is available for all RoHS regulated substances.

RoHS Conformance Certified by Plants

All Elektrisola plants certify, that their products meet the Restriction of the use of certain hazardous substances in electrical and electronic equipment (RoHS) as specified in the EU directive 2002/95/EC, and the other aforementioned environmental standards.

The respective certificates can be viewed or downloaded here:

Laboratory Analysis Results by Enamel / Wire Types

Elektrisola Wire Types are subject to independent laboratory analysis for hazardous materials repeatedly. The test results prove the environmental compatibility of Elektrisola products.

The laboratory analysis results are composed of the results for the conductor material and the results for the base enamel, a top coat and a selfbonding varnish where applicable.

Conductor:

Base enamel:

for P130, P155, P155b, P155p, Pg155, P180, Pv180, P190, P210, P230, G155, G155p, G170, G180 (polyurethane-based insulation varnish)
for E180, A200 (polyesterimide-based insulation varnish)
for I220 (polyamideimide-based insulation varnish)
for ML240 (polyimide-based insulation varnish)

Top coat:

for PN155, PN15p, PN180, EN180 (polyamide-based insulation varnish)
for AI210 (polyamideimide-based insulation varnish)

Selfbonding enamel:

for AB-, BB-, CB and DB-series (butybond selfbonding varnish)
for CS-, DS-,ES-, FS-, HS-, IS-, KS-, MS-, OS- and PS-series (solabond selfbonding varnish)
for BE-, ET-, GT-, HT-, KT-, LT-, OT-, QT-, RT-, ST-, TT- and VT-series (thermobond selfbonding varnish)

REACH Correspondance Certified by Plants

Although magnet wire is not required to be listed by REACH, the European Community Regulation on chemicals and their safe use, all Elektrisola plants certify, that their magnet wire products contain less than 0.1% of the Substances of Very High Concern (SVHC) published by ECHA, the European Chemical Agency.

The respective certificates can be viewed or downloaded here:

Bondable magnet wire types

bondABLE MAGNET Wire Types

General

There is a large variety of bondable magnet wire types available. The different base coats and self bonding overcoats are described in different standards, such as IEC 60317, NEMA MW 1000 or JIS C3202, which sometimes utilize different test methods.

Under the respective standard the typical technical values are given for the different base coats such as Polyurethane, Polyester, Polyesterimide etc. and for different bond coats such as Polyvinylbutyral, Polyamide etc.

For easier comparison of products and the evaluation of their suitability for certain applications, there is a check box below each of the product-codes and a "Compare Selected Items" button in the precolumn of the table. When this button is clicked, only the marked items appear side by side. This view of the table is also suitable for printing; to use the options of your browser for this purpose, please use the "Show all" button to make the invisible products reappear again.

Europe

Asia (standard)

Asia (high performance)

America

Europe

Bondable Magnet Wire acc. to IEC

Thermal Stability acc. to IEC 60172

The line chart below is for technical comparison only and cannot be used to forecast lifetime of wound products (see also IEC 60172)

Thermal Stability in Hours [h] vs. Temperature in Degrees Celsius [°C]

Average breakdown voltage at 20°C

Calculation of average value Ds

Ds=t*Vµ(volt), with
Ds : breakdown voltage
t : increase with insulation, t = da - dnom, with
da : outer diameter
dnom : bare wire diameter
Vµ : Volt per micron insulation

Example

Test with cylindrical electrode
dnom = 0.071mm (41 AWG)
da = 0.083mm
t = da - dnom = 0.083 - 0.071 = 0.012mm = 12 µm
Vµ = 220 V/µm, therefore
Ds = 12µ * 220 V/µ = 2,640 V

Calculation of Breakdown Voltage (Test acc. to IEC 60851-5 4.)

Solderability of different Wire Types

Tinning time [sec] for wire 0.25mm Grade 1 vs. Tin bath temp. [°C]

Product-Code	AB15	FS15	FSP18	FS18	PSP15	STP18	QTP18	RT21
Product-Name	Butybond AB15	Solabond FS15	Solabond FSP18	Solabond FS18	Solabond PSP15	Thermobond STP18	Thermobond QTP18	Thermobond RT21
General Description
Base coat	mod. Polyurethane	mod. Polyurethane	mod. Polyurethane	Polyesterimide	mod. Polyurethane	mod. Polyurethane	mod. Polyurethane	A200 + Polyamidimide
Bond coat	Polyvinylbutyral	Polyamide	Polyamide	Polyamide	Polyamide	Polyamide	Polyamide	aromatic Polyamide
IEC (including the following norms)	IEC 60317-35, 60317-2	IEC 60317-35, 60317-2		IEC 60317-36	IEC 60317-35, 60317-2		IEC 60317-35	IEC 60317-38
NEMA (including the following norms)	MW 131-C	MW 131			MW 131	MW 131	MW 131	MW 102
Diameters available	0.01 - 0.50 mm	0.01 - 0.50 mm	0.01 - 0.50 mm	0.01 - 0.50 mm	0.01 - 0.50 mm	0.01 - 0.50 mm	0.015 - 0.50 mm	0.015 - 0.50 mm
Properties	Low bonding temperature, wide process window, non-hygroscopic	All bonding methods applicable, good processability, hygroscopic (not suited for humid regions)	All bonding methods applicable, good processability, hygroscopic	Solvent bonding possible, high resoftening temperature, high thermal and mechanical properties of base coat, hygroscopic thus not suitable for Asia	All purpose selfbonding enamel, wide process window, high bonding strength, thermosetting applicable, non-hygroscopic	Good winding ability, thermosetting applicable	higher thermal and mechanical properties, very high resoftening temperature after thermosetting	very high thermal and mechanical properties, very high resoftening temperature
Shelf life in months (at 25°C / 60% rel. humidity)	≤ 6	≤ 3 (hygroscopic)	≤ 5 (hygroscopic)	≤ 5 (hygroscopic)	≤ 6	≤ 6	≤ 6	≤ 6
Applications	Stepping motors for quartz watches, instrument coils, voice coils, Sensors, Transponders	Loudspeakers, small motors, sensors, Transponders	Loudspeakers, small motors, sensors, Transponders	Loudspeakers, small motors, sensors, Transponders	Instrument coils, loudspeakers, vibration motors, sensors, receiver and speaker for mobile phones	High power speaker, vibration motors	high power speaker and receiver, micro speaker, high temperature applications	motors, loudspeakers
Thermal values of base coat
Temperature index 20.000 h acc. to IEC 60172	158°C	158°C	192°C	195°C	158°C	192°C	192°C	212°C
Thermal stability chart [view]
Cut through temperature
0.05mm: acc. to IEC 60851-6 4	≥ 200°C	≥ 200°C	≥ 230°C	≥ 265°C	≥ 200°C	≥ 230°C	≥ 230°C	≥ 320°C
Elektrisola typical value	225°C	225°C	260°C	315°C	225°C	260°C	260°C	365°C
0.25mm: acc. to IEC 60851-6 4	≥ 200°C	≥ 200°C	≥ 230°C	≥ 265°C	≥ 200°C	≥ 230°C	≥ 230°C	≥ 320°C
Elektrisola typical value	230°C	230°C	265°C	325°C	230°C	265°C	265°C	380°C
Heat Shock
0.05mm: acc. to IEC 60851-6 3	≥ 175°C	≥ 175°C	≥ 200°C	≥ 200°C	≥ 175°C	≥ 200°C	≥ 200°C	≥ 220°C
Elektrisola typical value	190°C	190°C	210°C	260°C	190°C	210°C	210°C	250°C
0.25mm: acc. to IEC 60851-6 3	≥ 175°C	≥ 175°C	≥ 200°C	≥ 200°C	≥ 175°C	≥ 200°C	≥ 200°C	≥ 220°C
Elektrisola typical value	180°C	180°C	200°C	250°C	180°C	200°C	200°C	240°C
Electrical values
Low voltage continuity for Grade 1B wires
0.05mm: acc. to IEC 60851-5 1	≤ 40	≤ 40	≤ 40	≤ 40	≤ 40	≤ 40	≤ 40	≤ 40
Elektrisola typical value	0	0	0	0	0	0	0	0
High voltage continuity for Grade 1B wires
0.05mm: Elektrisola typical value	0	0	0	0	0	0	0	0
0.25mm: acc. to IEC 60851-5 2	≤ 10	≤ 10	≤ 10	≤ 10	≤ 10	≤ 10	≤ 10	≤ 10
0.25mm: Elektrisola typical value	0	0	0	0	0	0	0	0
Breakdown voltage acc. to IEC 60851-5 4 (at 20 °C, 35% humidity)
0.05mm: Elektrisola typical value	160 V/µm	160 V/µm	160 V/µm	160 V/µm	160 V/µm	160 V/µm	160 V/µm	160 V/µm
0.25mm: Elektrisola typical value	120 V/µm	120 V/µm	120 V/µm	120 V/µm	120 V/µm	120 V/µm	120 V/µm	120 V/µm
Calculation method of break voltage [view]
Pinholes acc. to IEC 60851-5 7
with 0.05mm: 0% elongation	good	good	very good	very good	very good	very good
with 0.25mm: 0% elongation	good	good	very good	very good	very good	very good
Mechanical values
Elongation for Grade 1B wire
0.05mm: acc. to IEC 60851-3 3.1	≥ 14%	≥ 14%	≥ 14%	≥ 14%	≥ 14%	≥ 14%	≥ 14%	≥ 14%
Elektrisola typical value	23%	23%	23%	23%	23%	23%	23%	23%
0.25mm: acc. to IEC 60851-3 3.1	≥ 25%	≥ 25%	≥ 25%	≥ 25%	≥ 25%	≥ 25%	≥ 25%	≥ 25%
Elektrisola typical value	40%	40%	40%	40%	40%	40%	40%	40%
Tensile strength for Grade 1B wires
0.05mm: Elektrisola typical value	57 cN	57 cN	57 cN	57 cN	57 cN	57 cN	57 cN	57 cN
0.25mm: Elektrisola typical value	1370 cN	1370 cN	1370 cN	1370 cN	1370 cN	1370 cN	1370 cN	1370 cN
Stress strain chart [view]
Bonding of wire
Hot air bonding	0.01 - 0.50 mm	0.01 - 0.50 mm	0.015 - 0.50 mm	0.01 - 0.50 mm	0.01 - 0.50 mm	0.01 - 0.50 mm	0.015 – 0.50 mm	limited
Oven bonding	0.10 - 0.50 mm	0.10 - 0.50 mm	0.10 - 0.50 mm	0.10 - 0.50 mm	0.10 - 0.50 mm	0.10 - 0.50 mm	0.10 – 0.50 mm	0.10 – 0.50 mm
Resistance bonding	0.10 - 0.50 mm	0.10 - 0.50 mm	0.10 - 0.50 mm	0.10 - 0.50 mm	0.10 - 0.50 mm	0.10 - 0.50 mm	0.10 – 0.50 mm	0.10 – 0.50 mm
Solvent bonding	limited	suitable	suitable	suitable	not suitable	not suitable	not suitable	not suitable
Recommended solvent	Ethanol / Methanol	Ethanol / Methanol	Ethanol / Methanol	Ethanol / Methanol	N/A	N/A	N/A	N/A
Recommended bonding temperature	120 - 140°C	150 - 170°C	150 - 170°C	150 - 170°C	150 - 170°C	180 - 200°C	200 – 220°C	200 – 220°C
Resoftening temperature for 0.25mm (IEC 60851-3 7.1.2.4)	≥ 100°C	≥ 140°C	≥ 170°C	≥ 180°C	≥ 180°C	≥ 145°C	≥ 190°C	≥ 200°C
Bond strength chart
RoHS laboratory analysis	view	view	view	view		view
Solderability
Solderability for Grade 1B wires
0.05mm: max. acc. to IEC 60851-4 5	2.0s / 390°C	2.0s / 390°C	2.0s / 390°C	3.0s / 470°C	2.0s / 390°C	3.0s / 390°C	3.0s / 390°C	---
Elektrisola typical value	0.8s / 390°C	0.4s / 390°C	0.7s / 390°C	1.3s / 470°C	0.4s / 390°C	0.4s / 420°C	1.0s / 390°C	---
Elektrisola typical value	1.5s / 370°C	0.5s / 370°C	1.0s / 370°C		0.7s / 370°C	---
0.25mm: max. acc. to IEC 60851-4 5	3.0s / 390°C	3.0s / 390°C	3.0s / 390°C	3.0s / 470°C	3.0s / 390°C	3.0s / 390°C	3.0s / 390°C	---
Elektrisola typical value	1.4s / 390°C	0.7s / 390°C	1.6s / 390°C	3.0s / 470°C	0.7s / 390°C	0.8s / 420°C	2.0s / 390°C	---
Elektrisola typical value	2.0s / 370°C	1.2s / 370°C	2.8s / 370°C		1.2s / 370°C
Solderability of different wire types chart [view]

Asia (standard)

Bondable Magnet Wire acc. to IEC

Product-Code	BQP15	CSP15	ES22	ESP15	KSP15	KSP18	KS18	KS22
Product-Name	Polyesterbond BQP15	Solabond CSP15	Solabond ES22	Solabond ESP15	Solabond KSP15	Solabond KSP18	Solabond KS18	Solabond KS22
General Description
Base coat	mod. Polyurethane	mod. Polyurethane	Polyamideimide	mod. Polyurethane	mod. Polyurethane	mod. Polyurethane	Polyesterimide	Polyamideimide
Bond coat	mod. Polyester	Polyamide	Polyamide	Polyamide	Polyamide	Polyamide	Polyamide	Polyamide
IEC (including the following standards)	IEC 60317-35, 60317-2	IEC 60317-35, 60317-2	---	IEC 60317-35, 60317-2	IEC 60317-35, 60317-2	IEC 60317-35	IEC 60317-36	---
NEMA (including the following standards)	MW 131	MW 131	---	MW 131	MW 131	---	---	---
Diameters available	0.015 - 0.50 mm	0.015 - 0.50 mm	0.050 - 0.70 mm	0.015 - 0.50 mm	0.015 - 0.50 mm	0.015 - 0.50 mm	0.015 - 0.50 mm	0.050 - 0.60 mm
Properties	Easy bonding, wide process window	Excellent solvent bonding, heat bonding possible	Suitable for hot air bonding, very high thermal properties of base coat	Suitable for hot air bonding, very good winding properties	Suitable for hot air bonding, excellent solderability	Suitable for hot air bonding, high thermal properties of base coat	Suitable for hot air bonding, higher thermal properties of base coat	Suitable for hot air bonding, very high thermal properties of base coat
Shelf life in months (at 25°C / 60% rel. humidity)	≤6	≤6	≤6	≤6	≤6	≤6	≤6	≤6
Applications	For sensors, instrument coils, RFID, transponders, card application	For voice coils, small motor, vibration motors, transponders	For molding inductor, small motor	For sensors, instrument coils, voice coils, vibration motors	For small motor, instrument coils, loudspeaker, sensors	For small motor, instrument coils, loudspeaker, sensors, transponders	For small motor, loudspeaker	For small motor, inductor
Thermal values of base coat
Temperature index 20.000 h acc. IEC 60172	164°C	164°C	230°C	164°C	164°C	192°C	195°C	230°C
Cut through temperature min. °C acc. to IEC 60851-6 4.	≥ 200°C	≥ 200°C	≥ 350°C	≥ 200°C	≥ 200°C	≥ 230°C	≥ 265°C	≥ 350°C
ELEKTRISOLA-typical values for 0.05 mm/0.25 mm, Grade 1B	225 / 230°C	225 / 230°C	390 / 410°C	225 / 230°C	225 / 230°C	260 / 265°C	315 / 325°C	390 / 410°C
Heat shock min. °C acc. to IEC 60851-6 3.	≥ 175°C	≥ 175°C	≥ 240°C	≥ 175°C	≥ 175°C	≥ 200°C	≥ 200°C	≥ 240°C
ELEKTRISOLA-typical values for 0.05 mm/0.25 mm, Grade 1B	190 / 180°C	190 / 180°C	250 / 240°C	190 / 180°C	190 / 180°C	210 / 200°C	260 / 250°C	250 / 240°C
Electrical values
Low voltage continuity max. acc. to IEC 60851-5 5.2 for 0.05 mm	≤ 40	≤ 40	≤ 40	≤ 40	≤ 40	≤ 40	≤ 40	≤ 40
ELEKTRISOLA-typical values for 0.05 mm, Grade 1B	0	0	0	0	0	0	0	0
High voltage continuity max. acc. to IEC 60851-5 5.3 for 0.25 mm	≤ 10	≤ 10	≤ 10	≤ 10	≤ 10	≤ 10	≤ 10	≤ 10
ELEKTRISOLA-typical values for 0.25 mm, Grade 1B	0	0	0	0	0	0	0	0
Breakdown voltage acc. IEC 60851-5 4., (at 20°C, 35% humidity)
ELEKTRISOLA-typical values for 0.05 mm/0.25 mm, Grade 1B	160 / 120 V/μm	160 / 120 V/μm	160 / 120 V/µm	160 / 120 V/μm	160 / 120 V/μm	160 / 120 V/μm	160 / 120 V/μm	160 / 120 V/μm
Mechanical values
Elongation min. acc. to IEC 60851-3 3.1 for 0.05 mm/0.25 mm, Grade 1B	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%
ELEKTRISOLA-typical values for 0.05 mm/0.25 mm, Grade 1B	23% / 40%	23% / 40%	23% / 40%	23% / 40%	23% / 40%	23% / 40%	23% / 40%	23% / 40%
Tensile strength
ELEKTRISOLA-typical values for 0.05 mm/0.25 mm, Grade 1B	57 / 1370 cN	57 / 1370 cN	57 / 1370 cN	57 / 1370 cN	57 / 1370 cN	57 / 1370 cN	57 / 1370 cN	57 / 1370 cN
Bonding of wire
Hot air bonding	Suitable	Suitable	Suitable	Suitable	Suitable	Suitable	Suitable	Suitable
Oven bonding	Suitable	Suitable	Suitable	Suitable	Suitable	Suitable	Suitable	Suitable
Resistance bonding	Suitable	Suitable	Suitable	Suitable	Suitable	Suitable	Suitable	Suitable
Solvent bonding	Not suitable	Suitable	Not suitable	Not suitable	Not suitable	Not suitable	Not suitable	Not suitable
Recommended solvent	--	Ethanol / Isopropanol	---	---	---	---	---	---
Recommended bonding temperature	120 - 140°C	170 - 200°C	160 - 190°C	160 - 190°C	150 - 170°C	150 - 170°C	150 - 170°C	150 - 170°C
Resoftening temperature	≥ 90°C	≥ 140°C	≥ 130°C	≥ 130°C	≥ 105°C	≥ 105°C	≥ 105°C	≥ 105°C
Solderability
Acc. to IEC 60851-4 5. max . seconds at °C for 0.05 mm/0.25 mm, Grade 1B	2.0s/390°C / 3.0s/390°C	2.0s/390°C / 3.0s/390°C		2.0s/390°C / 3.0s/390°C	2.0s/390°C / 3.0s/390°C	3.0s/390°C / 3.0s/390°C	3.0s/470°C / 3.0s/470°C	Not Solderable
ELEKTRISOLA-typical values IEC 60851-4 5.
for 0.05 mm, Grade 1B,	0.5s/370°C / 0.4s/390°C	1.0s/370°C / 0.6s/390°C	---	1.0s/370°C / 0.6s/390°C	0.5s/370°C / 0.4s/390°C	1.0s/370°C / 0.7s/390°C	1.9s/470°C	---
seconds at °C
for 0.25 mm, Grade 1B,	1.2s/370°C / 0.7s/390°C	1.6s/370°C / 0.8s/390°C	---	1.6s/370°C / 0.8s/390°C	1.2s/370°C / 0.7s/390°C	2.8s/370°C / 1.6s/390°C	3.4s/470°C	---
seconds at °C

Asia (high performance)

Bondable Magnet Wire acc. to IEC

Product-Code	PSP15	PSP18	STP18	KTP18	KT22	LTP18	ETP18	ET22
Product-Name	Solabond PSP15	Solabond PSP18	Thermobond STP18	Thermobond KTP18	Thermobond KT22	Thermobond LTP18	Thermobond ETP18	Thermobond ET22
General Description
Base coat	mod.Polyurethane	mod.Polyurethane	mod.Polyurethane	mod.Polyurethane	mod.Polyamidimide	mod.Polyurethane	mod.Polyurethane	mod.Polyamidimide
Bond coat	Polyamide	Polyamide	Polyamide	Polyamide	Polyamide	Polyamide	Polyamide	Polyamide
IEC (including the following standards)	IEC 60317-35, 60317-2	IEC 60317-35	IEC 60317-35	IEC 60317-35	---	IEC 60317-35	IEC 60317-35	---
NEMA (including the following standards)	MW 131	---	MW 131	---	---	---	---	---
Diameters available	0.010 - 0.50 mm	0.010 - 0.50 mm	0.015 - 0.50 mm	0.015 - 0.50 mm	0.015 - 0.50 mm	0.015 - 0.50 mm	0.015 - 0.50 mm	0.015 - 0.50 mm
Properties	high resoftening temperature after thermosetting, very good properties for hot-air bonding, very good winding properties, non-hyproscopic	Thermosetting possible, high bonding strength, non-hygroscopic	Higher thermal and mechanical properties, very high resoftening temperature after thermosetting, non-hygroscopic	High resoftening temperature, suitable for High Current Test (HCT), high bonding strength, non-hygroscopic	Very High resoftening temperature, suitable for High Current Test (HCT), high bonding strength, non-hygroscopic	High resoftening temperature, suitable for High Current Test (HCT), high bonding strength, non-hygroscopic	Excellent winding performance, high resoftening temperature, high bonding strength at the coil ends, suitable for High Current Test (HCT), non-hygroscopic	Excellent winding performance, high resoftening temperature, high bonding strength at the coil ends, suitable for High Current Test (HCT), non-hygroscopic
Shelf life in months (at 25°C / 60% rel. humidity)	≤6	≤6	≤6	≤6	≤6	≤6	≤6	≤6
Applications	Instrument coils, loudspeakers, small motors, sensors, receiver and speaker for mobile phones	Instrument coils, loudspeakers, motors, sensors	High power speaker and receiver, micro speaker, high temperature applications	High power speaker / receiver, Micro speaker	High power speaker / receiver, Micro speaker	Loudspeakers, Stepping motors, Voice coils, Sensors, Transponders	High power speaker / receiver, Micro speaker	High power speaker / receiver, Micro speaker
Thermal values of base coat
Temperature index 20.000 h acc. IEC 60172	158°C	192°C	192°C	192°C	230°C	192°C	192°C	230°C
Cut through temperature min. °C acc. to IEC 60851-6 4.	≥ 200°C	≥ 230°C	≥ 230°C	≥ 230°C	≥ 350°C	≥ 230°C	≥ 230°C	≥ 350°C
ELEKTRISOLA-typical values for 0.05 mm/0.25 mm, Grade 1B	225 / 230°C	260 / 265°C	260 / 265°C	260 / 265°C	390 / 410°C	260 / 265°C	260 / 265°C	390 / 410°C
Heat shock min. °C acc. to IEC 60851-6 3.	≥ 175°C	≥ 200°C	≥ 200°C	≥ 200°C	≥ 220°C	≥ 200°C	≥ 200°C	≥ 200°C
ELEKTRISOLA-typical values for 0.05 mm/0.25 mm, Grade 1B	190 / 180°C	210 / 200°C	210 / 200°C	210 / 200°C	250 / 240°C	210 / 200°C	210 / 200°C	250 / 240°C
Electrical values
Low voltage continuity max. acc. to IEC 60851-5 5.2 for 0.05 mm Grade 1 B	≤ 40	≤ 40	≤ 40	≤ 40	≤ 40	≤ 40	≤ 40	≤ 40
ELEKTRISOLA-typical values for 0.05 mm, Grade 1B	0	0	0	0	0	0	0	0
High voltage continuity max. acc. to IEC 60851-5 5.3 for 0.25 mm Grade 1B	≤ 10	≤ 10	≤ 10	≤ 10	≤ 10	≤ 10	≤ 10	≤ 10
ELEKTRISOLA-typical values for 0.25 mm, Grade 1B	0	0	0	0	0	0	0	0
Breakdown voltage acc. IEC 60851-5 4., (at 20°C, 35% humidity)
ELEKTRISOLA-typical values test for 0.05 mm/0.25 mm, Grade 1B	160 / 120 V/μm	160 / 120 V/μm	160 / 120 V/μm	160 / 120 V/μm	160 / 120 V/μm	160 / 120 V/μm	160 / 120 V/μm	160 / 120 V/μm
Mechanical values
Elongation min. acc. to 60851-3 3.1 for 0.05 mm/0.25 mm, Grade 1B	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%
ELEKTRISOLA-typical values for 0.05 mm/0.25 mm, Grade 1B	23% / 40%	23% / 40%	23% / 40%	23% / 40%	23% / 40%	23% / 40%	23% / 40%	23% / 40%
Tensile strength
ELEKTRISOLA-typical values for 0.05 mm/0.25 mm, Grade 1B	57 / 1370 cN	57 / 1370 cN	57 / 1370 cN	57 / 1370 cN	57 / 1370 cN	57 / 1370 cN	57 / 1370 cN	57 / 1370 cN
Bonding of wire
Hot air bonding	0.010-0.50mm	0.010-0.50mm	0.015-0.50mm	0.015-0.50mm	0.015-0.50mm	Limited	0.015-0.50mm	0.015-0.50mm
Oven bonding	0.100-0.50mm	0.100-0.50mm	0.100-0.50mm	0.100-0.50mm	0.100-0.50mm	Limited	0.100-0.50mm	0.100-0.50mm
Resistance bonding	0.100-0.50mm.	0.100-0.50mm	0.100-0.50mm	0.100-0.50mm	0.100-0.50mm	Limited	0.100-0.50mm	0.100-0.50mm
Solvent bonding	Not suitable	Not suitable	Not suitable	Not suitable	Not suitable	0.015-0.50mm	Not suitable	Not suitable
Recommended solvent	---	---	---	---	---	Ethanol/Methanol	---	---
Recommended bonding temperature	150 - 170°C	150 - 170°C	180 - 200°C	220°C	220°C	220°C	220°C	220°C
Resoftening temperature (after postbacking)	≥ 125°C (180°C)	≥ 125°C (180°C)	≥ 145°C (190°C)	≥ 230°C	≥ 230°C	≥ 210°C	≥ 260°C	≥ 260°C
Solderability
acc. to IEC 60851-4 5. max . seconds at °C for 0.05 mm/0.25 mm, Grade 1B	2.0s/390°C / 3.0s/390°C	3.0s/390°C / 3.0s/390°C	3.0s/390°C / 3.0s/390°C	3.0s/390°C / 3.0s/390°C	Not solderable	3.0s/390°C / 3.0s/390°C	3.0s/390°C / 3.0s/390°C	Not solderable
ELEKTRISOLA-typical values IEC 60851-4 5.
for 0.05 mm, Grade 1B,	0.7s/370°C / 0.4s/390°C	1.2s/390°C	0.4s/420°C	0.5s/470°C	---	n.a/420°C	0.6s/470°C	---
seconds at °C
for 0.25 mm, Grade 1B,	1.2s/370°C / 0.7s/390°C	1.5s/390°C	0.8s/420°C	---	---	n.a/420°C	---	---
seconds at °C

America

Bondable Magnet Wire acc. to NEMA

Product-Code	ABN15	FS15	FSP18	FS18	AE21	AQ21	UT18	RT21
General Description
Base Coat / Base Coat Type	mod. Polyurethane+Polyamide	mod. Polyurethane	mod. Polyurethane	Polyesterimide	A200 + Polyamidimide	A200 + Polyamidimide	Polyesterimide	A200 + Polyamidimide
Bond Coat / Bond Coat Type	Polyvinylbutyral	Polyamide	Polyamide	Polyamide	Epoxy	Polyester	Polyamide	Aromatic Polyamide
NEMA (including the following norms)	MW136	MW131	MW137			MW102		MW102
IEC (including the following norms)	IEC 60317-35, 60317-2	IEC 60317-35, 60317-2	IEC 60317-35	IEC 60317-36	IEC 60317-38	IEC 60317-38	IEC 60317-36	IEC 60317-38
Diameter Available
AWG	24-58 AWG	24-58 AWG	24-58 AWG	24-54 AWG	24-58 AWG	24-54 AWG	24-54 AWG	24-58 AWG
mm	0.01 - 0.50 mm	0.01 - 0.50 mm	0.01 - 0.50 mm	0.015 - 0.50 mm	0.01 - 0.50 mm	0.015 - 0.50 mm	0.015 - 0.50 mm	0.01 - 0.50 mm
Properties	Low Bonding Temperature	Solvent Bonding Possible	Solvent bonding possible, higher thermal properties.	Solvent bonding possible, higher thermal properties.	Low bonding temperature & Solvent bonding possible.	High thermal and mechanical properties and high resoftening temperature.	High thermal and mechanical properties, high resoftening temperature.	Very high thermal and mechanical properties, very high resoftening temperature (non hygroscopic)
Shelf life in months (at 25°C / 60% rel. humidity)	≤ 6	≤ 3 (hygroscopic)	≤ 5 (hygroscopic)	≤ 5 (hygroscopic)	≤ 6	≤ 6	≤ 6 (Hygroscopic)	≤ 6
Applications	Stepper motors for watches, instrument coils, voice coils, sensors, transponders	Instrument coils, loudspeakers, small motors, sensors	Instrument coils, loudspeakers, small motors, sensors, transponders	High power speaker and receiver, micro speaker, high temperature applications	Instrument coils, loudspeakers, small motors, sensors, receiver and speaker for mobile phones	High power speaker and receiver, micro speaker, high temperature applications	High power speaker and receiver, micro speaker, high temperature applications	Motors, loudspeakers
Thermal Values of Base Coat
Temperature index 20.000 h acc. To IEC 60172	158°C	158°C	192°C	195°C	212°C	212°C	195°C	212°C
Cut-through Temperature
Acc. to NEMA MW1000 3.5 for 44/30AWG:	≥ 200°C / ≥ 200°C	≥ 200°C / ≥ 200°C	≥ 230°C / ≥ 230°C	≥ 225°C	≥ 320°C	≥ 320°C	≥ 265°C	≥ 320°C
Elektrisola typical value for 44/30AWG:	225°C / 230°C	225°C / 230°C	260°C / 265°C	260°C / 265°C	365°C / 380°C	365°C / 380°C	260°C / 265°C	365°C / 380°C
Heat Shock
Acc. To NEMA MW1000 3.5 for 44/30AWG:	≥ 175°C / ≥ 175°C	≥ 175°C / ≥ 175°C	≥ 200°C / ≥ 200°C	≥ 200°C	≥ 220°C	≥ 220°C	≥ 200°C	≥ 220°C
Elektrisola typical value for 44/30AWG:	190°C / 180°C	190°C / 180°C	210°C / 200°C	310°C / 320°C	250°C / 240°C	250°C / 240°C	310°C / 320°C	250°C / 240°C
Mechanical Values
Elongation for Type 1
Acc. to NEMA MW1000 3.4 for 44/30AWG:	≥ 10% / ≥ 22%	≥ 10% / ≥ 22%	≥ 10% / ≥ 22%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%	≥ 14% / ≥ 25%
Elektrisola typical value for 44/30AWG:	23% / 40%	23% / 40%	23% / 40%	23% / 40%	23% / 40%	23% / 40%	23% / 40%	23% / 40%
Bonding of Wire
Hot Air Bonding	24-58 AWG	24-58 AWG	24-58 AWG	24-58 AWG	24-58 AWG	24-58 AWG	24-58 AWG	24-58 AWG
Oven Bonding	38-24 AWG	38-24 AWG	38-24 AWG	38-24 AWG	38-24 AWG	38-24 AWG	38-24 AWG	38-24 AWG
Resistance Bonding	38-24 AWG	38-24 AWG	38-24 AWG	38-24 AWG	38-24 AWG	38-24 AWG	38-24 AWG	38-24 AWG
Solvent Bonding	Limited	Suitable	Suitable	Suitable	Suitable	Suitable	N/A	N/A
Recommended Solvent	Ethanol / Methanol	Ethanol / Methanol	Ethanol / Methanol	Ethanol / Methanol	Acetone/MEK	Acetone/MEK
Recommended Bonding Temperature	120°C - 140°C	150°C - 170°C	150°C - 170°C	180°C - 220°C	120°C - 140°C	160°C - 190°C	180°C - 220°C	200°C - 220°C
Resoftening Temperature for 30AWG	≥ 100°C	≥ 140°C	≥ 170°C	≥ 180°C	≥ 100°C	≥ 180°C	≥ 180°C	≥ 200°C
Solderability
Solderability for Type 1
Acc. to NEMA MW1000 3.11 for 44/30AWG:	2.0s/390°C / 3.0s/390°C	2.0s/390°C / 3.0s/390°C	2.0s/390°C / 3.0s/390°C	2.0s/470°C / 3.0s/470°C	-	-		-
Elektrisola typical value for 44 AWG:	0.8s/390°C / 1.3s/370°C	0.4s/390°C / 0.5s/370°C	0.7s/390°C / 1.0s/370°C	1.6s/470C	-	-		-
Elektrisola typical value for 30 AWG:	1.4s/390°C / 2.8s/370°C	0.7s/390°C / 1.2s/370°C	2.0s/390°C / 2.8s/370°C	3.0s/470C	-	-	5.5s/470C	-

Elektrisola typical values are the result of various tests and represent average values.

We believe that all information in this catalogue is reliable and accurate, but the accuracy or completeness thereof is not guaranted.

Breakdown Voltage (BDV)

Fully Insulated Wire

Breakdown Voltage Calculation acc. to FIW Standard IEC 60317-0-7

Test is done by cylinder BDV test acc. to IEC 60851-4.3.2. The minimum breakdown voltage has to be calculated for every specific FIW wire size using the increase by insulation and the specific V/µm-value from below table.

Nominal conductor diameter mm		Minimum specific breakdown voltage V/µm increase
over	up to and including	at room temperature	at 180°C
- -	>0.100	81	56
0.100	0.355	76	53
0.355	0.500	70	49
0.500	1.000	53	37
1.000	1.600	47	33

NOTE: The specific breakdown voltage is the result of the quotient of the measured value and enamel increase.

Example of formula for calculation of breakdown voltage (BDV):

BDV = min. increase *min. spec. BDV in V/μm

Example: 0.2 mm FIW6 with min. OD 0.303 mm

min. increase = min. OD - nom. dia. = 0.303 mm - 0.2 mm = 0.103 mm = 103 μm

=> BDV = 103 μm x 76 V/μm = 7828 V

Calculated Minimum Breakdown Voltage at 20 °C acc. to FIW Standard IEC 60317-56

	FIW3	FIW4	FIW5	FIW6	FIW7	FIW8	FIW9
Nominal Diameter	min	min	min	min	min	min	min
[mm]	[V]	[V]	[V]	[V]	[V]	[V]	[V]
0.071	1701	2187	3240	4293	5346	6399	7452
0.080	1782	2349	3483	4617	5751	6885	8019
0.090	1944	2511	3645	4779	5913	7047	8181
0.100	2106	2673	3969	5265	6561	7857	9153
0.106	2052	2660	3952	5244	6536	7828	9120
0.112	2128	2736	4028	5320	6612	7904	9196
0.118	2128	2812	4180	5548	6916	8284	9652
0.120	2280	2964	4332	5700	7068	8436	9804
0.125	2280	2964	4332	5700	7068	8436	9804
0.132	2356	3040	4560	6080	7600	9120	10640
0.140	2432	3192	4712	6232	7752	9272	10792
0.150	2508	3344	5016	6688	8360	10032	11704
0.160	2660	3496	5168	6840	8512	10184	11856
0.170	2736	3648	6232	8056	9880	11704	13528
0.180	2888	3800	5624	7448	9272	11096	12920
0.190	2964	3876	5776	7676	9576	11476	13376
0.200	3040	4028	5928	7828	9728	11628	13528
0.212	3268	4332	6384	8436	10488	12540	14592
0.220	3268	4332	6384	8436	10488	12540	14592
0.224	3268	4332	6384	8436	10488	12540	14592
0.236	3572	4788	7068	9348	11628	13908	16188
0.250	3648	4788	7068	9348	11628	13908	16188
0.265	3800	5016	7372	9728	12084	14440	16796
0.280	3800	5016	7372	9728	12084	14440	16796
0.300	4028	5320	7676	10032	12388	14744	17100
0.315	4028	5320	7676	10032	12388	14744	17100
0.330	4332	5624	7980	10336	12692	15048	17404
0.335	4332	5624	7980	10336	12692	15048	17404
0.350	4332	5624	7980	10336	12692	15048	16030
0.355	4332	5624	7980	10336	12692	15048	16030
0.375	4200	5530	7700	10290	12460	14630
0.400	4200	5530	7700	9870	12040	14210
0.425	4480	5880	8050	10220	12390	14560
0.450	4480	5880	8050	10220	12390	14560
0.475	4690	6160	9030	11900	14770	17640
0.500	4690	6160	9030	11900	14770
0.530	3710	4982	7155	9328	11501
0.550	3763	4982	7155	9328	11501
0.560	3763	4982	7155	9328	11501
0.600	3975	5247	7420	9593	11766
0.630	3975	5247	7420	9593	11766
0.650	4240	5565	7738	9911	12084
0.670	4240	5565	7738	9911	12084
0.710	4240	5565	7738	9911	12084

Highlighted = item available from stock

Breakdown Voltage Calculation acc. to Transformer Standard IEC 61558-1

U=OD - Cu∅ x V/µm x 10³ x 0.85 (at 180°C for 60 seconds)

	FIW3	FIW4	FIW5	FIW6	FIW7	FIW8	FIW9
Nominal Diameter	min	min	min	min	min	min	min
[mm]	[V]	[V]	[V]	[V]	[V]	[V]	[V]
0.040	714	904	1428	1904	2380	2856
0.045	809	1047	1618	2142	2666	3189
0.050	809	1095	1618	2142	2666	3189
0.056	904	1238	1761	2332	2904	3475
0.063	1000	1285	1904	2523	3142	3760
0.071	1000	1285	1904	2523	3142	3760	4379
0.080	1047	1380	2047	2713	3380	4046	4712
0.090	1142	1476	2142	2808	3475	4141	4808
0.100	1238	1571	2332	3094	3856	4617	5379
0.112	1261	1622	2388	3154	3919	4685	5451
0.125	1352	1757	2568	3379	4190	5001	5811
0.140	1442	1892	2793	3694	4595	5496	6397
0.160	1577	2072	3063	4055	5046	6037	7028
0.180	1712	2253	3334	4415	5496	6577	7659
0.200	1802	2388	3514	4640	5766	6893	8019
0.224	1937	2568	3784	5001	6217	7433	8650
0.250	2162	2838	4190	5541	6893	8244	9596
0.280	2253	2973	4370	5766	7163	8560	9956
0.315	2388	3154	4550	5947	7343	8740	10136
0.355	2568	3334	4730	6127	7523	8920	10316
0.400	2499	3290	4582	5873	7164	8455
0.450	2666	3499	4790	6081	7372
0.500	2791	3665	5373	7081	8788
0.560	2233	2956	4246	5535	6825
0.630	2359	3114	4403	5692	6982
0.710	2516	3302	4592	5681	7171
0.800	2673	3522	5126	6730
0.900	2831	3743	5347	6950
1.000	2988	3931	5535	7139
1.120	2749	3618	5330
1.250	2805	3703	5414
1.400	2889	3815	5526
1.600	3001	3955	5666

Minimum BDV acc. IEC 62368

Nominal conductor diameter	Minimum specific breakdown voltage a	Minimum overall FIW diameter d o [mm]							Minimum dielectric strength test voltage values per wire for basic or reinforced insulation at overall diameter. U s [V] (duration of 60 s)
d Cu [mm]	Ub [V/μm]	Grade of FIW 3	Grade of FIW 4	Grade of FIW 5	Grade of FIW 6	Grade of FIW 7	Grade of FIW 8	Grade of FIW 9	Grade of FIW 3	Grade of FIW 4	Grade of FIW 5	Grade of FIW 6	Grade of FIW 7	Grade of FIW 8	Grade of FIW 9
0.04	56	0.055	0.059	0.070	0.080	0.090	0.100		714	904	1428	1904	2380	2856
0.045	56	0.062	0.067	0.079	0.090	0.101	0.112		809	1 047	1 618	2 142	2 666	3 189
0.05	56	0.067	0.073	0.084	0.095	0.106	0.117		809	1095	1618	2142	2666	3189
0.056	56	0.075	0.082	0.093	0.105	0.117	0.129		904	1238	1761	2332	2904	3475
0.063	56	0.084	0.090	0.103	0.116	0.129	0.142		1000	1285	1904	2523	3142	3760
0.071	56	0.092	0.098	0.111	0.124	0.137	0.150	0.163	1000	1285	1904	2523	3142	3760	4379
0.08	56	0.102	0.109	0.123	0.137	0.151	0.165	0.179	1047	1380	2047	2713	3380	4046	4712
0.09	56	0.114	0.121	0.135	0.149	0.163	0.177	0.191	1142	1476	2142	2808	3475	4141	4808
0.1	56	0.126	0.133	0.149	0.165	0.181	0.197	0.213	1238	1571	2332	3856	3856	4617	5379
0.112	53	0.140	0.148	0.165	0.182	0.199	0.216	0.233	1261	1622	2388	3154	3919	4685	5451
0.125	53	0.155	0.164	0.182	0.200	0.218	0.236	0.254	1352	1757	2568	3379	4190	5001	5811
0.14	53	0.172	0.182	0.202	0.222	0.242	0.262	0.282	1442	1892	2793	3694	4595	5496	6397
0.16	53	0.195	0.206	0.228	0.250	0.272	0.294	0.316	1577	2072	3063	4055	5046	6037	7028
0.18	53	0.218	0.230	0.254	0.278	0.302	0.326	0.350	1712	2253	3334	4415	5496	6577	7659
0.2	53	0.240	0.253	0.278	0.303	0.328	0.353	0.378	1802	2388	3514	4640	5766	6893	8019
0.224	53	0.267	0.281	0.308	0.335	0.362	0.389	0.416	1937	2568	3784	5001	6217	7433	8650
0.25	53	0.298	0.313	0.343	0.373	0.403	0.433	0.463	2162	2838	4190	5541	6893	8244	9596
0.28	53	0.330	0.346	0.377	0.408	0.439	0.470	0.501	2253	2973	4370	5766	7163	8560	9956
0.315	53	0.368	0.385	0.416	0.447	0.478	0.509	0.540	2388	3154	4550	5947	7343	8740	10136
0.355	53	0.412	0.429	0.460	0.491	0.522	0.553	0.584	2568	3334	4730	6127	7523	8920	10316
0.4	49	0.460	0.479	0.510	0.541	0.572	0.603		2499	3290	4582	5873	7164	8455
0.45	49	0.514	0.534	0.565	0.596	0.627	0.658		2666	3499	4790	6081	7372
0.5	49	0.567	0.588	0.629	0.670	0.711			2791	3665	5373	7081	8788
0.56	37	0.631	0.654	0.695	0.736	0.777			2233	2956	4246	5535	6825
0.63	37	0.705	0.729	0.770	0.811	0.852			2359	3114	4403	5692	6982
0.71	37	0.790	0.815	0.856	0.897	0.938			2516	3302	4592	5881	7171
0.8	37	0.885	0.912	0.963	1.014				2673	3522	5126	6730
0.9	37	0.990	1.019	1.070	1.121				2831	3743	5347	6950
1	37	1.095	1.125	1.176	1.227				2988	3931	5535	7139
1.12	33	1.218	1.249	1.310					2749	3618	5330
1.25	33	1.350	1.382	1.443					2805	3703	5414
1.4	33	1.503	1.536	1.597					2889	3815	5526
1.6	33	1.707	1.741	1.802					3001	3955	5666

Comments on different BDV standards

The actual version of the Transformer Standard IEC 61558-1 gives much lower values than IEC 60317-0-7.
The specific voltage per micron is given acc. to IEC 60317-0-7 at room temperature, while IEC 61558 calculates values of 180 °C and a safety margin (0.85). Actually needed temperature of SMPS (Switch Mode Power Supply) is somewhere in between.
IEC 62368 follows the BDV values of IEC 61558, but does not specify 180 °C as test temperature as IEC 61558.

Global Footprint

ELEKTRISOLA is a true global producer of fine magnet wires with 9 plants in the 3 most important continents for the automotive and the electrical industry using the same state-of-the-art machines to produce the same high quality standard.

Advantages of Elektrisola Global Footprint

1. Worldwide supply of identical quality

same management of ownership
same products
same in-house designed machines
same processes
same work instructions
same quality approvals (ISO, IATF)
same UL-approvals
same test procedures
ideal for global projects

2. Safety of supply

easy backup of other Elektrisola plants with identical products

3. Local production and supply

fast and efficient delivery
local currency
local sales and service

4. Local service

local engineering support for R&D and process improvement
fast working as in the same time zone
easy communication in local language
assistance for global projects with local production

5. Environment friendly

short transportation distances
local spool recycling
worldwide system for emission control (sniff during your visit)

Elektrisola Locations

Plants

Warehouse

Sale office

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History

History of ELEKTRISOLA

1948

Foundation of Elektrisola in Germany

Founder
Dr. Gerd Schildbach
1948
First building in Eckenhagen,
Germany
1949

Elektrisola was founded by Dr. Gerd Schildbach on July 1, 1948 in Eckenhagen, Germany. His father, Dr. Ing. Richard Schildbach, was already producing fine resistance wires and held the world record in drawing the finest wire (0.008 mm) in 1938. Based on this wire drawing knowledge, Dr. Gerd Schildbach started to design and build his own fine wire enameling machines. This internally developed process technology later became a major contributor to the rapid growth of the Elektrisola fine wire production worldwide.

1961

Italy: The first factory outside Germany

Elektrisola Atesina I, Molini di Tures, Italy

Rapid sales growth in new markets required construction of additional production capacity. Elektrisola Atesina was built in the Alps mountains in the German speaking part of northern Italy and started production in 1964.

1968

First factory in EFTA economic area

Elektrisola Feindraht AG, Escholzmatt, Switzerland

Between 1957 and 1960, Europe had been divided into 2 different blocks, EWG (Belgium, France, Germany, Italy, Luxemburg and The Netherlands), which became EU in 1993, and EFTA (Austria, Denmark, Great Britain, Norway, Portugal, Sweden, Switzerland), with duties levied for trading between those blocks. In order to serve customers in the EFTA zone, Elektrisola Feindraht, Switzerland, was founded in 1968.

1970

Wire drawing factory in Italy

Elektrisola Atesina II, Lutago, Italy

Rapid expansion of the Italian Atesina plant required construction of a second plant 15 km away from the original factory to have better access to workers close by. In 1973 this new factory opened its doors, specializing in bare wire production.

1976

First factory outside Europe

Elektrisola Inc., Boscawen, NH, U.S.A.

Elektrisola began exporting fine wire to the US market in the 1960’s. Due to the continued growth of this newest market the decision was made to build a new fine wire plant in the United States. In 1976 Elektrisola Inc. was opened in Boscawen, NH and continued to expand into the largest fine wire factory in North America.

1984

First sales company of Asia

Sales to Asia became a new challenge in the 1980’s. Therefore a trading company, Elektrisola Hong Kong Ltd., was founded in Hong Kong in 1984.

1993

First factory of Asia

Elektrisola (Malaysia) Sdn. Bhd., Bentong, Malaysia

To support the fast growing Asian market with local production, Elektrisola (Malaysia) was built and began operations in 1993 near Bentong, Malaysia.

1993

Generation change in Management

Dr. Detlef, Dr. Gerd and Dr. Oliver Schildbach

Dr. Gerd Schildbach passes the management of the Elektrisola Group on to his sons, Dr. Detlef and Dr. Oliver Schildbach.

1994

Sales office in Japan

The Japanese fine wire market was one of the most important in the world. Sales and Technical support was required locally in Japan to represent the other Elektrisola plants worldwide. Therefore, Nippon Elektrisola was established in 1994 as a trading company to serve the Japanese market.

1995

Expansion in North America with a factory in Mexico

Elektrisola S.A. de C.V., Cuauhtémoc, Mexico

In the late 1980’s, industrial production in North America began moving south from the US into Mexico. In 1995, Elektrisola S.A. de C.V. began operation in Cuauhtémoc, Mexico, supplying fine wire to customers in the southwest US, Mexico and South America.

1997

Acquisition of ultrafine wire production from Huber & Suhner and from Polydraht, Switzerland

1999

Trading Company France

Following the death of the French Elektrisola sales agent in 1999, Elektrisola France was established as a trading company in a facility located northwest of Paris to distribute Elektrisola magnet wire products.

1999

Trading Company Korea

In 1999, Elektrisola Korea was established as a trading company to support the Korean market.

2002-2005

Taped, profiled and extruded litz wire production started in Elektrisola Eckenhagen, Germany

2005

First factory in China

Elektrisola Hangzhou, P.R. China

With new emerging markets rapidly growing in China, this Asian market became very important for the electronic industry. After exporting magnet wire to China since 1982, Elektrisola Hangzhou was established in 2005 to supply customers in China.

2005-2008

More Sales Offices in Asia

Continued growth in Asia required additional sales offices to support the local markets. 2005 est. Elektrisola Thailand, 2006 est. Elektrisola Indonesia, 2008 est. Elektrisola India

2006

Takeover of sales organisation in Italy

In 2006, Cofili S.r.l. was purchased by Elektrisola and a new sales office was established in Biassone.

2007

Start of Litz wire production in Elektrisola Malaysia

2008

Development of new conductor materials

High strength alloys including High Tension Copper Clad Aluminium conductors were introduced by Elektrisola Feindraht in Switzerland for use in magnet wire as well as Litz wire production.

2009

New hall for solar wires in Elektrisola Feindraht, Switzerland