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IATF 16949:2016 certified.
H I G H P E R F O R M A N C E W I R E S State-of-the-art electric motors for EV’s, PHEV’s and HEV’s require new and sophisticated solutions – especially in the field of stator winding and insulation materials. HPW – as a specialist for flat insulated copper winding wires over decades – developed different solutions suitable for various applications, voltage levels and other special requirements.
Starting from bare copper rod, we cover the entire manufacturing process including surface preparation and cleaning, rolling, drawing and insulation. Our enamel wires with improved properties significantly reduce typical failure rates in the industry. For high voltage applications we offer extruded insulation systems out of high performance polymers such as PEEK or PI setting a new industry standard and targeting specific requirements of our customers. Enameled Flat Wires Smooth, even surface Good adhesion on copper surface Almost pin-hole and blister free (< 1 fault / 1000m) even, closed 200 max. 100μm + min. 2x bare wire width/thickness + ~ – only Flat Comparison of properties of different insulation systems Surface Temperature class Possible Coating Thickness Flexibility in Coating Thickness Minimum Bending Diameter Electrical Properties Aging Resistance Corona Resistance Possible Wire Shape
Extruded PEEK insulated Flat & Round Wires Extruded Polyimide insulated Flat & Round Wires Polyimide-film insulated Flat & Round Wires Smooth, even surface Smooth, even surface Good adhesion on copper surface Excellent adhesion on copper surface without any further bonding layer Excellent adhesion on copper surface without any further bonding layer High flexibility of insulation material High flexibility of insulation material Very good aging and PD resistance Very good aging and PD resistance Proven insulation material Standard insulation material in traction motors for decades even, closed 240-260 max. 300μm even, closed un-even, with tape edges 240 240 max. 300μm max. 230μm (two layers) ++ ++ ~ min. 1x bare wire width/thickness min. 1x bare wire width/thickness min. 2x bare wire width/thickness ++ ++ +++ ++ +++ +++ ++ + + Flat & Round Flat & Round Flat & Round Detailed information regarding oil- and PD-resistance may be provided upon request.
Conductors for high performance rigid busbars
C Rigid Busbars are used in electric vehicles – they require outstanding dimensional and insulation properties. Narrow bending angles cause high mechanical stress in conductor and insulation. Therefore highest possible bonding properties between conductor and insulation are needed. PA12-BUSBAR WIRES conductor material Aluminium or Copper Excellent adhesion on conductor surface No bonding layer between conductor and insulation even, closed max. 50 mm max. 8 mm 0,25 – 1 mm 200 – 270 N/mm² ≥ 32% ≤ 6,0° RAL 2003 – RAL 2008 PA12 insulated Busbars Surface Width of conductor Thickness of conductor Insulation increase Tensile strength Elongation Springback angle Color
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