PEEK WIRE | Insulated Copper Wire | PEEK Electrical Cable Φ0.2-Φ5mm Available

PEEK wire can be stabilized at high voltages due to their excellent electrical properties. The specific high voltage resistance varies depending on the diameter of the cable and the thickness of the insulation.

With the rapid development of new energy electric vehicle technology, 800V or 1200V drive systems are becoming the focus of attention for major manufacturers. one of the key challenges for 800V motors is the stability of flat winding wires at high voltages.

To solve this problem, one of the most popular solutions is to use peek wire coating instead of traditional thick enameled wires.

In comparison, PEEK extruded flat wire is not only a simpler production process, but also a more stable product. It does not require multiple coats and baking to achieve excellent pressure resistance. In addition, the flat wire is able to withstand repeated bending without breaking when processing hairpins.

With many years of experience in the development and production of motor magnet wire, the BW material company, through the tireless efforts of its R&D and technical teams, has succeeded in developing PEEK insulated wires with high-temperature resistance, high flame retardancy, power up high-voltage mobility, radiation resistance, and excellent mechanical properties. This is a revolutionary success, and this new breakthrough provides a more reliable and stable solution for high voltage drive systems for new energy motors.

More details, contact us!

PEEK Insulated Copper Wire Specification

Specification

The following is the general high voltage resistance of PEEK Wire/PEEK Cable:

Low diameter wire (e.g. 0.10 mm): can withstand high voltages ranging from hundreds to thousands of volts.
Medium diameter wire (e.g. 0.50 mm): can withstand high voltages of 5,000 volts or more.
Large diameter wire (e.g. 1.00 mm and above): can withstand high voltages above 10,000 volts.

References https://www.tau.group/post/peek-magnet-wire

PEEK Wire Insulation Properties

PEEK MAGNET WIRE PROPERTIES
	Property	PEEK WIRE
Electrical Properties	Electrical Insulation	Excellent
	Dielectric Strength	Superior,dielectric strength is 20-24 kV/mm
	Secondary Insulation	with excellent electrical insulation performance and low dielectric loss
	Electrical Strength	High tensile strength and excellent mechanical properties
Mechanical Properties	Adhesion	Maintains over 91% even after 2000 hours at 150°C in ATF
	Viscosity and Temperature Change	Stable at high temperatures
	Strength	Constant expansion rate
	Expansion Rate	Low thermal expansion coefficient, ensuring dimensional stability within the temperature range
	Speed	Achieves high-speed processing due to good thermal stability and mechanical strength
Environmental Adaptability	Thermal Stability	Up to 240°C
	Chemical Resistance	Excellent
	Thermal Conductivity	Thermal conductivity coefficient is 0.35 W/m·K
	Tg (Glass Transition Temperature)	Approximately 143°C, indicating high-temperature stability
	Glass Transition Temperature	-40°C to 130°C
	Environmental Friendliness	Does not contain volatile organic compounds (VOCs) or carcinogens
Special Application Properties	Applicable Scenarios	Electric vehicles, high-voltage motors, harsh environments, and high-temperature applications
	Special Properties	Resistant to ATF fluid and vapor, suitable for scenarios requiring high adhesion and strength
	Curing Characteristics	Precise control of curing conditions is required to ensure uniform insulation
	Adhesion Analysis	Ensures reliable performance under mechanical stress due to strong molecular adhesion
	Peak Coating Wires	Provides durable coatings suitable for high-performance applications
	Copper Slot Fill Volume	Due to the superior properties of PEEK, the insulation layer is thinner, resulting in a higher fill volume
Other Properties	Resin Absorption in Windings	Fast absorption due to low viscosity at processing temperatures
Other Properties	Thermal Expansion Coefficient	48 ppm (low temperature) to 208 ppm (high temperature)

Reference data sources:PEEK coating Wire

PEEK Wire Features & Benefits

At 800V or 1200V, PEEK insulated wire can provide the following roles and advantages:

Electrical insulation: The PEEK coating has excellent electrical insulation properties and prevents electrical breakdown in high voltage environments.
High Temperature Resistance: After 2000 hours of exposure to 150°C ATF (Automatic Transmission Fluid), the PEEK coating retains more than 91% of its original adhesion, demonstrating that the PEEK coating maintains its mechanical and electrical properties in high temperature environments.
Mechanical durability: In harsh environments such as high temperatures and high pressures, PEEK coated wires demonstrate excellent mechanical durability and are able to withstand extreme conditions without failure. Tests have shown that the insulation strength of peek magnet wire does not decrease significantly when exposed to high temperatures and ATF vapors.
Thermal Conductivity: The thermal conductivity of PEEK wire coating (0.35 W/m-K) is superior to that of aramid paper (0.1 W/m-K), which helps dissipate heat more efficiently and prevent overheating in high voltage applications.
Chemical resistance: PEEK coating wire have excellent chemical stability and are resistant to a wide range of chemicals, including ATF, making them particularly suitable for electric vehicles and other industrial applications that require long-term exposure to high voltages and chemicals.
Reduced system weight and size: Due to the higher copper channel fill of peek magnet wire conductors (more than 10% increase), electrical and mechanical properties are guaranteed while reducing the overall size and weight of the system.

PEEK Insulated Cable FAQ

Testing

Rated voltage: 750V
Temperature resistance range: -40℃ - 125℃
Test voltage: 4000V/min
Conductor DC resistance: 40.1Ω/km
Minimum bending radius of cable: <6D (D is the outer diameter of cable)
Cable fire performance: in line with BS6853 standard
Cable oil resistance performance: in line with TB/T1484.2 standardHigh temperature test: 125 ℃ / 6H, conductor shielding does not blacken, insulation core line of the non-stick, sheath does not crack
Low-temperature test: -40℃/6H, low-temperature winding without cracking.

Sizing

peek_insulated_copper_wire_diameter_available_36.xlsx

No	W	T	T	T	T	T	T	T	T	T	T	T	T	T	T	T	T	T	T	T	T
1	0.3	0.2
2	0.5	0.2	0.5
3	1	0.2	0.5	0.75	1	1.25	1.5	1.75
4	2	0.2	0.5	0.75	1	1.25	1.5	1.75
5	3	0.2	0.5	0.75	1	1.25	1.5	1.75	2	2.25	2.5
6	4	0.2	0.5	0.75	1	1.25	1.5	1.75	2	2.25	2.5	2.75	3	3.25	3.5
7	5	0.2	0.5	0.75	1	1.25	1.5	1.75	2	2.25	2.5	2.75	3	3.25	3.5	3.75	4	4.25
8	6	0.2	0.5	0.75	1	1.25	1.5	1.75	2	2.25	2.5	2.75	3	3.25	3.5	3.75	4	4.25	4.5	4.75	5
9	7	0.5	0.75	1	1.25	1.5	1.75	2	2.25	2.5	2.75	3	3.25	3.5	3.75	4	4.25	4.5	4.75	5
10	8	0.5	0.75	1	1.25	1.5	1.75	2	2.25	2.5	2.75	3	3.25	3.5	3.75	4	4.25	4.5	4.75	5
11	9	0.5	0.75	1	1.25	1.5	1.75	2	2.25	2.5	2.75	3	3.25	3.5	3.75	4	4.25	4.5	4.75	5
12	10	0.5	0.75	1	1.25	1.5	1.75	2	2.25	2.5	2.75	3	3.25	3.5	3.75	4	4.25	4.5	4.75	5
13	12	0.5	0.75	1	1.25	1.5	1.75	2	2.25	2.5	2.75	3	3.25	3.5	3.75	4	4.25	4.5	4.75	5
14	14	0.5	0.75	1	1.25	1.5	1.75	2	2.25	2.5	2.75	3	3.25	3.5	3.75	4	4.25	4.5	4.75	5
15	16	0.75	1	1.25	1.5	1.75	2	2.25	2.5	2.75	3	3.25	3.5	3.75	4	4.25	4.5	4.75	5
16	18	0.75	1	1.25	1.5	1.75	2	2.25	2.5	2.75	3	3.25	3.5	3.75	4	4.25	4.5	4.75	5
17	20	0.75	1	1.25	1.5	1.75	2	2.25	2.5	2.75	3	3.25	3.5	3.75	4	4.25	4.5	4.75	5
18	23	0.75	1	1.25	1.5	1.75	2	2.25	2.5	2.75	3	3.25	3.5	3.75	4	4.25	4.5	4.75	5
19	25	1	1.25	1.5	1.75	2	2.25	2.5	2.75	3	3.25	3.5	3.75	4	4.25	4.5	4.75	5

Application Scenarios for PEEK Automotive Cable

Electric Vehicles:

Due to the rise of electric vehicles, new energy electric vehicle manufacturers are committed to improve motor efficiency and shorten battery charging time, PEEK enameled wire due to its superior electrical insulation properties and high temperature resistance, more and more manufacturers choose PEEK insulated wire used in high performance motors in electric vehicles, so peek insulated wire has become the best choice for the electric vehicle industry. peek wire insulation is the best choice for the electric vehicle industry.

High voltage motors:

In high voltage motors from 800V to 1200V, PEEK insulated wires can provide higher power output and higher copper slot filling, thus improving system efficiency.

Harsh Environments:

The chemical resistance and mechanical durability of makes it suitable for peek wire insulation equipment operating in harsh environments with high temperatures, high humidity and chemicals such as ATF automatic transmission fluid.

How do we produce PEEK insulated Cable?

The production of PEEK enameled wire involves a series of delicate process steps to ensure the quality and performance of the product. The following is a detailed description of each key step:

Wire drawing and calendering

Drawing Round Wire: This section uses high purity copper cathodes to draw round copper wire of specific specifications to ensure the purity and quality of the base material.

Rolling flat wire: Round copper wire is rolled into flat wire through high precision imported equipment and advanced calendering technology. Online monitoring using laser equipment ensures the precision and stability of the products and realizes online automatic control.

Annealing and drying

Using electric heating tubes to heat and dry the drawn flat wires, this process eliminates internal stresses and restores the flexibility of the copper wires so that they can adapt to the subsequent processing steps.

Lacquering and curing

The lacquer is evenly applied to the flat copper wire by means of a fully automatic recirculating reflux lacquer supply system using, for example, felts or molds. The multi-stage electric heater enameling oven uses digital control technology to precisely control the baking temperature and time to fully cure the lacquer film and ensure the uniformity and durability of the lacquer layer.

Winding

Flat enameled wires are leveled by digital programming technology for subsequent use and handling.

Inspection

The flat wires are thoroughly tested for appearance, dimensions, electrical, mechanical and thermal properties. The process generates non-conforming products, which are screened out to ensure the quality of the final product.

Packaging into warehouse or into PEEK production line

Qualified products are partly packaged and warehoused for shipment, while the other part enters the PEEK production line for further processing.

PEEK Insulated Cable Voltage and PDIV of Different Enamelled Thinkness

Product Name	Product Size Range	Product Enamelled Thickness:	Pre-side Insulation Thickness	BDV(V)	PDIV(Vp)
PEEK flat Copper Wire	Width: 0.30 ≤ W ≤ 25.00mm	Grade 0 (more than 150um by pre-side)	0.15	>20000	>2100
	Thickness: 0.20 ≤ T ≤ 5.00mm	Grade 1 (120-150um by pre-side)	0.120-0.150	>15000	>1800
	Width Thickness Ratio: 1:1 ≤ T:W ≤ 1:30	Grade 2 (90-120um by pre-side)	0.090-0.120	>12000	>1600
		Grade 3 (60-90um by pre-side)	0.060-0.090	>9000	>1400
		Grade 4 (30-60um by pre-side)	0.030-0.060	>6000	>1200
PEEK Round Wire	∅0.65 - 4.20mm	Grade 0 (more than 150um by pre-side)	0.15	>20000	>2100
		Grade 1 (120-150um by pre-side)	0.120-0.150	>15000	>1800
		Grade 2 (90-120um by pre-side)	0.090-0.120	>12000	>1600

PEEK WIRE | Insulated Copper Wire | PEEK Electrical Cable Φ0.2-Φ5mm Available

PEEK Insulated Copper Wire Specification

Specification

PEEK Wire Insulation Properties

PEEK Wire Features & Benefits

PEEK Insulated Cable FAQ

Testing

Sizing

peek_insulated_copper_wire_diameter_available_36.xlsx

Application Scenarios for PEEK Automotive Cable

How do we produce PEEK insulated Cable?

PEEK Insulated Cable Voltage and PDIV of Different Enamelled Thinkness

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Zhejiang BW industry co., ltd