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Email:yewu001@yushengdz.com
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Self-Bonding Insulated Coils are cutting-edge electromagnetic components engineered to deliver exceptional performance in demanding electrical and electronic applications. These coils employ a revolutionary self-bonding insulation mechanism, where the conductive wire is pre-coated with a thermosetting adhesive layer. When subjected to controlled heat during the curing process, this adhesive activates, fusing adjacent wire turns into a unified, solid structure. This innovative approach eliminates the reliance on traditional insulation methods such as interleaving tapes, impregnating resins, or secondary varnishes, resulting in a mechanically robust, lightweight, and space-optimized design. Ideal for high-density assemblies, these coils excel in environments requiring resistance to thermal stress, vibration, and electrical arcing. They are rigorously tested to comply with global industry standards, making them a preferred choice for sectors like automotive electrification, industrial automation, and next-generation power distribution systems.
Specification Item | Value |
Conductor | Enamelled Litz Wire |
Insulated Wire Type | Telfon Insulated Litz Wire |
Insulated Wire Model | 0.1*130 FLW-F(lz)-XQ |
Appearance Confirmation | The surface should be free of discoloration, damage, copper leakage, scratches, contamination, cracks, oxidation, black spots, foreign objects, etc. |
Color Confirmation | Yellow |
Coil Type | Dual Coil Connection |
Number of Loops | 11TS |
Inside Diameter of Coil | MINՓ27 |
Outside Diameter of Coil | MAX50 |
Self-Bonding Insulation Technology: The wire’s unique adhesive coating undergoes cross-linking polymerization when heated, creating an interlocked insulation matrix. This not only prevents coil relaxation but also improves thermal conductivity by 15–20% compared to conventional insulated wires.
Superior Thermal Endurance: With a thermal index rating of 200°C (Class N) and a glass transition temperature (Tg) exceeding 180°C, these coils maintain structural integrity under prolonged thermal loads, ensuring consistent performance in overload scenarios.
High Dielectric Performance: Achieves a dielectric withstand voltage of 6 kV/mm and partial discharge levels below 5 pC, critical for high-voltage applications such as EV traction inverters and industrial motor drives.
Optimized Winding Density: The adhesive’s zero-overlap特性 enables ultra-tight winding with fill factors above 90%, reducing core size by up to 30% while maintaining equivalent inductance values.
Material Versatility: Compatible with rectangular, round, or Litz wire configurations in copper or aluminum variants (AWG 12–44). Compatible core options include nanocrystalline alloys for high-frequency operations and silicon steel for cost-sensitive projects.
Environmental Robustness: Passes MIL-STD-810G testing for humidity (95% RH), salt spray (500 hours), and thermal shock (-55°C to +175°C), ensuring deployment in offshore wind farms or desert solar installations.
Regulatory Compliance: Meets UL 1446 (Class 180), IEC 61857-1 for insulation systems, and features halogen-free materials per IEC 61249-2 standards.
Electric Vehicle Powertrains: Serve as key components in traction motor windings, bidirectional DC-DC converters, and wireless charging pads, where reduced eddy current losses and high power-to-weight ratios are paramount.
Industrial Drives and Actuators: Implemented in variable-frequency drives (VFDs), CNC machine spindle motors, and robotic arm actuators to enhance torque consistency and dynamic response.
Energy Storage Systems: Critical in flywheel energy storage coils and lithium-ion battery management systems (BMS), providing stable inductance for charge/discharge cycles and fault current limitation.
Aerospace Power Distribution: Utilized in aircraft generator windings, satellite attitude control thrusters, and UAV propulsion systems, meeting DO-160G standards for airborne electronic reliability.
High-Speed Rail Networks: Integrated into pantograph transformers and regenerative braking systems, offering vibration resistance for 25+ years of service in high-acceleration environments.
Smart Home Infrastructure: Enable compact designs in HVAC inverter boards, smart meter current sensors, and IoT-enabled power strips with reduced audible noise (<20 dB).
Self-Bonding Coil Applications
Electronic transformers
High-frequency inductors
Automotive relays and coils
Consumer electronics
Self-Bonding Coil Customization
We offer customized solutions to meet the specific requirements of your applications, including varying thicknesses, size, color and withstand voltage.
Self-Bonding Insulated Coils are cutting-edge electromagnetic components engineered to deliver exceptional performance in demanding electrical and electronic applications. These coils employ a revolutionary self-bonding insulation mechanism, where the conductive wire is pre-coated with a thermosetting adhesive layer. When subjected to controlled heat during the curing process, this adhesive activates, fusing adjacent wire turns into a unified, solid structure. This innovative approach eliminates the reliance on traditional insulation methods such as interleaving tapes, impregnating resins, or secondary varnishes, resulting in a mechanically robust, lightweight, and space-optimized design. Ideal for high-density assemblies, these coils excel in environments requiring resistance to thermal stress, vibration, and electrical arcing. They are rigorously tested to comply with global industry standards, making them a preferred choice for sectors like automotive electrification, industrial automation, and next-generation power distribution systems.
Specification Item | Value |
Conductor | Enamelled Litz Wire |
Insulated Wire Type | Telfon Insulated Litz Wire |
Insulated Wire Model | 0.1*130 FLW-F(lz)-XQ |
Appearance Confirmation | The surface should be free of discoloration, damage, copper leakage, scratches, contamination, cracks, oxidation, black spots, foreign objects, etc. |
Color Confirmation | Yellow |
Coil Type | Dual Coil Connection |
Number of Loops | 11TS |
Inside Diameter of Coil | MINՓ27 |
Outside Diameter of Coil | MAX50 |
Self-Bonding Insulation Technology: The wire’s unique adhesive coating undergoes cross-linking polymerization when heated, creating an interlocked insulation matrix. This not only prevents coil relaxation but also improves thermal conductivity by 15–20% compared to conventional insulated wires.
Superior Thermal Endurance: With a thermal index rating of 200°C (Class N) and a glass transition temperature (Tg) exceeding 180°C, these coils maintain structural integrity under prolonged thermal loads, ensuring consistent performance in overload scenarios.
High Dielectric Performance: Achieves a dielectric withstand voltage of 6 kV/mm and partial discharge levels below 5 pC, critical for high-voltage applications such as EV traction inverters and industrial motor drives.
Optimized Winding Density: The adhesive’s zero-overlap特性 enables ultra-tight winding with fill factors above 90%, reducing core size by up to 30% while maintaining equivalent inductance values.
Material Versatility: Compatible with rectangular, round, or Litz wire configurations in copper or aluminum variants (AWG 12–44). Compatible core options include nanocrystalline alloys for high-frequency operations and silicon steel for cost-sensitive projects.
Environmental Robustness: Passes MIL-STD-810G testing for humidity (95% RH), salt spray (500 hours), and thermal shock (-55°C to +175°C), ensuring deployment in offshore wind farms or desert solar installations.
Regulatory Compliance: Meets UL 1446 (Class 180), IEC 61857-1 for insulation systems, and features halogen-free materials per IEC 61249-2 standards.
Electric Vehicle Powertrains: Serve as key components in traction motor windings, bidirectional DC-DC converters, and wireless charging pads, where reduced eddy current losses and high power-to-weight ratios are paramount.
Industrial Drives and Actuators: Implemented in variable-frequency drives (VFDs), CNC machine spindle motors, and robotic arm actuators to enhance torque consistency and dynamic response.
Energy Storage Systems: Critical in flywheel energy storage coils and lithium-ion battery management systems (BMS), providing stable inductance for charge/discharge cycles and fault current limitation.
Aerospace Power Distribution: Utilized in aircraft generator windings, satellite attitude control thrusters, and UAV propulsion systems, meeting DO-160G standards for airborne electronic reliability.
High-Speed Rail Networks: Integrated into pantograph transformers and regenerative braking systems, offering vibration resistance for 25+ years of service in high-acceleration environments.
Smart Home Infrastructure: Enable compact designs in HVAC inverter boards, smart meter current sensors, and IoT-enabled power strips with reduced audible noise (<20 dB).
Self-Bonding Coil Applications
Electronic transformers
High-frequency inductors
Automotive relays and coils
Consumer electronics
Self-Bonding Coil Customization
We offer customized solutions to meet the specific requirements of your applications, including varying thicknesses, size, color and withstand voltage.