What is Enameled Flat & Rectangular Copper Wire?
Enameled Flat & Rectangular Copper Wire (or enameled strip or flat magnet wire) is a high quality electrical conductor, which is extruded/drawn from high purity oxygen free copper bar. This is formed into a very accurate square or rectangular shape before being covered with insulation lacquer in several coats.
Compared to the conventional round type of magnet wire, the rectangular shape provides the ability to wind electromagnetic coils more tightly and without gaps. Not only does this unique profile greatly improve the slot fill factor (up to 78–85%), but it improves the heat transfer rate and reduces the total size of electrical equipment utilized in high power density applications such as NEV Hairpin motors, industrial transformers, wind turbine generators and heavy duty reactors.
Applications of Enameled Rectangular Copper Wire
Electric Motors: Used for high-power-density motor windings, helping to improve slot fill factor and space utilization.
EV & Traction Motors: Rectangular enamel-coated copper wire is particularly suitable for hairpin/rectangular winding architectures.
Transformers: Suitable for dry-type transformers, specialty transformers, and high-current windings.
Generators: Used for generator stator and rotor windings.
Reactors & Inductors: Suitable for high-current inductors, reactors, etc.
Industrial Electrical Equipment: Welding machines, generators, motors, transformers, reactors, inductors.
Enameled Rectangular Copper Wire Key Technical Specifications
| Name | Enameled Rectangular Copper Wire |
| Conductor | Copper |
| Dimension | Thickness(a):0.8-8.0mm; Width(b):2.0-22.5mm or custom sizes |
| Thermal Class | 120°C(Class E), 180°C(Class H), 200°C(Class C), 220°C(Class C+), 240°C(Class HC) |
| Insulation Thickness: | G1 / G2 / single build / heavy build |
| Standard | IEC 60317 / NEMA MW 1000 / JIS / GB |
| Certificate | UL, ISO |
| Insulation | UEW, PEW, EIW, EI/AIW |
| Corner Radius (R) | Customized |
| Packing | 30kg-150kg ply-wood spool(250*400 / 250*500/ 250*600/ 250*730) |
Enameled copper wire packing size
Zhengzhou LP Industry enameled flat copper wire packing:
Plywood wooden spool/bobbin, spool/bobbin common specifications: one spool/bobbin wire weight 30~150kgs
Outer packing: pallet or plywood box, suitable for shipping by sea
| Reel Type | Range of Dimeter( mm) | Weight of Wire Spool (KG) | Diameter (mm) | |||||
| D1：Top Flange | D2：Bottom Flange | d1：Top Core | d2：Bottom Core | W | h(d3)：Center bore | |||
| 250*400 MDF wooden | 3.0~6.0 | 25~35 | 400±2.0 | 400±2.0 | 210±1.0 | 280±1.0 | 250±2.0 | 100±0.5 |
| 250*500 MDF wooden | 3.0~6.0 | 40~60 | 500±2.0 | 500±2.0 | 210±1.0 | 210±1.0 | 250±2.0 | 60±0.5 |
| 250*600 MDF wooden | 3.0~8.0 | 80~100 | 600±2.0 | 600±2.0 | 210±1.0 | 210±1.0 | 250±2.0 | 60±0.5 |
| 250*730 MDF wooden | 3.0~8.0 | 90~130 | 730±2.0 | 730±2.0 | 210±1.0 | 210±1.0 | 250±2.0 | 60±0.5 |
| 250*730 MDF wooden | 3.6~8.0 | 110~140 | 730±2.0 | 730±2.0 | 210±1.0 | 210±1.0 | 250±2.0 | 60±0.5 |
| 500*500 MDF wooden | 1.0~8.0 | 100~120 | 500±2.0 | 500±2.0 | 210±1.0 | 210±1.0 | 500±2.0 | 60±0.5 |
We also manufacture specialized enameled flat copper wire—specifically hairpin motor flat wire—for New Energy Vehicles (NEVs).
What Information Do We Need for a Rectangular Magnet Wire Quote?
Get a quote for standard sizes, the client only needs to provide:
Conductor material
Width × thickness
Thermal class
Insulation type
Insulation build
Quantity
For custom sizes, please provide the required dimensions, corner radius, application, applicable standards, and detailed drawing or specifications.
The optimal conductor geometry depends on the winding design, slot geometry, current density and manufacturing process.
Frequently Asked Questions
Enameled rectangular copper wire is a copper conductor with one or more layers of electrical insulation enamel applied to its surface. Its rectangular cross-section allows more efficient use of winding space than conventional round wire in applications where high slot fill and compact winding designs are required. It is commonly used in motors, transformers, generators, reactors, and other electrical equipment.
Flat magnet wire generally refers to an insulated conductor with a flattened or rectangular cross-section. Rectangular magnet wire is a more precise technical term describing the conductor geometry. In many winding-wire applications, the terms “flat magnet wire” and “rectangular magnet wire” are used interchangeably, depending on the industry and application.
LP Industry can manufacture enameled rectangular copper wire with conductor thicknesses from approximately 0.8 to 8.0 mm and widths from approximately 2.0 to 22.5 mm. The actual available dimensions depend on the insulation system, applicable standard, dimensional tolerances, and production requirements.
Yes. LP Industry manufactures customized rectangular magnet wire according to customer specifications and drawings. Customization can include conductor width, thickness, corner radius, insulation type, insulation build, thermal class, dimensional tolerances, applicable standards, spool requirements, and packaging.
Depending on the required electrical, thermal, mechanical, and application performance, LP Industry can provide different enamel insulation systems, such as polyurethane, polyester, polyesterimide, polyamide-imide and other suitable insulation constructions. The specific insulation system should be selected according to the required thermal class, electrical performance, winding process, and applicable standard.
Grade 1 and Grade 2 generally refer to different levels of insulation build and enamel coverage according to the applicable magnet-wire standard. Grade 2 normally provides a greater insulation build than Grade 1, which can provide additional electrical and mechanical protection. The appropriate grade depends on the required insulation performance, available winding space, and applicable standard.
The corner radius, or R-angle, describes the radius of the rounded corners of the rectangular conductor. It is an important dimensional parameter because it affects insulation coverage, winding fit, mechanical performance, and compatibility with the customer’s winding design. LP Industry can manufacture the corner radius according to applicable specifications or customer drawings.
