Water-based Enamelled Winding Wire Insulation Coating It is a key type of winding wire, serving as a crucial raw material for products such as motors, household appliances, and electrical devices. Composed of two main components—the electrical conductor and the insulating layer—the bare wire is first softened through quenching, then coated multiple times with varnish before being baked to set. These wires are categorized based on their conductor materials into copper-core wires, aluminum wires, and aluminum alloy wires. They are further classified according to the insulation material used, including acetal-based enamelled winding wire insulation, polyester-based enamelled winding wire insulation, polyurethane-based enamelled winding wire insulation, polyester-imide enamelled winding wire insulation, and polyimide-based enamelled winding wire insulation. Additionally, they can be divided by the shape of the conductor material into round wires, flat wires, and hollow wires.

　　Production and Preparation Plan (Taking Copper Water-Based Enamelled Winding Wire Insulating Coating as an Example)

　　1. Laser Cutting

　　Water-based enamelled winding wire insulation consists of two parts: the conductor and the insulator, both of which exhibit excellent strength yet remain flexible. As a result, the TabCUT-200 high-precision automatic cutting machine—when paired with standard SiC grinding wheels—can efficiently perform laser cutting. Since the insulating material is applied directly onto the conductive wire and has significantly different mechanical properties (in terms of strength and elongation), the insulation layer possesses a certain degree of separability. Therefore, during the cutting process, it’s advisable to use soft materials like aluminum foil or plastic film to carefully wrap around the laser-cut area. This helps prevent the insulation layer from peeling off or detaching at the cut edges after the process is complete.

　　2. Embedding

　　Water-based enamelled winding wire insulation coatings all exhibit good strength and temperature resistance. Considering the flatness of the ground surface and the high efficiency of sample preparation, we strongly recommend using FlexPRESS for thermal embedding applications.

　　3. Grinding and Polishing

　　The Alpha-600 fully automatic polishing and grinding machine allows for the rapid and highly efficient preparation of specimens, ensuring both repeatability and consistency in sample quality. For grinding, standard carbon-carbon composite abrasive paper can be used. During polishing, to achieve a perfectly flat surface free of any unevenness, start with a relatively rigid, woven cloth material like YS, paired with diamond polishing liquid. In subsequent polishing stages, to thoroughly remove copper and insulating layer scratches, switch to medium- or short-pile polishing cloths such as YR or FinalRed, combined with aluminum oxide or specially formulated silica-based polishing liquids for fine finishing—ultimately yielding a smooth, flawless surface.

　　4. The grinding and polishing process is as follows:

　　Process

　　Surface Preparation

　　SiC Abrasive Sandpaper

　　YS Polishing Cloth

　　YR Polishing Cloth

　　FinalRed Polishing Cloth

　　Grain number

　　P180 to P2500

　　1μm Diamond Polishing Liquid

　　0.05% Aluminum Oxide Polishing Liquid

　　Specially formulated silica polishing liquid*

　　Refrigeration and Lubrication Fluid

　　PL-W Polishing Lubricant

　　Single specimen load/N

　　Duration/s

　　Grinding wheel speed / rpm

　　Vehicle chassis rotational speed / rpm

　　Converted to

　　In the same direction

　　In the same direction

　　In the same direction

　　In the opposite direction

　　*Add 25% sodium hydroxide and 3% hydrogen peroxide to the silica polishing slurry.

　　When performing the final polishing step with aluminum oxide, carefully control both the amplitude and duration of polishing to avoid significant protrusions in the specimen's conductive or insulating layers. Alternatively, you can use a lint-free, smooth ZN polishing cloth as a substitute. To further simplify the polishing process, another option is to combine aluminum oxide and silica polishing suspensions using the YR/FinalRed polishing cloth for simultaneous polishing, while adjusting the primary polishing parameters according to the silica-based solution.

　　Water-Based Enamelled Winding Wire Insulation Coating 100X