Switch-mode power supply (SMPS) transformers are an essential component in electronic devices that require a regulated power supply. One of the most popular materials for constructing SMPS transformers is enameled copper wire, which has a thin coating of enamel insulation that protects the copper wire. However, before the wire can be used in a transformer, it is necessary to remove the enamel coating. This process can be challenging, especially for those who are new to transformer winding.
Before we delve into the methods, let us understand the basics of enameled wire.
What is Enameled Wire?
Enameled wire is a type of wire that is coated with a thin layer of insulation to prevent it from coming into contact with other wires or conductive materials. This insulation is typically made from an organic material such as polyester, polyurethane, or polyamide-imide.
Enameled wire has a wide range of applications in electronics, including in transformers, motors, and generators. The insulation coating on the wire makes it resistant to high temperatures and electrical current, ensuring that it does not burn out or short-circuit.
However, when it comes to making SMPS transformers, the copper cover of the enameled wire needs to be removed to ensure efficient winding of the transformer. The following are some of the methods you can use to remove the copper cover from enameled wire when making SMPS transformers.
The following four remove copper covered methods may be helpful for you
Method 1: Scraping the Copper Cover
Scraping the copper cover is a simple and effective method of removing the copper cover from enameled wire. This method involves using a sharp blade or a scraper to remove the copper cover from the wire.
To use this method, you need to hold the wire firmly and gently scrape off the copper cover with the sharp blade. You should be careful not to apply too much pressure as this may damage the wire insulation.
While this method is simple and effective, it is time-consuming, and it can be difficult to achieve a uniform thickness of the copper cover on the wire.
Method 2: Electric peeling
Select an electric drill bit that matches the enameled wire. Copper wires are stripped and tinned at the end. The position control is better. If the stripped paint is too short, it may result in poor tinning. The pins at the beginning and end of the coil are crossed, and their paint stripping is too long, causing the tin to be on the PIN a lot, short-circuiting the pins at the beginning and end, which results in poor transformer quality.
Method 3: Burning Off the Copper Cover
Burning off the copper cover is another effective method of removing the copper cover from enameled wire. This method involves using a flame to burn off the copper cover from the wire.
To use this method, you need to hold the wire with a pair of pliers and apply a flame to the copper cover using a lighter or a propane torch. The heat from the flame will melt the copper cover, which can then be easily wiped off using a soft cloth.
While this method is quick and efficient, it can be dangerous, and there is a risk of damaging the wire insulation or burning the wire. You need to be careful when using this method and ensure that you have a fire extinguisher nearby in case of any accidents.
Method 4: Chemical Stripping
Chemical stripping is a method of removing the copper cover from enameled wire using chemicals. This method involves immersing the wire in a chemical solution that dissolves the copper cover, leaving the wire exposed.
To use these methods, you need to prepare a chemical solution by mixing a strong acid with water. The acid should be strong enough to dissolve the copper but not too strong to damage the wire insulation.
Once the chemical solution is ready, you need to immerse the wire in the solution for a few minutes until the copper cover dissolves. You should then rinse the wire thoroughly with water and dry it before using it in your transformer winding.
