It is not recommended use enameled wire plus sleeve replace triple insulation wire. It is expected that the enameled wire plus sleeve will cost less than the triple insulation wire in terms of material costs, however, the volume of the product, after including the retaining walls and sleeve, will increase considerably.
Further, enameled wire has to be sleeved separately, adding an additional production step, which increases the manufacturing costs of the product and reduces workers’ productivity in today’s increasingly high labor and management costs.
Lastly, due to the increased space of the retaining wall and sleeve, it will also cause adverse hidden dangers like high-frequency transformer inductance, high voltage, leakage inductance, and distributed capacitance.
What is triple insulation wire?
Three-layer insulated wire for high-frequency transformers is made up of three insulating layers and a core wire in the center. Among these layers, the first is a golden polyamine film, which measures several microns thick, but is able to withstand pulse voltages of up to 3KV; Secondly, a highly insulating paint coating is applied; In the third layer, a transparent glass fiber layer is deposited. The total thickness of the insulating layer is between 20 and 100 microns, and the dielectric strength is very high. Two layers will not be broken by a voltage of 3000 volts, and the current density is high.
Triple insulated wire storage conditions:
Triple insulated wires of high-frequency transformers should be stored at -25°C and 30°C with a relative humidity of 5%-75%. Wires that are triple-insulated cannot be stored in environments with high temperatures, high humidity, direct sunlight, or dust.
Shelf life of triple insulation wire:
1year, triple insulation wire that has exceeded the storage period must be tested again for insulation breakdown voltage, withstand voltage, and windability.
Why should high-frequency transformer be equipped with sleeve？
This sleeve is necessary in order to protect the insulating varnish on the outside of the copper wire from being scalded during tin immersion, which would result in the two cross wires coming into contact and causing a short circuit. During the construction of the high-frequency transformer, a sleeve is added to strengthen the insulation between the primary coil and secondary coil. It is used to test the insulation properties of high-frequency transformers by applying a high voltage of 3000 volts between the primary and secondary of the transformer. The high voltage used to conduct this test is used to test the primary and secondary insulation properties of high-frequency transformers.
