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The complete guide to triple insulated wires

What is triple insulated wire?

The triple-insulated wire is a new high-performance insulated wire that has been developed in the last few years in the world. Wires of this type consist of three layers of insulation, with a core wire in the middle. The first layer of the film is a golden polyamide film, also known as golden film abroad. The thickness of this film is several microns, but it can withstand high voltage pulses of 3kV; The second layer consists of a highly insulating paint coating, while the third (outermost) layer consists of a transparent fiberglass coating;This insulating layer consists of only 20-100 mils of thickness. Wires that are triple insulated can be used in a variety of cutting-edge technology and national defense applications, such as miniature motor windings and high-frequency transformer windings for miniaturized switching power supplies. With its high insulation strength, any two layers can withstand a safe voltage of 3000V AC. It does not require a barrier layer, and insulating tape is not required between stages, and the current density is high. Compared with enameled wire, it can cut down the volume of a high-frequency transformer by half. It is necessary to heat the tough texture of triple insulated wire to a temperature of 200 to 300°C in order to soften it prior to winding. Upon cooling, the coil will automatically form after the winding is completed.

What is principle of triple insulated wire?

The use of triple insulated wire is especially suitable for winding high-frequency transformers in miniaturized and high-efficiency switching power supplies. As an example, consider the high-frequency transformer wound with TEX-E. In this case, since the interlayer insulating tape and the barrier layer are not required, the transformer is 1/2 smaller and lighter than the traditional transformer wound with enameled wire. Below is a structural comparison of the two high-frequency transformers:

The triple insulated wire is especially good for winding the secondary winding of a miniaturized switching power supply, while the primary and feedback windings are still wound with enameled wire. A triple-insulated wire product must be certified by an international authority organization, such as Ul, CSA, BSI, NEMKO, VDE, or another certification agency. IEC950, UL1950, CSAC22.2No.950-95, EN60950A3A4, and HDl95S6 are the most commonly used safety standards.

What is the features of triple insulated wire?

  • A high degree of impact resistance
  • Suitable for all types of weather conditions
  • Chemical environment of good quality
  • There is a high degree of wear resistance on the surface
  • Water absorption is small, and dimensional stability is good
  • A good impact strength is achieved at low temperatures
  • Gas barrier properties that are good:
  1. A low specific gravity, a low water absorption rate, and a small change in physical properties following water absorption.
  2. The products have a wide temperature range for molding, are stable in size, have a high low-temperature impact strength, and are weather resistant.
  3. It has excellent oil resistance and chemical resistance, and is resistant to grease, gasoline, fuel oil, liquids, salt solutions, etc.
  4. Excellent wear resistance, good self-lubrication, and excellent fatigue resistance.
  5. High performance polymers have the same excellent processability as other materials developed by the High Performance Polymers Division.

What is the function of triple insulated wire?

Wire with a triple insulation construction and reinforced insulation for use in switching power supply transformers. They can be downsized for a low profile and help reduce the amount of heat generated by the coils.

What are the advantages of triple insulated wire?

  1. There is no need to layer an insulating layer between the primary and secondary coils of the transformer, which allows the transformer to be miniaturized and light in weight while saving 1/2 the volume of traditional winding.
  2. It has a high insulation level, excellent voltage resistance performance, and a breakdown voltage greater than 16KV. There is no insulating paper or insulating varnish between conventional windings.
  3. Chemical solvent and varnish resistance is good.
  4. It can be wound automatically due to its excellent wear resistance and smooth surface.
  5. It is not necessary to peel off the insulation layer, it can be directly welded.

In the market, who are the most reputable insulated wire manufacturer?

Among the well-known manufacturers of triple insulated wires on the market, there are the following:

1.Triple insulated wire tex-e

The Tex-e insulated wire is formed using a method of extruding coated resin three times consecutively (continuous use can withstand a temperature of 120°C). Soldering polyester heat-resistant resin (Modified PET) is used for the first and second layers, and polyamide resin (Polyamide) is used for the third layer (outermost layer). Among them, the polyamide used in the third layer is a material that can exert its chemical and mechanical characteristics, is free from chemical influences brought by transformer life tests, and is suitable for coil winding.

A standard wire of TEX series, TEX-E, is solderable wire of single conductor and triple insulation layers. The layers are organized by heat resistant modified polyester and polyamide.

Click here for more information: http://www.TEX-E.com

2.Leoflon triple insulated wire

Leoflon is one of Tawain triple insulated wire manufacturers, this company produces insulated triple wire that meets the following specifications:

  • Conductor : Solid and Stranded Copper & TIN Plated Copper
  • Insulation Thickness : 0.075mm~0.1mm(each layer : 0.025~0.033mm)
  • Wall Thickness : 0.075mm~0.1mm
  • Temperature & Voltage Rating : Rating130℃ ~155℃ , 600V(Class B)
  • Dielectrical Strength : 5KV~6KV(70KV /mm)
  • Colors : Yellow, Black
  • Benefit : Triple insulated wire offers extra protection against pinholes
  • UL FINE NO. E211989
  • VDE LIENCE No.136581 V-0

Click here for more information: https://www.leoflon.com

Triple insulated wire TOTOKU

This is a well-known Japanese brand of reinforced insulated wires with triple insulation structure for switching power supply transformers. Totoku is one of the world’s leading manufacturers of triple insulated wires. Using them, the coils produce less heat and can be downsized to lower their profile. They provide Class B heat-resistance triple insulated winding wire B, Class F heat-resistance triple insulated winding wire F and Class H heat-resistance triple insulated winding wire H.

Click here for more information: https://www.totoku.com

What are the disadvantages of triple insulated wire?

  1. In the production of high-frequency transformers, the high price of triple insulated wire prevents its widespread adoption on a massive scale due to its high cost
  2. In the process of winding the wire, it is very easy for the triple-insulated wire to break
  3. The biggest problem with using triple insulated wire is that it is extremely hard to peel it off the insulation

The development trend of triple insulated wire

With the development of mobile technology such as mobile phones and notebook computers, the market is driven by a growing requirement for transformers to be both small in size and lightweight in order to support the growing demand. Therefore, it can be predicted that the triple insulated wire market is going to expand in the foreseeable future. In the same way, we are seeing a similar development trend in the international market. Power supply equipment is in demand or becoming more and more light weight, small in size, long lasting, safe, and multifunctional. The triple insulated wire may become a substitute for enameled wires over the next few years.

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