IEC 60317 Glass Fiber Covered Enameled Rectangular Copper Wire

    1. Scope And Definition

    Applicable to copper conductors with rectangular cross-section, with bare copper or coated with varnish (such as polyester, polyimide, etc.).

    The outer layer of the conductor is wrapped with glass fiber yarn and impregnated with resin or varnish to improve mechanical strength and heat resistance.

    Mainly used in electrical insulation systems with high heat resistance grades (such as Class 155/F and above).

    2. Dimensions

    (1) Conductor size (bare copper or enameled)

    Width (a): The standard range is usually 2mm ~ 16mm (see manufacturer specifications for details).

    Thickness (b): The standard range is usually 0.8mm ~ 5.6mm.

    Corner radius (r): The four corners of the conductor are rounded, and the radius is usually 0.3mm ~ 1.0mm (depending on the size).

    (2) Glass fiber coating

    Number of wrapping layers: single or multiple layers (such as 1~2 layers), depending on the insulation requirements.

    Impregnation material: epoxy resin, polyester paint or high temperature resistant silicone resin.

    Final insulation thickness: usually 0.1mm~0.5mm more than the bare conductor (depending on the number of wrapping layers and impregnation process).

    (3) Tolerance requirements

    Parameter Tolerance (typical value)

    Conductor width (a) ±0.02mm~±0.1mm

    Conductor thickness (b) ±0.02mm~±0.08mm

    Total size after insulation ±(5%~10%)

    3. Key Test Items

    (1) Dimension detection

    Width and thickness measurement (micrometer or optical measurement).

    Corner radius inspection (projector or microscope).

    (2) Electrical performance test

    Conductor DC resistance (in accordance with IEC 60851-3).

    Withstand voltage test (e.g. 3kV/1min, no breakdown).

    Insulation resistance (≥100MΩ, 500V DC test).

    Withstand Voltage Requirements (IEC 60317-0-5)

    Test Type Test Voltage (RMS) Duration Pass Criteria
    AC Voltage Test 2.5kV – 3.5kV 1 min No breakdown, leakage <1mA
    DC Voltage Test 1.5kV – 3.0kV 1 min No breakdown or arcing
    Short-Time Test 3.5kV – 5.0kV 3 sec No instantaneous breakdown

    (3) Mechanical property test

    Flexibility (bending test): bend around a mandrel of specified diameter to check for cracking.

    Adhesion test: the glass fiber layer should not come loose (such as testing with tape stripping method).

    Abrasion resistance (scratch test): scratch with a steel needle to check for insulation damage.

    (4) Thermal performance test

    Thermal Shock Test (e.g. 250℃/1h, no cracking).

    Conditions:

    Conductor temperature 250℃ maintained for 1 hour

    Quick cooling to room temperature

    Qualification standard:

    No cracking or delamination of the insulation layer

    The breakdown voltage does not drop by more than 20%

    Long-Term Heat Aging (e.g. 155℃/1000h, performance does not drop by more than 50%).

    Purpose: To evaluate the long-term high-temperature aging characteristics of the material

    Method:

    The sample is continuously aged at a set temperature (e.g. 155℃, 180℃), and the breakdown voltage and mechanical properties are tested regularly

    Requirements:

    After aging, the initial breakdown voltage must be maintained at more than 50%:

    Grade 155: 5000 hours

    Grade 180: 3000 hours

    Softening breakdown test (to test the stability of the paint film at high temperatures).

    Typical thermal performance test data

    Test Parameter Class 155 (F) Class 180 (H)
    Continuous Operating Temp 155°C 180°C
    Short-Term Overload 200°C for 72h 220°C for 48h
    Heat Shock Resistance Pass at 250°C Pass at 280°C
    Thermal Cycling Pass 100 cycles Pass 100 cycles
    Temperature Index (TI) ≥155 ≥180

    (5) Chemical resistance test

    Solvent resistance (e.g. impregnation varnish is not soluble in transformer oil or coolant).

    Moisture and heat resistance (85℃/85% RH, insulation resistance meets the standard after 48h).