AIW-1 Rectangular Enameled Copper Wire – Grade 1 Thin Build
| Insulation: Polyamide-Imide (PAI) | Thermal Class: 220°C | Profile: Rectangular | Film Grade: Grade 1 (Thin) |
AIW-1 is a Grade 1 thin-build rectangular enameled copper wire with polyamide-imide (PAI) insulation – Class 220. Compared to Grade 2 heavy build, Grade 1 offers a thinner insulation layer, enabling higher copper fill factor and more compact winding designs where space is at a premium.
The rectangular cross-section maximizes copper density within the slot, reducing I²R losses and improving efficiency. The PAI insulation provides excellent thermal stability, chemical resistance, and mechanical toughness, making AIW-1 suitable for high-frequency inductors, compact transformers, and space-constrained motor windings where the voltage stress is moderate.
With a thermal class of 220°C, heat shock resistance up to 220°C, and a cut-through temperature exceeding 320°C, AIW-1 delivers reliable performance in demanding industrial and automotive applications. Grade 2 (heavy build) is available for higher voltage stress requirements.
Key Features & Benefits
· Thin Grade 1 Insulation – Maximizes copper fill factor for compact, high-density windings where space is limited.
· Class 220 Polyamide-Imide – Excellent thermal stability and chemical resistance, with cut-through ≥320°C.
· Rectangular Cross-Section – 25-30% higher copper density vs round wire, reducing I²R losses and improving efficiency.
· Precision Profile – Tight dimensional control with uniform insulation, suitable for edge-wound and formed coils.
· Cost-Effective – Lower insulation material consumption than Grade 2, while maintaining Class 220 performance.
· Standards Compliance – Meets GB/T 6109.20, IEC 60317-13, and NEMA MW 35-C requirements.
Product Parameters
| Model Number | Conductor Material | Thermal Class | Insulation Material | Cross-Section (mm²) | Film Grade |
| AIW-1/220 | Copper (OFHC) | 220 | Polyamide-Imide (PAI) | 0.0125 – 25 | 1 (Thin Build) |
| AIW-2/220 | Copper (OFHC) | 220 | Polyamide-Imide (PAI) | 0.0125 – 25 | 2 (Heavy Build) – available |
Key Technical Data: Heat Shock: 220°C · Cut-through Temperature: ≥320°C · Standards: GB/T 6109.20, IEC 60317-13, NEMA MW 35-C · Insulation: Polyamide-Imide (PAI)
Custom cross-sections and film grades are available upon request. Aluminum and CCA versions also available.
Dimensional Specifications (Grade 1 / Thin Build – Representative Sizes)
Below are representative sizes for Grade 1. Grade 2 (heavy build) is available upon request. Full dimensional table (0.0125–25 mm²) is available upon request.
| a × b (mm) | Tolerance (mm) | Min. Film Build Gr.1 (mm) | Max. Outer Dimension (mm) | Typical Breakdown Voltage (V) |
| 1.00 × 2.00 | ±0.03 / ±0.05 | 0.030 | 1.08 × 2.08 | ≥ 1200 |
| 1.20 × 2.50 | ±0.03 / ±0.05 | 0.032 | 1.28 × 2.58 | ≥ 1500 |
| 1.50 × 3.00 | ±0.04 / ±0.06 | 0.035 | 1.59 × 3.09 | ≥ 1800 |
| 1.80 × 4.00 | ±0.04 / ±0.06 | 0.038 | 1.90 × 4.10 | ≥ 2200 |
| 2.00 × 5.00 | ±0.04 / ±0.07 | 0.040 | 2.10 × 5.10 | ≥ 2500 |
| 2.50 × 6.30 | ±0.05 / ±0.08 | 0.042 | 2.62 × 6.42 | ≥ 2800 |
| 3.00 × 8.00 | ±0.06 / ±0.10 | 0.045 | 3.13 × 8.13 | ≥ 3200 |
Representative dimensions for Grade 1 thin build. Custom sizes and film grades available. Corner radius can be tailored. Breakdown voltage values are typical and depend on thickness and test method.
Typical Applications
AIW-1 Grade 1 rectangular wire is specified where compact winding and moderate voltage stress are key considerations:
| Application | Description |
| High-Frequency Inductors | Compact inductors and chokes for power electronics |
| Dry-Type Transformers | Small to medium transformers where space efficiency is critical |
| EV Charging Coils | Wireless charging and resonant coils with space constraints |
| Solar Inverter Chokes | Compact magnetic components for renewable energy systems |
| Industrial Power Supplies | UPS, SMPS, and general-purpose power conversion |
| Motor Windings (Low Voltage) | Low-voltage motor windings where maximum copper fill is desired |
Packaging & Transportation
| Spool Type | d1 (mm) | d4 (mm) | l1 (mm) | l2 (mm) | Spool Weight (g) | Net Wire Weight (kg) | Spools per Box |
| PL-1 | 80 | 20 | 120 | 100 | 240 | 0.5 | 8 |
| PL-4 | 125 | 25 | 190 | 160 | 860 | 4 | 4 |
| P-5 | 160 | 20 | 114 | 90 | 290 | 4 | 4 |
| P-10 | 200 | 25 | 134 | 110 | 500 | 8 | 2 |
| P-30 | 300 | 31 | 160 | 130 | 1290 | 25 | 1 |
| PC400 | 400 | 52 | 260 | 224 | 2500 | 60 | 1 |
Valid for copper wire. Other spool types available upon request.
Why Choose CHINGCUNG for AIW-1 Rectangular Wires?
· Dedicated Rectangular Wire Production – Specialized lines with in-line dimension laser gauges for tight tolerance control.
· Class 220 PAI Insulation – Proven thermal and chemical performance for demanding applications.
· Grade 1 and Grade 2 Available – Flexible film build selection to match your voltage stress and space requirements.
· Global Compliance – GB/T 6109.20, IEC 60317-13, NEMA MW 35-C.
· Flexible MOQ – Sample orders welcome for qualification testing.
· Engineering Support – Free DFM feedback for customized profiles and dimensions.
Ordering Information
| Model Format | AIW-x/220-a*b (example: AIW-1/220-2.00*5.00) |
| Film Grade | Grade 1 (Thin) standard; Grade 2 (Heavy) available |
| Minimum Order Quantity | Sample orders accepted |
| Lead Time | Sample 3–5 days; bulk 15–20 days |
| Packaging | Spools customized to customer requirements |
Need an AIW-1 Grade 1 rectangular wire sample or technical datasheet?
Contact our engineering team for free samples, detailed specifications, or a customized quotation.
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Tel: +86-13621982708 | www.evmagnetwire.com
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AIW-1 Rectangular Enameled Copper Wire – Grade 1 Thin Build | CHINGCUNG Images
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