PEEK Flat Wire – High-Performance Insulated Wire for Demanding Applications
| Insulation: PEEK | Thermal Class: 240°C | Profile: Flat (Rectangular) | Key Feature: High PDIV & Corona Resistance |
PEEK is a high-performance thermoplastic polymer widely recognized as one of the most advanced insulating materials available. PEEK enameled flat wire combines excellent thermal stability, chemical resistance, and electrical insulation properties, making it ideal for applications in new energy vehicles, aerospace, industrial motors, and high-voltage systems.
CHINGCUNG offers PEEK insulated flat wires with a continuous operating temperature rating of 240°C (up to 260°C intermittent). The insulation is applied via a single-layer extrusion process, delivering superior concentricity, higher partial discharge inception voltage (PDIV), and greater reliability compared to traditional multi-layer enameled wires.
1. Product Overview
| Insulation Material | PEEK |
| Thermal Class | 240°C (continuous) / 260°C (intermittent) |
| Conductor Material | Copper (oxygen-free, annealed) |
| Profile | Flat (rectangular) |
| Glass Transition Temperature (Tg) | 143°C |
| Melting Point (Tm) | ~343°C |
| Processing Method | Single-layer extrusion (solvent-free) |
| Key Features | High PDIV, excellent chemical resistance, low dielectric constant, flame retardant (UL94 V-0), radiation resistant |
2. Model Numbering System
CHINGCUNG PEEK flat wires are identified using the following model format:
PKW-Gx-T*W
PKW = PEEK Wire | Gx = Film Grade (G1–G4, with G4 being the thickest) | T*W = Thickness (mm) × Width (mm)
| Model Example | Description |
| PKW-G2-1.50*3.00 | Grade 2 insulation, thickness 1.50mm × width 3.00mm |
| PKW-G3-2.00*4.50 | Grade 3 insulation, thickness 2.00mm × width 4.50mm |
| PKW-G1-1.00*2.50 | Grade 1 insulation, thickness 1.00mm × width 2.50mm |
| PKW-G4-1.80*6.00 | Grade 4 insulation (thickest), thickness 1.80mm × width 6.00mm |
3. Product Size Range (Flat Wire)
Dimensions are specified as Thickness (T) × Width (W).
| Dimension | Range |
| Thickness (T) | 0.20 mm – 5.00 mm |
| Width (W) | 0.30 mm – 25.00 mm |
| Width-to-Thickness Ratio | 1:1 – 1:30 |
Custom dimensions are available upon request.
4. Manufacturing Capability Chart
The shaded area below represents the range of thickness and width combinations that can be manufactured for PEEK flat wires.
Figure: PEEK flat wire manufacturing capability – thickness (T) vs. width (W). Shaded area indicates producible range. T:W ratio limit 1:30 shown by dashed red line.
5. Insulation Film Grades & Voltage Performance
CHINGCUNG PEEK flat wires are available in four insulation thickness grades. Grade 1 is the thinnest; Grade 4 is the thickest. Higher grades offer increased dielectric strength and partial discharge inception voltage (PDIV) for demanding high-voltage applications.
| Grade | Pre-side Insulation Thickness (μm) | Breakdown Voltage (V) | PDIV (Vp) |
| Grade 1 | 30 – 60 | > 600 | > 1200 |
| Grade 2 | 60 – 90 | > 900 | > 1400 |
| Grade 3 | 90 – 120 | > 1200 | > 1600 |
| Grade 4 | 120 – 150 | > 1500 | > 1800 |
Typical values. Actual performance may vary. PDIV values can reach above 2300Vp with optimized extrusion processes.
6. Performance Characteristics
| Thermal Class | 240°C (continuous), 260°C (intermittent) |
| Dielectric Constant (εr) at 25°C | 3.2 – 3.3 |
| Volume Resistivity at 23°C | > 6 × 10¹³ Ω·m |
| Volume Resistivity at 140°C | > 8 × 10¹² Ω·m |
| Volume Resistivity at 200°C | > 6 × 10⁹ Ω·m |
| Surface Resistivity (25°C, 50% RH) | 2.0 × 10¹⁶ Ω |
| Flame Retardancy | UL94 V-0 (self-extinguishing) |
| Radiation Resistance | > 1100 Mrad (γ-ray) |
| Chemical Resistance | Excellent (ATF oil, lubricants, impregnating varnish, epoxy) |
| Flexibility | Excellent – withstands repeated bending without cracking |
| Environmental Compliance | RoHS compliant (halogen-free) |
7. Key Advantages of PEEK Insulation
· High-temperature performance – Continuous operation up to 260°C, with a melting point of ~343°C.
· Excellent abrasion resistance – Suitable for dynamic applications and repeated bending.
· Superior chemical resistance – Resistant to ATF oil, lubricants, impregnating paints, and epoxy resins.
· High PDIV and dielectric strength – Enables reliable operation in high-voltage 800V systems.
· Low dielectric constant – εr ~3.2, reduces capacitive coupling and improves power density.
· Flame retardant and self-extinguishing – UL94 V-0 rated, low smoke emission.
· Radiation resistance – Stable insulation properties even at high γ-ray doses.
· Environmentally friendly – Halogen-free and RoHS compliant; single-layer extrusion process uses up to 5× less energy than traditional enamel coating.
8. Typical Applications
| Application | Description |
| Electric Vehicles | Traction motors for 800V high-voltage platforms; hairpin windings |
| Aerospace | Actuators, sensors, and cables requiring high reliability, low weight, and radiation resistance |
| Industrial Motors | High-speed spindles, servo motors, and variable frequency drive motors |
| Rail Transit | Traction motors and auxiliary systems |
| Oil & Gas | Downhole motors and sensors operating in high-temperature, corrosive environments |
| Medical Equipment | MRI coils and diagnostic instruments requiring biocompatibility and high performance |
9. Quality Standards
· Thermal Class: 240°C (IEC 60172)
· Flammability Rating: UL94 V-0
· Environmental Compliance: RoHS, REACH
· Quality System: Manufactured in ISO 9001 certified facilities
All products are tested for dielectric strength, adhesion, flexibility, and thermal performance before shipment.
10. Why Choose CHINGCUNG?
· Material expertise – Over 10 years of experience in high-performance insulated wire manufacturing
· Flexible production – Custom dimensions, thickness grades, and packaging options
· Quality assurance – Strict process control and 100% testing on key parameters
· Competitive pricing – Efficient single-layer extrusion process reduces production costs
· Global supply – Serving customers in North America, Europe, and Asia
11. Ordering Information
| Model Format | PKW-Gx-T*W (example: PKW-G2-1.50*3.00) |
| Minimum Order Quantity | Sample orders accepted |
| Lead Time | 2–4 weeks depending on quantity and specifications |
| Packaging | Spools or coils, customized to customer requirements |
Need a PEEK flat wire sample or technical datasheet?
Contact our team for free samples, detailed specifications, or engineering consultation.
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Tel: +86-13621982708 | www.evmagnetwire.com
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PEEK Flat Wire PKW – High-Temperature Insulated Wire | CHINGCUNG Images
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