Fine rectangular magnet wires with ultra thin insulation and its applications

Typically rectangular magnet wires have been used for conductors larger than approx. 2 sq.mm. Fine rectangular wires showed poor performance, because of difficulties in building uniform insulation on fine rectangular conductors. Conventionally, round magnet wires were used for fine sizes. Mitsubishi Cable Industries, Ltd., have developed MEDIS (Mitsubishi Electro-Deposition Insulating System) which is a very unique system for producing magnet wires. We developed a fine rectangular magnet wire ("SX WIRE") with very good performance through this MEDIS process. We were also successful in making an ultra thin insulation with very good uniformity. The following issues are reported in this paper: fine rectangular magnet wires by MEDIS; ultra thin insulation (min. 0.001 mm) rectangular magnet wires; characteristics of ultra thin insulation wires; advanced MEDIS process for fine rectangular magnet wires; and applications and advantages of applied devices.