Graphene-Coated Enameled Flat-Wire Air-Core Coil

Graphene-Enhanced Enameled Flat Wire: Breaking the Conductivity Limit

The integration of graphene into enameled flat-wire technology has pushed the boundaries of electrical performance. By achieving a conductivity of 104% to 106% IACS, this "Super Copper" wire exceeds the theoretical limits of high-purity oxygen-free copper.

Key Performance Breakthroughs:

Superior Conductivity: Achieving 104%–106% IACS, which is a 3% increase over standard high-purity oxygen-free copper, significantly reducing resistive losses.

Enhanced Thermal Management: Thermal conductivity improvements have led to a 7% reduction in the Temperature Coefficient of Resistance (TCR), ensuring stability under high-load conditions.

High-Temperature Insulation: Utilizing a specialized manufacturing process, the graphene super copper is coated with a high-performance Polyimide (PI) layer. This provides a Class 240 thermal rating, combining extreme conductivity with high-reliability insulation.

Overcoming Manufacturing Challenges:

The production of graphene-enhanced enameled wire requires surmounting two major technical hurdles: graphene material forming and coating compatibility (wettability). Through proprietary manufacturing techniques, we have successfully achieved a uniform, high-adhesion coating on the graphene-modified surface, ensuring the mechanical and electrical integrity of the flat-wire structure.

Internal Liquid Cooling Technology: Revolutionizing Thermal Management for EV & eVTOL Motors

In high-performance motor design, thermal conductivity is the ultimate bottleneck. Standard insulation coatings typically offer a thermal conductivity of only 0.12 to 0.35 W/(m·K). In stark contrast, copper reaches up to 401 W/(m·K)—thousands of times higher than the coating layer.

By utilizing internally cooled conductors—where cooling liquid flows directly through the hollow interior of the conductor—heat transfer efficiency is dramatically enhanced. This method ensures uniform heat distribution and eliminates the thermal resistance caused by external insulation.

Key Advantages for Next-Gen Mobility:

Reduced Power Loss: Maintaining lower operating temperatures significantly reduces the DC resistance of the copper, minimizing energy waste.

Extended Range: Higher efficiency translates directly into longer battery life and increased vehicle range.

Sustained High-Speed Performance: Enables motors to operate at peak power for extended periods without thermal throttling, a critical requirement for EV racing and eVTOL (Electric Vertical Take-off and Landing) aircraft.

About Guangdong Zongheng Technology Co., Ltd.

With 15 years of dedicated expertise, Guangdong Zongheng Technology focuses on the R&D and intelligent manufacturing of forming winding machines for Air-Core Coils, Alpha Coils, and Voice Coils. Our equipment is widely utilized in smartphones, 3C electronics, New Energy Vehicles (NEV), home appliances, aerospace, military, and nuclear power sectors.

Contact Us: +86-139-2581-0131 (Mr. Feng)