Comax can source just about any type or form of wire, cable, mesh and material.

   

Wire Gauge Chart:

Compare SWG, AWG & ISO wire gauges

Tel:
(44) 01977 681913
Fax:
(44) 01977 685813
E-mail:
sales@comax.uk.com

 

Transformer Winding Wire

Triple Extrusion TIW-M
Special Transformer Winding Wire

For the past 30 years, Comax have searched for the new technology to assist in reducing the size and cost of transformers.

Finally a high molecular compound and extrusion technology is available to assist the transformer manufacturer to achieve this goal.

The triple extrusion technology we offer is UL approved, gives efficient manufacturing and overall quality gains for the finished product.

Advantages of TIW-M

Miniatursation of Switching Transformers

  • Exclusion of 'Creepage Distance' requirements and interleaving insulation bring dramatic miniaturisation.

Excellent Insulation Quality

  • Supreme reinforced insulation, with UL approval.

  • Latest advanced Triple extrusion materials.

  • Electric Strength test :

    • Straight Test : above 3kV

    • Twisted Test : above 6 kV

Suitability for High-Frequency

  • Withstand transient voltage gradients

  • Suitability for 30kHz above design frequency

  • Equalised extruded insulation

  • Low dielectric constant

  • Superior abrasion resistance and physical strength

  • High flexibility

Improved Productivity

  • Soft feel and easy workability

  • Simplified production cycling, no barrier tape and interleaved insulation required

  • Solderability without removal of insulation

Specification for TIW-M

  • Insulation grade : Reinforced Insulation
  • Temp. rating : 105-130 șC (Class A-B)
  • Voltage rating : 1,000 Vrms (max)
  • Conductor : All sizes (0.2mm - 1.0mm)
  • Standard colour : Yellow

 

TIW-M cross-sectional view

 

Miniaturize of Switching Transformer


(Click for larger view)

 


(Click for larger view)

With removal of barrier tape and interleaved insulation tape, the size of transformer becomes 1/2 and the weight become 2/3 winding transformer.

Special Transformer Winding Wire

Insulation Grade Wire Formation Reference
Basic Insulation One layer of extruding or 2 layers of Taping
Supplementary Insulation 2 layers of extruding or 2 layers of Taping
Reinforced Insulation 3 layers of extruding or 3 layers of Taping TIW-M : 3 layer extruding

 

Application of Creepage Distance

Because of protection from hazards, Creepage Distance required
Insulation = Thickness of insulation layer + Creepage/Clearance + Dielectric withstand voltage
  
Additionally to prevent electric shock and energy (heating) hazard

ELV circuit = Supplementary Insulation for wire

Hazard Voltage = Reinforced Insulation for wire
  
Above insulation systems shall replace creepage distance

Application of Interleaved Insulation

In the winding process, the thickness of insulation shall be more than 0.4mm in 1st and 2nd circuits, or triple insulation shall be applied without insulation thickness requirement.
Triple insulation can replace the interleaved insulation with relative specification (UL1950, IEC 60950, BSEN 60950)

Relative Specification for TIW-M

Certification Organization UL CSA TUV SEMKO VDE BSI
Applied Spec. UL1950, 1411 C22.2 No.1

No. 950

C/A Notice 15A

IEC60950

EN60950

EN60065

EN60335-1

IEC60950

EN60950

EN60950

EN60335

EN60950

EN60065

Standard Spec. for TIW-M

Construction Break down Voltage Conductor resistance (20șC) Length BOBBIN SIZE WEIGHT
Conductor Overall Diameter Max. Dia.
Diameter Tolerance
(mm) (mm) (mm) (mm) (V) (Ω /km) (m) - (kg)
0.20 ±0.008 0.380~0.400~0.420 0.430 6000 607.6 6000 PT-10 2.9
0.23 ±0.008 0.410~0.430~0.450 0.460 6000 465.5 6000 PT-10 3.5
0.25 ±0.008 0.430~0.450~0.470 0.480 6000 382.5 6000 PT-10 4.0
0.28 ±0.008 0.460~0.480~0.500 0.510 6000 307.3 6000 PT-10 4.7
0.30 ±0.01 0.480~0.500~0.520 0.540 6500 262.9 5000 PT-10 4.5
0.35 ±0.01 0.530~0.550~0.570 0.600 6500 191.2 5000 PT-10 5.7
0.40 ±0.01 0.580~0.600~0.620 0.660 7000 145.3 5000 PT-15 7.3
0.45 ±0.01 0.630~0.650~0.670 0.710 7000 114.2 5000 PT-15 8.9
0.50 ±0.01 0.680~0.700~0.720 0.760 7000 91.43 4000 PT-15 8.7
0.55 ±0.02 0.720~0.750~0.780 0.810 7000 78.15 4000 PT-15 10.3
0.60 ±0.02 0.770~0.800~0.830 0.860 7000 65.26 3000 PT-15 9.1
0.65 ±0.02 0.820~0.850~0.880 0.910 7000 55.31 3000 PT-15 10.5
0.70 ±0.02 0.870~0.900~0.930 0.960 7000 47.47 3000 PT-25 12.2
0.75 ±0.02 0.920~0.950~0.950 1.010 7000 41.19 3000 PT-25 13.8
0.80 ±0.02 0.970~1.000~1.030 1.060 7000 36.08 3000 PT-25 15.5
0.85 ±0.02 1.020~1.050~1.080 1.110 7000 31.87 2000 PT-25 11.9
0.90 ±0.02 1.070~1.100~1.130 1.160 7000 28.35 2000 PT-25 13.1
0.95 ±0.02 1.120~1.150~1.180 1.210 7000 25.38 2000 PT-25 14.5
1.00 ±0.03 1.170~1.200~1.230 1.260 7000 23.33 2000 PT-25 15.9
(*Length can be modified by request)

APPLICABLE COLOUR : Standard : Yellow

Applicable Colour

  • Standard : Yellow

Bobbin Size
Spool Flange Diameter
(mm)		 Barrel Diameter
(mm)		 Inside Width  Flance Thickness Bore Diameter Spool Net Weight Standard Net Weight
D1 D2 d1 d2 (mm) (mm) (mm) (g) (kg)
PT-10 180±0.5 160±0.5 110±0.5

96±0.5

 200±0.4 15±0.2 26± 520±2 10.0
PT-15 200±0.5 180±0.5 110±0.5 96±0.5 200±0.4 15±0.2 30± 740±10 15.0
PT-25 230±0.5 130±0.5 110±0.5 250±0.4 15±0.2 1000±1.5 25.0

 

TIW-M is usable for the following items

  • SMPS (Switching Mode Power Supply)
    • Multi power supply system for electric equipment
  • Battery Charger for Cellular Phone / PCS Phone
  • Adapter
    • Exterior multi-power supply system for electric equipment
  • Laptop computer
  • Digital camera
  • Other electrical items

 

 

Copyright © 2000, 2002, Colin Wells T/A Comax
Comax - Manufacturer of Specialty Copper Wires and Electrical Materials