Insulated Winding Wire
Wire Engineered for Higher-Voltage Demands
Where Precision Winding Wire Meets Proven Engineering
In the 1990s, Rubadue Wire created its groundbreaking extruded triple-insulated wire technology. This breakthrough transformed the power electronics industry by enabling engineers to achieve reinforced insulation while eliminating the need for margin tape and creepage and clearance distances, resulting in smaller components.
The design incorporates three separate pinhole-free insulation layers that surround a central conductor. Engineers commonly rely on this wire for high-voltage applications up to 1,500 Vpk offering more design flexibility when compared against traditional enameled winding wires.
More Efficiency, Superior Quality, Longer Life
Insulated wires utilize a non-conductive barrier between the winding wire and grounded surfaces or dead metal components, as well as between separate windings. This protective barrier allows insulated wires to handle greater voltages, withstand higher temperatures, and eliminates the need for barrier tapes, valuable in space-constrained designs.
- Enhanced safety and protection
- Exceptional thermal resistance for high temperature reflow processing
- Options available with improved resistance to partial discharge
- Approved for use with UL Electrical Insulation Systems
- Engineered for high temperature applications at 155°C (Class F) and 180°C (Class H)
- Insulation layers as thin as .001" (0.025mm)
- Ideal for components with size constraints
- Available in multiple colors for easy wire identification
- Extended service life and superior reliability
- Engineered for high reliability applications
- Excellent for processing on automated winding lines
Types of Insulated Wire
Triple
Rubadue pioneered triple-insulated wire with extruded insulations, the first with three separate layers. The Reinforced Insulation enables direct winding on top of magnet wire and removes the need for barrier tapes.
Double
Double-insulated wires include an additional insulation layer that reduces the risk of electric shock in the event of a failure of the Basic Insulation layer. Double-insulated wire provides Supplementary Insulation.
Single
Our single-insulated wire features one protective layer and provides Basic Insulation.
Regulatory Compliance Made Faster and Cheaper
Rubadue holds several Underwriters Laboratories Inc. insulation systems (UL 1446) that customers can use without any fees, provided they keep the filament wires in our insulation systems unchanged. This approach helps customers save both time and money.
While you have the option to create your own EIS following UL 1446 guidelines, this route usually requires 12-18 months and costs around $150,000 - $180,000. A simpler and more cost-effective approach is to use our existing systems. Rubadue offers two Class F systems that are available for adoption without charge. Additionally, our products appear in systems from other suppliers. Contact us to learn more about these options.
| Property | ETFE | FEP | PFA |
|---|---|---|---|
| Temperature Rating | Class F 155°C | Class F 155°C | Class H 180°C* |
| Layer Thickness (Minimum) | 0.001″ | 0.002″ | 0.0015″ |
| Total Thickness Supplementary (Minimum) | 0.002″ | 0.004″ | 0.003″ |
| Total Thickness Reinforced (Minimum) | 0.003″ | 0.006″ | 0.003″ |
- UL 2353 OBJT2 E206198
- UL OBMW2 E190291
- UL 60950-1 Annex U
- UL 1446 Electrical Insulation Systems
- RXT-2, TCA
- OBJS2 File E188330
- UL/IEC 60601-1, Annex L
- IEC 62368-1, Annex J
- IEC 615581-1, Annex K
- Clear
- White
- Black
- Red
- Green
- Yellow
- Blue
- Brown
- Orange
- Gray
- Violet
Markets
Industries We Serve
We offer fine AWG, very thin-wall and thick-wall winding wires for a variety of applications.
Automotive
High-Frequency Performance for EV Systems
Rubadue creates customized solutions for leading global electric vehicle manufacturers. Our insulated wires support everything from onboard charging systems to fast-charging power supplies and controls, delivering the efficiency, durability, and reliability that modern electric vehicles demand.
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Part Builder
Build Your Custom Wire Specification Online
Our interactive Part Number Builders can help you create custom specifications for your application. You can configure various wire types, including single, double, and triple-insulated wires, as well as bare and served wires, based on AWG size, conductor strands, material, and color code.
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Custom Solutions
Take Your Design Further With Custom Wire
With direct access to our engineering team, we work with you from concept to delivery.
Speak to an EngineerBacked by Decades of Engineering Expertise
Rubadue Wire pioneered extruded triple-insulated wire, which offers superior safety and high-temperature resistance. From initial prototype development through full-scale manufacturing, our team provides the quality, reliability, and production capacity that your challenging applications require.
Our reputation is built on decades of exceptional product quality, with zero field failures to date. Many customers turn to us after experiencing quality problems with other suppliers.
Our wire insulations include the highest quality fluoropolymers produced by Chemours, which have excellent dielectric strength and low dielectric constants, making them ideal for high voltage applications where partial discharge is a concern.
Resources
Skin Effect and Proximity Effect Losses in Litz Wires
Understand the impact of skin effect and proximity effect on Litz wire performance and how to minimize these losses.
Tips on How to Avoid Damaging Insulated Winding Wires in Your Process
Learn best practices for handling and processing insulated winding wires to prevent damage.
Insulated Winding Wire 101: Selecting an Insulated Winding Wire Part I: Temperature Ratings
Learn about temperature ratings and thermal life considerations when selecting insulated winding wires.
Frequently Asked Questions
Insulated winding wire consists of copper conductors covered with one or more layers of thin, flexible insulations made of fluoropolymers or other high-temperature insulation materials. This specialized wire is engineered for creating compact, densely packed coils used in motors, transformers, and inductors. What sets it apart from regular magnet wire is its superior operating voltage capabilities, partial discharge resistance, and the option for transformer manufacturers to wind these wires directly on top of magnet wires or grounded/dead metal without the need for additional tape insulations.