1 Introduction
Small electronics devices cover miniaturization, lightweight, high-performance electronic devices in consumer electronics, medical electronics, automotive electronics, industrial electronics, aviation electronics, instrumentation, wearable devices, smart home, IoT terminal, 5G communication, robot and other key application fields, including micro motor, small transformer, small inductor, sensor, coil, speaker, microphone, vibration motor, camera module, wireless charging coil and other key components.
Enameled wire is the key basic material for small electronics device winding, is the core raw material for micro motor, small transformer, small inductor, sensor, coil and other components. Based on IEC 60317, NEMA MW 1000-2018, GB/T 6109, JB/T 4074 and other international and domestic standards, this article systematically describes the application technology, engineering practice, design method and development trend of enameled wire in small electronics devices from seven dimensions including product system, small motor, small transformer and inductor, consumer electronics, medical electronics, selection design and summary.
2 Small Electronics Devices and Enameled Wire Overview
2.1 Small Electronics Device Classification
Small electronics devices are divided into ten major categories by application field including consumer electronics, medical electronics, automotive electronics, industrial electronics, aviation electronics, instrumentation, wearable devices, smart home, IoT terminal, 5G communication.
Consumer electronics cover mobile phone, tablet, laptop, watch, earphone, speaker, game console, camera. Medical electronics cover hearing aid, blood pressure meter, blood glucose meter, MRI coil, pacemaker. Automotive electronics cover camera, radar, ECU, BMS, motor controller. Industrial electronics cover sensor, robot, PLC, frequency converter, servo. Aviation electronics cover flight control, navigation, communication. Instrumentation cover oscilloscope, spectrum analyzer. Wearable cover smart bracelet, watch. Smart home cover smart speaker, camera. IoT cover smart water electric gas meter. 5G cover base station, terminal.
2.2 Enameled Wire Product System
Enameled wire covers seven major categories including round copper, flat copper, enameled aluminum, copper clad aluminum, self adhesive, direct solder, special. Round copper wire is mainstream, conductor 0.012 to 1.60 mm, heat resistance 105 to 240 degrees Celsius, varnish film covers UEW, PEW, EIW, AIW, PI, composite coating.
Flat copper wire width 1.00 to 16.00 mm, thickness 0.20 to 5.60 mm, suitable for high frequency magnetic element. Enameled aluminum, copper clad aluminum line is low cost alternative, copper 10% to 15%.
Self adhesive enameled wire heat or solvent activate film self adhesive. Direct solder enameled wire no need to remove film, UEW direct solder 375 to 410 degrees Celsius. Special enameled wire covers corona resistant, frequency conversion resistant, self lubricating, radiation resistant, flame retardant, biocompatible.
2.3 Small Electronics Device Enameled Wire Technical Features
Small electronics device enameled wire technical features embody seven dimensions. Miniaturization, conductor 0.012 to 0.10 mm, varnish film 2 to 10 micron, precision plus minus 0.001 to 0.005 mm. High frequency, 100 kHz to 10 MHz, tanδ not exceeds 0.005. High efficiency, switching power supply 90% to 98%. High reliability, service life 5 to 20 years. Low noise, 30 to 50 dB. Lightweight, 0.1 to 100 g. Low cost, single unit 0.01 to 1 dollar.
3 Enameled Wire Application in Small Motor
3.1 Micro Motor and Vibration Motor
Micro motor is the micro special motor with output power 1 to 750 watt, used for consumer electronics, automotive electronics, medical device, industrial automation, aviation aerospace. Divided into DC, brushless DC, stepping, servo, permanent magnet synchronous, induction, harmonic, claw pole motor eight major categories.
DC micro motor 0.5 to 50 watt, 1000 to 20000 rpm, efficiency 50% to 80%, conductor 0.05 to 0.50 mm, heat resistance 130 to 180 degrees Celsius.
Brushless DC BLDC 1 to 750 watt, 1000 to 60000 rpm, efficiency 80% to 95%, conductor 0.10 to 1.00 mm, heat resistance 130 to 180 degrees Celsius.
Stepping motor step angle 0.9 to 1.8 degree, 0.1 to 5 A, conductor 0.10 to 0.50 mm, B to H class.
Vibration motor ERM 0.1 to 5 watt, 5000 to 15000 rpm, conductor 0.05 to 0.30 mm, heat resistance 130 degrees Celsius.
Linear motor LRA 100 to 300 Hz, vibration force 0.5 to 3 N, conductor 0.05 to 0.20 mm, heat resistance 130 to 155 degrees Celsius.
3.2 Micro Servo Motor and Robot Motor
Micro servo motor 0.5 to 50 watt, position precision 0.1 to 1 degree, conductor 0.10 to 0.50 mm, B to F class.
Harmonic motor 0.5 to 100 watt, reduction ratio 30:1 to 100:1, positioning 1 arc minute, conductor 0.05 to 0.30 mm, 130 to 180 degrees Celsius.
Claw pole motor 0.5 to 30 watt, 500 to 3000 rpm, conductor 0.05 to 0.30 mm, B to F class.
Hard disk spindle motor 0.5 to 5 watt, 5400 to 15000 rpm, service life 5 years plus, conductor 0.05 to 0.20 mm, 130 to 155 degrees Celsius.
3.3 Disc and Optical Drive Spindle Motor
Optical drive spindle motor, CD/DVD spindle motor power 0.3 to 3 watt, 5 V, 200 to 10000 rpm, enameled round copper wire, conductor 0.05 to 0.15 mm, heat resistance 130 to 155 degrees Celsius.
4 Enameled Wire Application in Small Transformer and Inductor
4.1 Small Power Transformer
Power transformer 0.1 to 100 watt, 50 Hz to 1 MHz, efficiency 80% to 98%, primary 0.05 to 0.50 mm, secondary 0.10 to 1.00 mm.
Mobile phone charger 5 to 65 watt, 50 to 500 kHz, efficiency 85% to 95%.
Laptop power adapter 30 to 240 watt, efficiency 90% to 96%.
LED driver 3 to 200 watt, 30 to 300 kHz, efficiency 85% to 95%, conductor 0.10 to 0.40 mm, 130 to 180 degrees Celsius.
4.2 Planar Transformer and Wireless Charging Coil
Planar transformer PCB winding, 100 kHz to 10 MHz, power density 50 to 500 W/in³, efficiency 95% to 99%.
Wireless charging transmitter 85 to 205 kHz, 1 to 80 watt, efficiency 80% to 95%.
Wireless charging receiver 85 to 205 kHz, 1 to 50 watt, efficiency 80% to 92%.
4.3 Power Inductor and Common Mode Inductor
Power inductor 0.1 to 1000 watt, 1 μH to 100 mH, saturation 0.1 to 100 A.
Common mode inductor 100 μH to 100 mH, 0.1 to 30 A, 130 to 180 degrees Celsius.
Differential mode inductor 10 μH to 10 mH, 0.5 to 50 A, 130 to 180 degrees Celsius.
Resonant inductor 10 μH to 1 mH, Q greater than or equal to 100.
5 Enameled Wire Application in Consumer Electronics
5.1 Smart Phone and Tablet Computer
Smart phone enameled wire application covers vibration motor, VCM voice coil motor, wireless charging receiving coil, speaker voice coil, microphone voice coil, NFC coil, magnetic charging coil.
Camera VCM voice coil motor conductor 0.020 to 0.050 mm, 130 degrees Celsius, UEW, has extremely high requirement for precision, varnish film uniformity, adhesion.
Wireless charging receiving coil conductor 0.05 to 0.20 mm, 130 to 155 degrees Celsius, outer diameter 30 to 50 mm, 8 to 15 turns, Qi 110 to 205 kHz, 5 to 15 watt.
Speaker voice coil 0.020 to 0.080 mm, 130 to 155 degrees Celsius, 0.1 to 5 watt, 80 to 95 dB.
Microphone voice coil 0.015 to 0.040 mm, 130 degrees Celsius.
NFC coil 0.05 to 0.10 mm, 130 degrees Celsius, outer diameter 20 to 40 mm, 3 to 6 turns, 13.56 MHz.
Tablet computer and mobile phone enameled wire application basically same, diameter slightly larger, power slightly higher.
5.2 Smart Watch and Wireless Earphone
Smart watch enameled wire application covers vibration motor, wireless charging receiving coil, heart rate detection coil, NFC coil.
Smart watch LRA vibration motor 0.03 to 0.10 mm, 130 degrees Celsius. Wireless charging 0.05 to 0.15 mm, outer diameter 20 to 35 mm, 6 to 12 turns, 2 to 10 watt.
Smart watch heart rate detection 0.05 to 0.10 mm, outer diameter 15 to 25 mm, 5 to 10 turns, 100 kHz to 1 MHz.
Wireless earphone speaker 0.020 to 0.060 mm, 130 to 155 degrees Celsius, 0.05 to 1 watt, 90 to 110 dB. Microphone 0.010 to 0.030 mm.
Wireless earphone charging box 0.05 to 0.15 mm, outer diameter 20 to 40 mm, 5 to 12 turns, 1 to 5 watt.
5.3 Smart Speaker, Game Device, Laptop, Digital Camera
Smart speaker main speaker 0.05 to 0.20 mm, 130 to 180 degrees Celsius, 5 to 50 watt, 80 to 95 dB. Subwoofer 0.10 to 0.40 mm, 155 to 180 degrees Celsius, 20 to 100 watt.
Smart speaker microphone array 0.010 to 0.030 mm, 130 degrees Celsius, 4 to 7 microphone.
PS5 DualSense dual linear motor, conductor 0.05 to 0.15 mm, vibration force 0.5 to 3 N.
Xbox dual vibration 0.05 to 0.20 mm. Switch HD vibration 0.03 to 0.10 mm.
Laptop speaker 1 to 5 watt, fan 0.5 to 5 watt, 2000 to 6000 rpm, 5 to 50 CFM, 20 to 35 dB.
Digital camera lens VCM 0.020 to 0.080 mm, focusing 0.01 to 0.1 mm. OIS VCM 0.020 to 0.060 mm, stabilization 0.1 to 1 degree. Aperture 0.020 to 0.050 mm, 5 to 11 blade.
6 Enameled Wire Application in Medical Electronics
6.1 Hearing Aid and Auditory Implant
Hearing aid enameled wire application covers microphone voice coil, receiver voice coil, speaker voice coil, magnetic induction coil.
Hearing aid microphone enameled copper clad aluminum, 0.010 to 0.030 mm, copper 10% to 15%, sensitivity -38 to -42 dB.
Hearing aid receiver enameled copper clad aluminum, 0.015 to 0.040 mm, impedance 16 to 32 ohm, sensitivity 100 to 120 dB, distortion less than or equal to 3%.
Hearing aid T-coil 0.020 to 0.050 mm, outer diameter 5 to 15 mm, 50 to 200 turns, 1 to 10 mH.
Hearing aid charging 0.05 to 0.15 mm, outer diameter 10 to 20 mm, 5 to 15 turns, 0.1 to 1 watt.
6.2 Medical Imaging and Monitoring Device
Medical imaging device covers MRI, CT, X ray, ultrasound, endoscope, PET, SPECT. MRI coil 0.50 to 2.00 mm, F to H class, PI or AIW, outer diameter 100 to 500 mm, 4 to 16 turns, 8 to 128 MHz, no magnetization.
CT slip ring 0.20 to 0.80 mm, F to H class. X ray readout 0.05 to 0.30 mm, B to F class.
Ultrasound 0.05 to 0.30 mm, B to F class, 2 to 15 MHz.
Endoscope camera 0.020 to 0.080 mm, 130 degrees Celsius.
Monitoring device covers ECG, EEG, EMG, multi parameter monitor. ECG 0.05 to 0.20 mm, B to F class, ISO 10993. EEG 0.05 to 0.20 mm, 16 to 256 lead.
6.3 Implantable Medical Device
Implantable device covers pacemaker, ICD, CRT, neural stimulator, insulin pump, artificial cochlea.
Implantable device for enameled wire has extremely high requirement, varnish film meets ISO 10993, body fluid resistance 5 to 20 years.
Implantable pacemaker lead enameled copper or MP35N alloy, 0.10 to 0.50 mm, F to H class, PI or PTFE, body fluid 10 years plus.
Implantable artificial cochlea electrode enameled tungsten or platinum iridium alloy, 0.05 to 0.20 mm, F to H class, PI or Parylene C, 16 to 24 channel.
Implantable neural stimulator electrode enameled tungsten or platinum iridium alloy, 0.05 to 0.30 mm, PI or Parylene C, spinal cord, deep brain, vagus, sacral nerve stimulation.
Implantable insulin pump 0.05 to 0.20 mm, 130 to 155 degrees Celsius, ISO 10993.
6.4 Portable Medical Device
Portable medical device covers blood pressure meter, blood glucose meter, body temperature meter, blood oxygen meter, ECG monitor, breathing machine, oxygen generator, atomizer, smart bracelet.
Blood pressure sensor 0.02 to 0.10 mm, B to F class. Blood pressure motor 0.05 to 0.30 mm, 130 to 155 degrees Celsius. Blood glucose 0.02 to 0.10 mm, 130 degrees Celsius, 0.1 to 1 mmol/L.
Blood oxygen 0.05 to 0.20 mm, B to F class, SpO2 and pulse. Breathing machine 0.10 to 0.50 mm, 130 to 180 degrees Celsius, 4 to 30 cmH2O, 50 to 200 L/min. Oxygen generator 0.20 to 0.50 mm, 130 to 180 degrees Celsius, 0.2 to 0.5 MPa.
7 Small Electronics Device Enameled Wire Selection and Design
7.1 Enameled Wire Selection Principle
Small electronics device enameled wire selection principle covers ten major principles.
Conductor specification, ultra fine 0.012 to 0.10 mm, precision plus minus 0.001 to 0.003. Medium 0.10 to 0.50 mm, plus minus 0.003 to 0.010. Thick 0.50 to 1.60 mm, plus minus 0.010 to 0.020 mm.
Varnish film system, 130 degrees Celsius UEW or PEW, direct solder 375 to 410 degrees Celsius. 155 PEW. 180 EIW, direct solder 390 to 410 degrees Celsius. 220 AIW. 240 PI.
Heat resistance, A 105 MW 1-C, B 130 MW 2-C, F 155 MW 5-C, H 180 MW 7-C, N 200 MW 8-C, R 220 MW 10-C.
Insulation, breakdown greater than or equal to 3 times working voltage, low voltage 200 to 500 V, medium voltage 500 to 3000 V, high voltage 3000 to 8000 V.
Electrical, resistivity less than or equal to 1.72×10⁻⁸ Ω·m, insulation greater than or equal to 1000 MΩ, tanδ less than or equal to 0.005.
Mechanical, wear resistance greater than or equal to 50 times, elongation greater than or equal to 15% to 30%, tensile 200 to 280 MPa.
Chemical, acid alkali salt fog resistance, damp heat aging, salt fog corrosion.
Reliability, consumer 5 to 10, automotive 10 to 15, medical 10 to 20, implantable 15 to 25 years.
7.2 Enameled Wire Winding Design
Winding design covers self supporting, skeleton, PCB, planar, thin film five major types.
Self supporting winding adopts self adhesive enameled wire. Skeleton winding adopts plastic or metal magnetic core skeleton.
PCB winding, PCB board etching, 100 kHz to 10 MHz. Planar winding, flat enameled copper wire, 50 to 500 W/in³.
Thin film winding, thin film carrier, 0.01 to 0.10 mm, suitable for micro motor, implantable medical.
7.3 Enameled Wire Insulation Treatment, Surface Treatment, Test
Insulation treatment, immersion, dip, roll, UV, electron beam curing. UV 1 to 10 seconds, 80 to 120 degrees Celsius. Electron beam 0.1 to 1 second.
Surface treatment, cleaning, activation, metallization. Cleaning uses plasma, UV ozone, solvent. Activation uses plasma, flame, chemical. Metallization uses chemical nickel plating, silver plating, vacuum aluminum plating.
Enameled wire test covers physical, chemical, electrical, mechanical, reliability, biocompatibility six major categories. Biocompatibility, cytotoxicity, sensitization, intracutaneous reaction, acute and subacute toxicity, teratogenicity, carcinogenicity, genotoxicity, implantation reaction, meets ISO 10993.
8 Summary
Enameled wire in small electronics devices application covers micro motor, small transformer, consumer electronics, medical electronics and other ten major fields, is irreplaceable raw material for winding.
Technical features are miniaturization, high frequency, high efficiency, high reliability, low noise, lightweight, low cost. Varnish film system covers 8 categories, heat resistance 105 to 240 degrees Celsius.
Application covers mobile phone, tablet, smart watch, earphone, speaker, laptop, camera, hearing aid, medical imaging, monitoring, implantable medical, portable medical, robot, drone, servo motor, magnetic induction coil, wireless charging, planar transformer, power inductor and other.
With small electronics device developing towards miniaturization, high performance, high frequency, low power consumption direction, enameled wire application technology will further improve.
Reference standards: IEC 60317-0-1 to 60317-86 / IEC 60851 / IEC 60172 / NEMA MW 1000-2018 / GB/T 6109 / GB/T 7095 / GB/T 4074 / JB/T 4074 / ISO 10993 / IPC-9201 / UL 1446.
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