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Winding Inductors with Teflon Wire

Discussion in 'Electronic Design' started by D from BC, Apr 25, 2007.

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  1. D from BC

    D from BC Guest

    I'm was on Ebay looking at Teflon wire because I think the insulation
    thickness is generally less than PVC.

    Is there other insulation or wire types could I search for that have
    very thin insulation (thin jacketing)? It'll most likely have a low
    voltage rating too.

    #14 to #16 AWG
    Vrating: 50Vrms min
    20 to 50 foot spool
    Online ordering preferred

    This is for easy winding of a high current inductor.
    D from BC
  2. John Larkin

    John Larkin Guest

    Formvar! Or solderable nylon or polyurethane "varnish."

  3. whats wrong with enammeled wire?

  4. Eeyore

    Eeyore Guest

    The insulation on triple insulated winding wire is fairly thin but good for
    several kV. I think it's great stuff. It avoids much of the need for fabricated
    safety margins in off-line power transformers too.

  5. D from BC

    D from BC Guest

    Too stiff...
    It's gotta bend on a ~2" circumference.
    Also it's easy to accidentally kink the wire when winding the toroid.
    D from BC
  6. D from BC

    D from BC Guest

    On stranded wire?

    Maybe I might get cheap PVC insulated #14 stranded wire
    ,strip off 20ft of PVC insulation
    and then run the wire through a pot of polyurethane..
    Hang... let dry..
    and presto...Highly flexible, highly conductive magnet wire. :)
    D from BC
  7. ah.. check out square section wire, sorry, no urls, just came across
    it while looking for geek porn


  8. So, the truth comes out. You get kinky with Toroids. :(

    Service to my country? Been there, Done that, and I've got my DD214 to
    prove it.
    Member of DAV #85.

    Michael A. Terrell
    Central Florida
  9. GregS

    GregS Guest

    Stranded would be much esier to acomplish, but you have to watch the TFE
    for sharp corners because it is so soft, and it continues to travel or flow after the
    initial wind if there is stress. A high temperature PVC might work. Just check out
    the available insulation thicknesses.

  10. John Larkin

    John Larkin Guest

    Oh. Stranded. Use the mil-type teflon then. The insulation is very
    thin. Or thinwall shrink tubing.

  11. D from BC

    D from BC Guest

    I should have called this post:
    "Microthin Jacketed Stranded Wire for High Current Toroids"

    Thanks..I'll do some Googling on the mil-type teflon..
    D from BC
  12. John Larkin

    John Larkin Guest

    Or just wind parallel pieces of smaller solid enameled wire, twisted
    or not. Less eddy-current loss. MWS sells pseudo-Litz wire like this,
    just stranded wire with enamel on the individual strands.

  13. D from BC

    D from BC Guest

    I just might do that...

    But...I'd like to try an alternative and that's to use heavy gauge
    thin jacketed stranded wire. Teflon wire was my first thought.

    I'm probably going to make my own multifilar wire with my left over
    magnet wire if I have nothing better.
    D from BC
  14. Tam/WB2TT

    Tam/WB2TT Guest

    I think #16 magnet wire would be easy enough to use. Start the winding from
    the middle of the wire so you don't have to pull the whole length through
    the core. I did once resort to using stranded Teflon wire, but that was #12
    for heavier current.

  15. Eeyore

    Eeyore Guest

    What frequency is this going to run at ?

  16. Barry Lennox

    Barry Lennox Guest

    Take a look at these guys. They have some very nice wire wrapped in
    Teflon and Kapton tapes. It's good to 200 deg C, does not kink, and
    has TUV approvals for PSU separation. The problem is that they only
    sell in larger reels 5 or 10 lbs. However, if you ask nicely, they
    will probably send a sample, - I got some a few years ago.

  17. john jardine

    john jardine Guest

    Some I used to dig myself out of a hole was bought in as 'airframe wire'.
    Thin Teflon coat over multistrand, silver plated wires. Lovely, magical
    stuff but 50mtr of 6mm^2, cost an arm and a leg.
  18. D from BC

    D from BC Guest

    100khz but....
    My app has 10x more DC current than AC current.
    D from BC
  19. D from BC

    D from BC Guest

    Doh!!...I can start winding in the middle or the wire..
    It just blows me away sometimes why I don't think of these things....
    D from BC
  20. D from BC

    D from BC Guest

    Next on EDN Magazine... "When Wire gets Sexy" :)

    Airframe wire??? Was that the official customs description for lower
    duty? Sneaky :)

    I've never used Teflon insulated wire before but I've seen some prices
    on Digikey.. ouch!
    D from BC
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