Motors for electric vehicles need to be compact in size but higher in output. This is possible when flat wires are used for the windings in place of round wires. Flat wires can give 70 to 75 % copper fill factor as against 45 to 50 % copper fill factor when round wires are used. Flat wires are enamelled with solid dies which ensures a very uniform coating guaranteeing consistent electrical and mechanical properties. Depending on the thermal class needed enamel type can be selected. Available thermal class is 200, 220 or 240 when polyimide enamel is applied. Fine coating of enamel when applied with solid dies ensures good electrical and mechanical and thermal conducting properties. Excellent flexibility of enamel coating offers better flexibility to form coils with short overhangs without cracks n the insulation.

Higher voltages or VFD motors need wire insulation to withstand corona effect. Daglas covered wire over enamel coating is the ideal choice. When slot dimensions are critical flat wires can be used with Daglas covering to compensate the additional insulation and consequent slot fill factor. Daglas insulation also offers better mechanical properties for coil forming. It also enhances strand to strand bond strength and better stability against vibration.