PEEK extrusion lines tackling new electrical insulation challenges

In response to the growing demand for high-performance electric vehicles, the transition in magnet wire production towards electrical insulation through plastic extrusion is gaining momentum. This change is driven by the latest generation of electric motors, which demand higher power and energy density and can operate at voltages up to 1,000 volts.

To ensure peak performance, motor windings are now insulated with advanced plastic materials like Polyether Ether Ketone (PEEK). PEEK is known for its excellent insulating properties, outstanding chemical resistance, and the ability to function at temperatures up to 240°C. Compared to traditional enameling, PEEK offers greater flexibility, enabling the creation of tighter bending radii. This, along with its reduced insulation thickness, significantly boosts energy density.

Over the past decade, Frigeco, a brand of MFL Group, has led the way in developing extrusion lines specifically designed for producing PEEK-coated cables for oil pumps. This endeavor has provided the company with vast experience in handling this material. Recently, notable progress has been made in producing insulated magnet wire using both PEEK and PPSU.

MFL Group’s expertise has resulted in remarkable outcomes, including precise management of the crystalline phase of the material, achieving minimal insulation thickness, and enhancing the adhesion capacity to the conductor. Currently, the MFL Group provides machinery that covers the full range of insulated magnet wire production in PEEK, from the initial rod breakdown machine to the final extrusion process.

The company’s staff plans to have a PEEK testing extrusion line operational at its Italian facility in Spinetoli.

In response to the evolving energy landscape, MFL Group is also developing polypropylene insulation for medium voltage cables, expanding its expertise and product offerings.

With its extensive experience and advanced machinery, the Italy-based company is well-equipped to meet the needs of existing enamel-coated cable manufacturers transitioning their production methods and to assist current electric cable producers in exploring opportunities in this fast-growing market.

To stay updated about further progress and technological improvements at MFL Group, we invite you to visit MFL Group's booth at wire China, taking place in Shanghai from September 25 to 28.