We offer AWG 11 – AWG 32 with Ratios of 1:2, 1:2.5, 1:3, 1:3.5, 1:4, but we can sometimes optimize a design even further than possible with the fixed ratios.
THE PROCESS OF FLATTENING WIRE
The wire that is already insulated or bare wire is flattened by making use of proprietary gear in a solitary process of deformation between mirror refined work surfaces. It is critical for the deformation process that it is performed with insignificant elongation. This means that the cross sectional area is reduced only slightly. The consequence is that even at the highest ratio of deformation, which is 1:4, the insulation is extended no more than 25% on the flat wire, and also in one direction only (crosswise).
Flattening conserves the reliability of virtually all types of insulation including high temperature polymide/imide coatings and bond-coats as well as solderable polyurethanes(MW16, MW35, MW79, MW80). Studies of sections of flattened wire show unbroken rather than a pointed conversion from the flats into semi elliptical edges, and do it with basically no stress concentrations. The flat wire also does not display the “dogbone” profile often shown in post insulated rectangular wire. This is due to surface tension deriving the varnish away from the wire edges.
Depending on what ratio the customer selected, the procedure usually engages an extent of work hardening. This leaves the wire fairly harder than post insulated wire. The amplified rigidity is perceived as a benefit in some applications.