SiC Device Large-scale Application Drives Material Innovation, Corona-resistant Enameled Wire Sees Surging Demand

Amid rapid technological iteration in the new energy power sector, silicon carbide (SiC), the representative of third-generation semiconductor devices, features outstanding advantages including high frequency, high voltage and high efficiency. It is comprehensively replacing traditional silicon-based devices and being widely adopted in new energy vehicles, energy storage systems, wind power converters, photovoltaic inverters and other core sectors. As electrical equipment evolves toward higher frequency, higher voltage, compact size and superior efficiency, operating switching frequency keeps rising. Steep-front pulse voltage generated during operation frequently triggers inter-turn partial discharge of windings, which accelerates insulation aging, cracking and even breakdown failure of conventional Enameled Wire. This severely impairs the service life and operational stability of power equipment. Against such industrial transformation, nano-modified corona-resistant enameled wire stands out with differentiated core performance. Its market demand is booming, fundamentally reshaping the material selection criteria and technical system for the industrial chains of magnet wires, transformers and high-end power equipment.

Authoritative industrial technical research shows that SiC power devices serve as core components for 800V high-voltage new energy vehicle electric drive platforms, large-capacity energy storage PCS converters, onshore and offshore wind power inverters, and premium photovoltaic boosting equipment. They are also critical supports for energy conservation, carbon reduction and efficient operation within the new power system. Nevertheless, high dv/dt voltage change rate generated during rapid switching of SiC devices creates continuous high-frequency steep pulse impacts, which induce persistent partial discharge between winding turns. Traditional high-temperature composite enameled wires are merely designed to meet thermal class requirements, only suitable for conventional power-frequency and low-frequency operating conditions. They cannot withstand long-term corona erosion caused by high-frequency pulses. Under prolonged partial discharge, the insulation film of ordinary enameled wires will gradually carbonize and peel off, directly resulting in abnormal heating of motors, insulation faults of transformers and attenuation of inductance performance. These problems greatly shorten equipment service life and push up failure risks and subsequent operation & maintenance costs, making conventional wires unable to satisfy stringent operating conditions of modern high-end new energy power equipment.

Nano-modified corona-resistant enameled wire delivers an all-round technical upgrade of insulation systems to tackle the industry-wide pain point of insulation failure under high-frequency and high-voltage operating conditions. By precisely doping nano-alumina and nano-silica functional fillers into high-end composite insulation coatings, a dense and stable microscopic protective barrier is formed inside the film to restrain the generation and spread of partial discharge from the source and significantly lift the core parameter — PDIV (Partial Discharge Inception Voltage). While enhancing corona resistance and anti-pulse breakdown capacity, the product retains excellent comprehensive properties including high temperature resistance, strong mechanical strength, superior film adhesion, outstanding aging resistance and moisture resistance. It achieves multi-dimensional improvements in heat resistance, insulation performance and impulse resistance. Currently, corona-resistant enameled wire has become a standard core winding material for new energy drive motors, large-capacity energy storage inverters, premium photovoltaic boosting inductors, special wind power transformers and other equipment, acting as a core guarantee for the safe and stable operation of high-frequency power equipment.

Global procurement standards for magnet wires are undergoing landmark and disruptive changes. For a long time, transformer, motor and electrical equipment manufacturers mainly took the thermal class of enameled wire as the sole or core evaluation indicator, leading to rigid and simplified material selection standards. However, as overseas high-end projects impose stricter requirements on equipment stability, durability and safety, high-end wind power projects in Europe and America, large overseas energy storage power stations and international new energy power engineering tenders have formally incorporated PDIV (Partial Discharge Inception Voltage) as a mandatory technical indicator. A dual-core acceptance standard covering thermal class and corona resistance has taken shape, putting an end to the era relying solely on heat resistance for material selection. At present, high-end wires with stable and excellent corona resistance, capable of providing complete authoritative PDIV test reports and traceable performance parameters, have become the preferred procurement option for leading downstream manufacturers and overseas engineering projects, boasting remarkable competitive edges.

The market demonstrates intensified structural differentiation with prominent market opportunities. Conventional 180℃ and 200℃ high-temperature composite enameled wires feature low technical barriers and excessive concentrated production capacity, resulting in severe homogenization, persistent vicious price competition and shrinking profit margins for low-end products. In contrast, corona-resistant enameled wires involve multiple technical barriers such as nano-material modification, insulation formula development, precision production technology and performance test calibration. Coupled with long R&D and certification cycles, effective high-end supply remains tight. These products maintain steady market premium, emerging as a key track for magnet wire enterprises to realize transformation, upgrading and profit growth.

The Industrial Research Center of SuoZhou Daiming Electrical Materials Co., Ltd. conducts in-depth analysis: Driven by continuous construction of the new power system and in-depth implementation of the dual-carbon strategy, the global installed capacity of energy storage keeps expanding, the installed volume of wind and photovoltaic power rises steadily, and the market penetration rate of 800V high-voltage new energy vehicles grows rapidly. The proportion of power equipment operating under high-frequency and high-voltage conditions will keep increasing, which will drive sustained growth in demand for high-reliability special magnet wires featuring corona resistance and high temperature resistance over the next 3 to 5 years.

The trend of industrial development is clear. Manufacturers of transformers, motors and power electronic equipment must comprehensively upgrade their logic for winding wire selection, shifting from the traditional single-minded pursuit of heat resistance to refined material selection standards that attach equal importance to thermal class, PDIV corona resistance, anti-pulse aging performance and long-term stability. Upgrading core materials helps improve the reliability and service life of end equipment from the source.

Keeping pace with the wave of industrial technological transformation, Suzhou Daiming Electrical Materials Co., Ltd. focuses on the high-end new energy magnet wire track and continuously increases R&D investment to tackle core technologies for corona-resistant insulation systems. The Company optimizes nano-filler ratio, improves film coating processes, upgrades production standards, and iterates high-performance corona-resistant round and flat enameled wire products. Meanwhile, we have built a complete PDIV performance testing system and standardized testing procedures to provide customers with accurate, authoritative and complete product performance test data and technical parameter reports. We fully meet stringent material selection requirements of domestic and overseas high-end new energy, energy storage, wind power and industrial control equipment, support downstream customers to develop high-performance, long-life and highly stable premium power equipment, and jointly promote the high-quality development of the new energy power industry.