Air core coil WL5058

insulationhigh-frequencyRF

Overview
The WL5058 flat wire coil is an electromagnetic winding manufactured from flat (rectangular) enameled copper conductor. Its geometry increases copper fill in the winding window, improving electrical efficiency and thermal dissipation. The WL5058 is intended for industrial applications requiring compact inductive components and can be supplied with customized mounting and encapsulation options.

Key product details
The flat conductor reduces gaps between turns, increases conductor contact area and lowers DC resistance compared with round-wire windings. The WL5058 can be specified for dimensions, inductance, resistance, operating temperature and mounting type to match application requirements.

Technical data (composition and mechanical)
Item: Description
Flat winding wire core: Enameled copper wire
Wire diameter: 0.45 mm (AWG options available)
Winding type: Single-layer round or sectional winding
Core material: Air (non-magnetic), copper conductor
Footprint length: 5 mm
Encapsulation: Optional varnish, epoxy or coating
Mounting: Through-hole / custom

Electrical specifications (typical)
Parameter: Description
Inductance range: 0.1 µH – 100 µH (customizable)
Inductance tolerance: ±2%, ±5%, ±10%
DC resistance (DCR): example 25 Ω with 27 turns
Q factor: High, optimized per frequency band
Self-resonant frequency: Application-dependent, typically high
Operating frequency: kHz to MHz range
Rated current: Defined per custom design
Insulation resistance: ≥100 MΩ

How flat coils work
When current flows through the flat conductor, a magnetic field is generated by electromagnetic induction. The flat geometry increases copper fill and reduces air gaps, improving magnetic efficiency, lowering losses and aiding heat dissipation. These characteristics suit motors, transformers, solenoids and high-frequency inductive circuits.

Features

• Higher copper fill factor for improved efficiency
• Lower DC resistance and reduced power loss
• Compact form factor for limited installation space
• Improved heat dissipation
• High magnetic field generation per volume
• Increased current carrying capacity
• Stable winding geometry for repeatable performance
• Reduced electromagnetic noise and vibration
• Suitable for wide frequency ranges, including high-frequency designs
• Available with varnish, epoxy or coating for environmental protection

Applications

• Electric motors and motor control systems (including EV applications)
• Transformers and power inductors for inverters and power supplies
• Solenoids, relays and electromagnetic actuators
• Automotive electronics (injectors, actuators, charging systems)
• Industrial automation, valves and robotic equipment
• Energy conversion and storage systems (inverters, converters)
• Medical devices requiring compact inductors and actuators
• RF and telecommunication circuits, aerospace electronics and consumer appliances

Advantages and disadvantages
Pros

• Better utilization of winding space and improved performance per volume
• Lower resistance reduces heat generation under current
• Enables smaller component footprints for equivalent electrical function
• Improved thermal path extends operational lifetime
• Lower vibration and electromagnetic emission in many designs

Cons

• Manufacturing requires specialized winding equipment
• Typically higher unit cost versus round-wire coils
• Insulation can be damaged if bent or handled improperly
• Compact construction may complicate field repair

Troubleshooting

• Excess heating: verify current rating, cooling and supply voltage
• Insulation failure: inspect coating integrity and avoid excessive bending
• Reduced magnetic force: check supply voltage, wiring and winding continuity
• Noise or vibration: verify mounting and stabilize power source
• Short circuits: inspect for contamination and damaged insulation
• Open circuits: inspect solder joints and wire integrity

FAQ - key points

• What is a flat coil? — An electromagnetic coil wound with flat/rectangular conductor to increase copper fill and improve thermal and electrical performance.
• Main benefits — Better space utilization, lower DCR, higher current capability and improved thermal behavior.
• Common uses — Motors, transformers, inductors, solenoids, power electronics and RF circuits.
• Customization — Inductance, resistance, wire dimension, insulation, mounting and encapsulation can be tailored to application needs.

Specifications (summary)

• Model: WL5058
• Wire core: Enameled copper
• Typical wire diameter: 0.45 mm
• Winding: Single-layer round or sectional
• Core: Air (non-magnetic)
• Footprint length: 5 mm
• Encapsulation: Varnish / epoxy / coating (optional)
• Mounting: Through-hole / custom
• Inductance: 0.1 µH – 100 µH (customizable)
• Tolerance: ±2%, ±5%, ±10%
• Example DCR: 25 Ω (27 turns)
• Operating frequency: kHz–MHz
• Insulation resistance: ≥100 MΩ