why copper strips are best for transformer winding

Why Copper Strips Are Best For Transformer Winding?

Copper strips have high electrical and thermal conductivity, that’s why copper strips are the best for transformer winding.

What’s more, copper strips transfer heat more effectively than other metals strips.

Copper strips are more malleable and have high tensile strength. Corrosion resistance, high degree stability, and heat dissipation of copper strips are superior to other metals.

Copper strips are mostly used in the electrical and electronics sectors because copper is non-magnetic and non-sparking. Copper strips are mostly used in heat exchangers, transformers winding, condensers, and lightning conductors.

Copper strip thickness range from 0.01mm to 3.0mm. Copper strips can be manufactured in different widths and thicknesses per the customer’s requirement.

Using the correct grade copper foils strips for transformer winding, you can reduce the short-circuiting problem in power transformers.

The copper strips mostly used in transformers are usually made by rolling; the required thickness of the strip is very thin.

We can easily achieve the desired thickness through the cold rolling process. The copper strips have a good surface finish and high corrosion resistance.

The alloy C1100 copper strips are used in the process of transformer winding. Because it has a low impurity content and high electrical conductivity (above 99.8% IACS), stability and malleability.

Grade C1100 copper strip for transformer winding is commonly used in transformers, reactors, filters, and mutual inductors.

Why copper strips used in transformer winding?

Due to the higher conductivity of copper strips, the current flow is more uniform when we use copper strips in the transformer winding.

In most cases, a relatively high content of copper in transformers increases energy efficiency and lowers lifespan costs.

Copper strips HV winding distribution transformers are less resistant to mechanical failure than transformers aluminum strips.

Distribution transformers with copper strips are almost smaller and lighter than those with aluminum strips of the same capacity and energy efficiency.

The electrical conductivity of copper strips is more than other metals. Copper is stronger and can carry current almost twice that of other metals.

The copper strip’s edge for the transformer winding has no roughness. The copper strip foil’s surface is given a surface treatment to make it brighter and cleaner.

What are the advantages and disadvantages of using copper vs. aluminum windings in a transformer?

The both aluminum and copper are used in the transformer winding. These metals have some similarities and some differences in properties. Here are some points to elaborate on which metal is best for transformer winding.

Advantages of copper winding vs. aluminum winding

  • Both materials have similar maintenance schedules, but copper is less expanded and more durable than aluminum.
  • The transformers with copper winding are smaller than aluminum because the copper’s current carrying capacity is twice that of aluminum.
  • Due to its smaller size, the copper winding transfer is less expensive than aluminum winding transformers in rare cases.
  • Compared to aluminum, copper is tougher, more ductile, expands less, and does not flow at terminations.

Disadvantages of copper winding vs. aluminum winding

Copper is a slightly more expensive material than aluminum.

Aluminum winding faces lesser mechanical stress than copper winding because it can more quickly adjust to the shape of the winding.

Copper windings stores slightly less heat than aluminum windings.

Why do most transformer industries customers choose copper strips for winding?

Copper strips are most widely used in transformer winding due to their excellent properties like strength, heat and electric conductivity, and good resistance against corrosion.

Most customers like Copper strip winding transformers due to their lower weight and small size. The small-size copper strip transformers used less core steel and physical elements than other transformers.

Because the copper strips are stronger and less likely to deform, copper can tolerate the pressures caused by high-frequency current better than aluminum, extending the transformer’s life and lowering maintenance costs.

Because copper strips have superior conductivity, connections inside the device stay tight, requiring less maintenance and extending the transformer’s life.

Due to these outstanding properties, the copper strips transformer costumer’s first choice.

How to make a thin copper strip roll?

Copper strips provide excellent electrical and high thermal conductivity. They are actually highly in demand in the transformers industry because of these properties.

When we make a copper strips roll, we start from the molten copper. In the first step, impurities are removed, and the product we get is in the form of a bloom, slab, and bullets.

Then these billets are rolled in finishing mills, and the strips are produced in the last stage. Wires, plates, foils, copper sheets, and many other sorts of profiles are made by manufacturers.

The final product is annealed before being packaged in accordance with the specifications.

We can make copper strips variety of thicknesses and widths to suit the requirements of different customers.

How to wind a transformer with a copper strip?

Copper strips play a very important role in transformers.

For the winding of small and medium dry transformers, copper strips are mostly used as a main component.

There is very little maintenance in dry transformers, and you can easily use them for indoor purposes.

In dry transformers, copper strips are mostly used as low-voltage side winding; with the help of strip winding, we can reduce the axial short circuit impact.

For winding a transformer with copper strip, we use a winding machine for this processes same as the wire winding.

Copper strips also use as an insulator between the primary and secondary copper wire windings.

Conclusion

Finally, copper strips are undoubtedly better for transformer winding than other metals strips, such as stainless steel strips, titanium strips.

Copper strips are very popular in transformers industries for high conductivity and corrosion resistance.

To increase the performance of your transformer and want to avoid short-circuiting, you need to use copper strips for winding.