I. Structure Comparison
1. Triple Insulated Wire (TIW)
◦ Composed of three layers of special insulation materials from inner to outer (typically Polyamide-imide + Polyester + Nylon).
◦ Integrated molding process with seamless insulation layers.
◦ Typical thickness: 0.1–0.3 mm.
2. Enameled Wire + Sleeve
◦ Enameled Wire: Single-layer polyurethane/polyester film (thickness is around 0.02–0.04 mm).
◦ Composite structure: air gaps exist between layers.
◦ Additional PVC/silicone sleeve (thickness: 0.3–0.5 mm).
II. Key Performance Differences
| Comparison Item | Triple Insulated Wire (TIW) | Enameled Wire + Sleeve |
| Voltage Resistance | 3kV-10kV (UL certified) | 1kV-3kV (dependent on sleeve) |
| Temperature Range | -40℃~155℃ (UL1557) | -20℃~105℃ (PVC sleeve) |
| Insulation Reliability | Seamless, moisture/corrosion resistant | Vulnerable to moisture penetration |
| Space Occupancy | Space-saving (30%-50% reduction) | Occupies more space |
| Manufacturing Complexity | Direct winding, no post-processing | Requires sleeve cutting/threading process |
III. Cost Comparison
• Triple Insulated Wire: 30–50% higher material cost but eliminates the cost of insulating sleeves.
• Enameled Wire + Sleeve: Lower material cost but higher labor costs
Kindly reminder:
After reading this comparison, how would you choose for your next design? Welcome to share your insights in the comments section!
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