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Product

TIW TEX-E triple-insulated transformer wireIEC 62368-1 Annex U / UL 23533,000 V AC (1 min) ReinforcedDirect Dip-Solderable (+420 °C)

TIW TEX-E Triple-Insulated Winding Wire (TIW) for High-FrequencyIEC 62368-1 Annex U / UL 2353 3-layer extruded reinforced-insulation winding wire (3.0 kV

Safety-certified Triple-Insulated Winding Wire (TIW TEX-E) built to IEC 62368-1 Annex U, IEC 60950-1, IEC 61558-1, IEC 60601-1 and UL 2353 (Class B 130 °C & Class F 155 °C), featuring three independent concentric extruded polymer/fluoropolymer.

Flame-retardant
Approved
Ozone, UV & moisture
Order designation
TIW-TEXE-0.40
Conductor
Ø 0.40 mm Solid SnCu
Cu area
0.126 mm²
Nominal OD
0.60 mm
Dielectric BDV
3.0 / 15.0 kV
All sizes (12)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
Safety class
Reinforced (3L)
Zero margin tape or barrier tape
Working voltage
Up to 1,000 Vrms
1,414 Vp primary-to-secondary
Dielectric test
3.0 kV AC / 1min
Typ. breakdown > 12–16 kV AC
Thermal class
Class B 130/F155
TEX-E (130 °C) & TEX-F / ETFE (155 °C)
Core Ø range
0.20 to 1.00 mm
Solid tinned Cu + multi-strand TIW-Litz
Termination
Dip-Solderable
+410 to +440 °C dip solder in 3–5 s

Typical values for this cable type, based on IEC 62368-1 Annex U / IEC 60950-1 / IEC 61558-1 / UL 2353 (OBJT2) — confirmed in the datasheet and quotation for your order.

Application fit

Is TIW TEX-E right for your machine?

Shrinks high-frequency flyback, forward and LLC switching transformer volume by 30–45 % by eliminating creepage margin tape and primary-to-secondary Mylar barrier layers.

VFD inverter to AC motor screened feeder

Suitable

Winding primary and secondary directly on top of each other eliminates margin tape, slashes leakage inductance and improves coupling.

Switchgear & control cabinet wiring

Suitable

Certified reinforced insulation to IEC 62368-1 Annex U, IEC 60601-1 (2×MOPP) and UL 2353 up to 1,000 Vrms working voltage.

Fixed installation

Suitable

Direct dip-solderable at +420 °C on automated transformer bobbin pin-soldering lines without mechanical stripping.

Furnace, kiln & high-temp zone

Suitable

Available in Class B (+130 °C polyamide/polyester) and Class F (+155 °C fluoropolymer ETFE) thermal systems.

Typical machinesUSB-PD GaN Fast Chargers, Laptop Adapters & Server SMPSEV On-Board Chargers (OBC), Auxiliary DC-DC & BMS IsolationMedical Power Supplies (IEC 60601-1 2×MOPP Isolation)Photovoltaic Microinverters & Industrial Gate-Drive TransformersTelecom 48 V Rectifiers & LED Driver Flyback Transformers

Construction

Layer by layer

Representative TIW TEX-E / TEX-F build: Annealed tinned copper conductor per JIS C 3152 / IEC 60317 (Ø 0.20 mm to Ø 1.00 mm, or bunched PU-enamelled Litz core) + 1st extruded modified polyester/PET layer + 2nd extruded modified polyester/fluoropolymer layer + 3rd extruded high-toughness Polyamide (PA) or ETFE outer jacket (~0.10 mm / 100 µm total radial wall).

1234
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
1Tinned annealed oxygen-free copper (or enamelled Litz core)Precision-drawn soft copper wire coated with a uniform concentric tin layer (Ø 0.20 mm to 1.00 mm) or multi-strand solderable PU Litz bundlePrevents copper oxidation during high-temperature extrusion and promotes rapid solder wicking onto transformer bobbin pins
21st Layer — Extruded golden modified polyester primary barrierFirst seamless pinhole-free extruded thermoplastic polyester insulation layer (~30–35 µm radial thickness)Provides the inner dielectric barrier and flexible adhesion to the tinned conductor
32nd Layer — Extruded middle dielectric isolation barrierSecond independent seamless extruded polyester or fluoropolymer (ETFE) middle layer (~30–35 µm radial thickness)Guarantees that any microscopic defect in one layer cannot align with another, satisfying IEC 62368-1 Annex U 3-layer independence
43rd Layer — Extruded Polyamide (TEX-E) or ETFE (TEX-F) outer skinTough outer extruded Polyamide (Class B 130 °C) or ETFE fluoropolymer (Class F 155 °C) protective layer (~30–35 µm radial thickness)Resists high-speed automatic CNC flyer winding abrasion and decomposes cleanly in a +420 °C solder pot

TIW TEX-E (Class B 130 °C, Direct Dip-Solderable Polyamide/PET)

Industry-standard 3-layer extruded tinned-copper TIW wire (Ø 0.20–1.00 mm) that solders directly at +410–430 °C in 3–4 seconds without stripping

TIW TEX-F / ETFE (Class F 155 °C, High-Temp Fluoropolymer TIW)

3-layer fluoropolymer (ETFE) insulated solid or multi-strand Litz TIW wire for +155 °C GaN/SiC planar & high-density automotive transformers

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on IEC 62368-1 Annex U / IEC 60950-1 / IEC 61558-1 / UL 2353 (OBJT2). Values for your order are confirmed in the datasheet and quotation.

Electrical

Safety isolation class
Reinforced / Double Insulation per IEC 62368-1 Annex U & UL 2353
Max rated working voltage
1,000 Vrms / 1,414 V peak (50/60 Hz to 1 MHz switching)
Routine 1-minute AC test
3,000 V AC rms (after mandrel bend, heat shock & abrasion)
Typical AC breakdown voltage
12.0 kV to 18.0 kV AC rms at +20 °C

Thermal

Thermal class
Class B (+130 °C, TEX-E) · Class F (+155 °C, TEX-F / ETFE)
Direct dip-solderability
+410 °C to +440 °C for 3–5 seconds (TEX-E Class B)

Mechanical

Solid conductor Ø range
0.20 mm to 1.00 mm (in 0.05 mm steps)
Radial insulation wall (3 layers)
0.095 mm to 0.115 mm (approx. 100 µm total radial wall, +0.20 mm on OD)

Resistance

High-speed winding
Low friction coefficient for 15,000 rpm CNC bobbin flyer winders
Varnish & potting compatibility
Resistant to transformer impregnating varnishes & epoxy potting

Reference standards

Safety agency standards
IEC 62368-1 Annex U · IEC 60950-1 · IEC 61558-1 · IEC 60601-1 · UL 2353 (OBJT2) · VDE
RoHS & halogen status
RoHS 2011/65/EU + 2015/863 · Halogen-free (TEX-E)

Identification

Standard outer colours
Natural Golden-Yellow, Red, Green, Blue, Violet (for multi-winding coding)
Customs tariff (HS)
8544.11

Sizes

12 standard TIW TEX-E (Class B 130 °C) & TIW-Litz (Class F 155 °C) winding wire sizes

Conductor diameter, 3-layer radial wall thickness, finished outer diameter, DC resistance and guaranteed 3.0 kV AC reinforced breakdown.

Bare Cu Ø, 3-layer wall, overall OD, R20 & breakdown
Order designationConductor Ø / StrandsCu Area
mm²		Min 3-Layer Wall
mm		Nom. OD
mm		Max R20
Ω/km		Min / Typ BDV
kV AC		Enquiry
TIW TEX-E Solid Tinned Copper 3-Layer Extruded Wire (Ø 0.20 mm – 1.00 mm, Class B 130 °C)
TIW-TEXE-0.20Ø 0.20 mm Solid SnCu0.0310.0900.40589.03.0 / 13.5 kV
TIW-TEXE-0.25Ø 0.25 mm Solid SnCu0.0490.0900.45376.03.0 / 14.0 kV
TIW-TEXE-0.30Ø 0.30 mm Solid SnCu0.0710.0950.50261.03.0 / 14.5 kV
TIW-TEXE-0.40Ø 0.40 mm Solid SnCu0.1260.0950.60145.03.0 / 15.0 kV
TIW-TEXE-0.50Ø 0.50 mm Solid SnCu0.1960.1000.7092.63.0 / 15.5 kV
TIW-TEXE-0.60Ø 0.60 mm Solid SnCu0.2830.1000.8064.33.0 / 16.0 kV
TIW-TEXE-0.80Ø 0.80 mm Solid SnCu0.5030.1001.0036.23.0 / 16.5 kV
TIW-TEXE-1.00Ø 1.00 mm Solid SnCu0.7850.1001.2023.13.0 / 17.0 kV
TIW-Litz Multi-Strand Enamelled + 3-Layer Extruded High-Frequency Wire (Class B / F)
TIW-LITZ-7X0.207 × 0.20 mm PU Litz + 3L0.2200.1000.8283.53.0 / 15.0 kV
TIW-LITZ-19X0.1519 × 0.15 mm PU Litz + 3L0.3360.1000.9854.83.0 / 15.5 kV
TIW-LITZ-30X0.1030 × 0.10 mm PU Litz + 3L0.2360.1000.8878.23.0 / 15.0 kV
TIW-LITZ-60X0.1060 × 0.10 mm PU Litz + 3L0.4710.1051.1839.13.0 / 16.0 kV
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • All TIW TEX-E sizes add only ~0.20 mm to the bare conductor diameter across all three extruded layers combined.

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

  1. ConductorClass 5 stranding
  2. Spark test100 % in-line
  3. Lay-upCores, earth, fillers
  4. SheathingInner, braid / screen, outer
  5. Electrical testsAC voltage, resistance
  6. DimensionsOD, wall thickness
  7. Inspection documents & dispatchDrum & dispatch
Testing & inspectionTest value / referenceFrequency
Routine tests
IEC 62368-1 Annex U.2.1 electric strength test (3,000 V AC / 1 min)Tested after winding under tension around a 3 × OD mandrelEvery production spool
100 % in-line 6.0 kV DC spark test & triple-layer optical concentricityContinuous spark test on each extruded layer plus final 3-layer OD verification100 % of wire length
Sample tests
Annex U.2.2 flexibility/adherence, U.2.3 heat shock & +420 °C dip-solder testMandrel wind + +225/+250 °C oven shock + 3.0 kV AC hipot + 4-second solder wettingEvery production lot

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

IEC 62368-1 Annex U / IEC 60950-1 / IEC 61558-1 Triple-InsulatedUL 2353 (OBJT2) Reinforced Insulation System Compliant

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

Spool Label with UL 2353 / IEC 62368-1 Annex U Traceability & Colour-Coded Outer Layer
Delivery form
Precision tapered / cylindrical winding spools (1.5 kg to 5.0 kg per spool)
Colour coding
Yellow (natural), Red, Green, Blue & Violet outer layer for multi-secondary ID
Lead time
Stock to 2 weeks ex-works

Technical documents

Downloads

PDFTIW TEX-E Triple-Insulated Winding Wire (TIW) for High-Frequency – technical datasheet12 sizes · construction, technical data, approvalsXLSXTIW TEX-E spec data (Excel)All 12 sizes with dimensions and data, for your BOM or quotation
Revision
2026-10-20
Updated
2026-10-20

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

How does Triple-Insulated Winding Wire (TIW TEX-E) reduce switching transformer size by 30–45 %?
In a conventional IEC 62368-1 / IEC 61558-1 safety transformer using ordinary enamelled magnet wire, you must place 3.0–6.4 mm of non-conductive creepage 'margin tape' at both ends of every bobbin layer plus 3 layers of Mylar barrier tape between primary and secondary—wasting up to half the bobbin window. Because TIW TEX-E is certified as self-contained Reinforced Insulation (3 independent extruded layers passing 3,000 V AC), you can wind the secondary edge-to-edge directly on top of the primary with zero margin tape and zero interlayer barrier tape.
How Does TIW TEX-E improve flyback and LLC transformer electrical performance?
Eliminating the thick 3–6 mm creepage margins and interlayer barrier tapes brings the primary and secondary windings into tight physical proximity across the full bobbin width. This slashes transformer leakage inductance by 40–60 %, reduces MOSFET/GaN voltage-clamp snubber losses, and lowers winding copper resistance.
Can TIW TEX-E really be soldered directly without stripping the 3 extruded layers?
Yes. On Class B (130 °C) TIW TEX-E, all three extruded modified-polyester and polyamide layers are engineered to depolymerize cleanly into non-corrosive fluxing vapor when dipped into a lead-free solder pot at +410 °C to +430 °C for 3 to 5 seconds, tinning the underlying pre-tinned copper wire directly onto the transformer bobbin pin.
When should I specify multi-strand TIW-Litz instead of solid-core TIW TEX-E?
Above ~100–150 kHz switching frequency and > 3–5 A secondary current (common in USB-PD 100–240 W GaN chargers and EV auxiliary DC-DC converters), a single Ø 0.60–1.00 mm solid wire suffers high AC skin and proximity losses. Multi-strand TIW-Litz encloses 7 to 60+ individually enamelled 0.10–0.20 mm Litz strands inside the same 3-layer extruded reinforced TIW wall.

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TIW TEX-E Triple-Insulated Winding Wire (TIW) for High-Frequency

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