Tyco Electronics - Cost-Effective Termination Solutions For Copper And Aluminum Magnet Conductors

“Many medium- and high-volume manufacturers of FHP motors for appliance, heating ventilation and air-conditioning (HVAC) equipment are evaluating a switch from copper to aluminium magnet wire to reduce raw material costs,” says Fabrizio Longo, Tyco Electronics Product Manager. “Copper contributes on average about 30 percent to the overall production cost of a FHP electric motor. Switching from copper to aluminium conductors can also reduce transportation costs, as aluminium is about one-third of the weight of copper. Our interconnection system allows manufacturers to easily and cost-effectively bridge the transitions many are making from copper to aluminium magnet wires.”

Aluminium conductors have approximately 61 percent of the conductivity and a small fraction of the tensile strength of their copper counterparts. Handling properties also differ as the softer aluminium lacks the resiliency of copper. The MAG-MATE IDC connector system compensates for these differences by providing a stable, long-term termination of aluminium magnet wire – possible because of two IDC slots that provide four gas-tight points of contact (two on each beam).

In addition, the MAG-MATE connector system simultaneously terminates two magnet wires of the same size in one terminal. It uses IDC technology to reduce assembly costs by eliminating soldering or stripping. The UL recognized product terminates wire sizes ranging from 34 AWG to 12 AWG for maximum flexibility. Product offerings include multiple lead wire attachment options and special versions that mate with RAST 2.5 IDC connectors.

This product family additionally offers slim-line and mini solutions to meet the needs of customers with space constraints. Specific applications of the product include motor windings, coil and bobbin connections, transformer windings, and lighting ballasts.