Enameled Aluminum Wire
Copper Foil vs. Aluminum Foil in Foil-Wound Transformers
In the world of foil-wound transformers, the choice between copper foil and aluminum foil affects key aspects such as efficiency, cost, weight, and durability.
Copper Foil: Key Properties and Benefits
Copper is widely valued for its superior electrical and thermal conductivity, making it the preferred option in high-performance transformers.
- High Conductivity: Low resistance means minimal energy loss.
- Mechanical Strength: Excellent resistance to stress and deformation.
- Thermal Efficiency: Superior heat dissipation.
- Corrosion Resistance: Naturally protective oxide layer.
Limitations: Higher cost and heavier weight.
Aluminum Foil: Key Properties and Benefits
Aluminum offers a lightweight and cost-effective solution, commonly used in modern foil-wound transformer designs.
- Lightweight: Up to 50% lighter than copper.
- Lower Cost: Budget-friendly for mass production.
- Flexible for Fabrication: Easy to shape and wind.
- Corrosion Resistant: Performs well with proper coating.
Limitations: Lower conductivity and thermal performance compared to copper.
Technical Specification Table
| Property | Copper Foil | Aluminum Foil |
|---|---|---|
| Electrical Conductivity | 100% (IACS) | ~61% (IACS) |
| Weight (Density) | 8.96 g/cm³ | 2.70 g/cm³ |
| Cost | High | Low |
| Mechanical Strength | Excellent | Good |
| Thermal Conductivity | 401 W/m·K | 237 W/m·K |
| Ease of Fabrication | Moderate | Easy |
| Corrosion Resistance | High (natural) | Moderate (with treatment) |
Which One Should You Choose?
| Application | Recommended Foil Type |
|---|---|
| High-performance industrial use | Copper Foil |
| Cost-sensitive large production | Aluminum Foil |
| Mobile or rooftop PV systems | Aluminum Foil (lightweight) |
| Compact transformers with space limits | Copper Foil |
| General power distribution | Both (based on specs) |
Both copper and aluminum foils serve critical roles in foil-wound transformers. The best choice depends on your specific technical requirements, budget, and application environment. Aluminum is widely used in solar and EV systems due to its light weight and low cost, while copper is ideal for high-efficiency, space-constrained designs.
Need Help Selecting the Right Foil Material?
We provide customized transformer solutions using both aluminum and copper foil windings.
- OEM/ODM support for global markets
- Expert technical consulting
- CE/UL certified products
