Electric car drive module benefits from copper square magnet wire
round vs square wire
Square magnet wire wire is useful where space constraints are concerned. When formed into a coil an equivalent amount of square wire put in a coil can be placed in a tighter coil configuration than the same amount of round wire. This enables engineers to create compact coils and small motors that deliver more power in less space. The opposite of this would be a random wire structure within the winding space, which is called “wild winding.”

For greater efficiency and reduced heat, dense packing of wires reduces air space and enables a higher fill factor. For best packing of round wires on a multi-layer winding, the wires in the upper layer are in the grooves of the lower layer for at least 300 degrees of the coil circumference. The wires occupy a dense package which is called “Orthocyclic winding”.

Copper Coil Winding Wire
What is a coil winding wire coil? Coil Winding Wire Coils provide the magnetic field of motors, transformers, and generators, and are used in the manufacturing of loudspeakers and microphones. The shape and dimension of the wire used in a coil winding are designed to fulfill a specific purpose.

Can copper wire increase motor efficiency? Researchers at Pacific Northwest National Laboratory (PNNL) have increased the conductivity of copper wire by about five percent. That may seem like a small amount but it can make a big difference in motor efficiency.
"Better" copper means higher-efficiency electric motors

What type of magnet wire is used in orthocyclic winding?  Rectangular magnet wire used in Orthocyclic winding The best volume use is found when the winding is parallel to the coil flange for most of its circumference. When the winding has been placed around the coil body it will meet with the previous positioned wire and needs to make a step with the size of the wire gauge.

What is Keerti kappagantula's ultra-high conductivity copper wire?PNNL Materials Scientist Keerti Kappagantula holds an ultra-high conductivity copper wire with graphene additives that is five percent more conductive than annealed copper, the industry standard for motor applications.

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