Abstract: A method for the continuous production of an elongated continuously extruded and in line polymer coated copper shape that comprises exposing an as extruded elongated copper shape to in line cooling with water covered by an inert gas before it reaches a polymer coating operation. Continuously extruded copper wire having an adherent in line applied polymer coating thereon is also described.

Abstract: A novel polymer coated magnet wire that includes an insulating polymeric coating on only one facet thereof. Such a magnet wire can be conventionally wound using current transformer manufacturing processes but can be produced at significantly lower cost due to the almost 75% reduction in the volume of insulating polymeric material applied to the magnet wire core as compared to similar prior art such products. The method provides for the application of the insulating polymeric coating to only a single minor axis facet of the magnet wire core through the use of custom dies and a modified manufacturing process.