Magnetic Wire

Part Number	Description / PDF	Quantity
WM22-0.5 NTE Electronics, Inc.	WIRE-MAGNET 22 AWG	31
41SNSP.125 Remington Industries	41SNSP.125 MAGNET WIRE, ENAMELED	44
36SNSP.25 Remington Industries	36SNSP.25 36 AWG MAGNET WIRE, EN	37
43SNSPR Remington Industries	43SNSPR 43 AWG MAGNET WIRE, ENAM	49
18HNS2.5 Remington Industries	MAGNET WIRE, HEAVY BUILD ENAMELE	49
44S200P.25 Remington Industries	44S200P.25 MAGNET WIRE, ENAMELED	43
14SNS Remington Industries	14SNS MAGNET WIRE, ENAMELED COPP	48
39SNS5 Remington Industries	MAGNET WIRE, ENAMELED COPPER WIR	50
22SNS2.5 Remington Industries	MAGNET WIRE, ENAMELED COPPER WIR	48
43PE Remington Industries	43PE 43 AWG MAGNET WIRE, PLAIN E	50
27SNSP.5 Remington Industries	27SNSP.5 27 AWG MAGNET WIRE, ENA	45
28SNSP.125 Remington Industries	28SNSP.125 MAGNET WIRE, ENAMELED	83
8053 Belden	MW-28C SL 26AWG	21
22SNSP.125 Remington Industries	22SNSP.125 MAGNET WIRE, ENAMELED	30
38SNSP.25 Remington Industries	38SNSP.25 38 AWG MAGNET WIRE, EN	42
24HNSP.25 Remington Industries	MAGNET WIRE, HEAVY BUILD ENAMELE	44
30H200P.125 Remington Industries	30H200P.125 MAGNET WIRE, ENAMELE	35
42SNSPR.25 Remington Industries	42SNSPR.25 42 AWG MAGNET WIRE, E	45
35SNS5 Remington Industries	MAGNET WIRE, ENAMELED COPPER WIR	50
30HNS10 Remington Industries	MAGNET WIRE, HEAVY BUILD ENAMELE	50

Magnetic Wire

1. Overview

Magnetic wire, also known as winding wire, is a critical component in electromagnetic devices such as transformers and inductors. It consists of a conductive core (typically copper or aluminum) insulated by a thin polymer coating. Its primary function is to convert electrical energy into magnetic energy and vice versa, enabling voltage transformation, current regulation, and energy storage. With the rapid development of power electronics, renewable energy systems, and electric vehicles, magnetic wire has become indispensable in modern electrical and electronic systems.

2. Main Types and Functional Classification

Type	Functional Characteristics	Application Examples
Enameled Wire	Thin enamel insulation, high thermal conductivity, excellent dielectric strength	High-frequency transformers, motors, inductors
Film-insulated Wire	Polyester or polyimide film wrapping, enhanced mechanical protection	High-reliability aerospace systems, medical devices
Silk-wrapped Wire	Natural silk fiber insulation, flexible for manual winding	Vintage audio equipment, specialized audio transformers
Self-bonding Wire	Adhesive coating enables coil self-support without bobbins	Compact inductors, wireless charging coils

3. Structure and Composition

A typical magnetic wire comprises three key layers:

Conductive Core: Oxygen-free copper (OFC) or aluminum for optimal conductivity
Primary Insulation: Thermosetting polymer enamel (e.g., polyurethane, polyester-imide)
Surface Coating: Optional adhesive or lubricant layer for winding process optimization

The cross-sectional diameter ranges from 0.02mm (magnet wire in micro-inductors) to 5.0mm (heavy-duty transformer windings).

4. Key Technical Specifications

Parameter	Description	Importance
Wire Gauge (AWG/mm )	Defines current-carrying capacity and resistance	Determines thermal performance and voltage drop
Temperature Class	Thermal endurance rating (130 C to 220 C)	Dictates operational lifespan in high-temperature environments
Dielectric Strength	Voltage withstand capability (kV/mm)	Ensures electrical safety and insulation reliability
Thermal Index	Resistance to thermal aging	Impacts long-term stability in power electronics

5. Application Fields

Power Industry: Grid transformers, HVDC converters
Electronics: Switch-mode power supplies (SMPS), EMI filters
Automotive: EV motor windings, onboard chargers
Renewables: Solar inverters, wind turbine generators

Case Study: In electric vehicles, 400V-class magnetic wires with Class 180 thermal rating enable compact traction motor designs achieving >95% efficiency.

6. Leading Manufacturers and Products

Manufacturer	Headquarters	Representative Product
Essex Furukawa	USA	ECW-180 (High-temperature enameled wire)
Leoni AG	Germany	AIWIRE (Automotive isolation wire)
Sumitomo Electric	Japan	PEEK-insulated wire for hybrid vehicles

7. Selection Guidelines

Calculate current density (typically 3-5A/mm for standard applications)
Select temperature class based on ambient conditions (+25 C derating per 10 C above rating)
Evaluate dielectric requirements per IEC 60317 standards
Consider cost/performance trade-offs: Copper (higher conductivity) vs. Aluminum (lightweight, lower cost)

8. Industry Trends

Miniaturization: Development of 0.01mm-diameter wires for 5G RF inductors
High-Temperature Materials: Polyamide-imide (PAI) enamel enabling 220 C operation
Sustainability: Bio-based insulation coatings reducing VOC emissions
Integrated Solutions: Embedded magnetic wires in PCB substrates for EV chargers

Market forecasts predict 6.2% CAGR through 2030 driven by renewable energy integration and electrified transportation demands.