Magnetic Wire

Part Number	Description / PDF	Quantity
40S2002.5 Remington Industries	MAGNET WIRE, 200C, 40 AWG, 2.5 L	48
32H200 Remington Industries	32H200 MAGNET WIRE, ENAMELED COP	50
43SNSPR.125 Remington Industries	43SNSPR.125 MAGNET WIRE, ENAMELE	46
42.5SNSP.5 Remington Industries	42.5SNSP.5 MAGNET WIRE, ENAMELED	50
21SNSP.125 Remington Industries	21SNSP.125 MAGNET WIRE, ENAMELED	42
32HNS2.5 Remington Industries	MAGNET WIRE, HEAVY BUILD ENAMELE	50
42HFVP.25 Remington Industries	42HFVP.25 42 AWG HEAVY BUILD MAG	50
38S200P.25 Remington Industries	38S200P.25 MAGNET WIRE, ENAMELED	93
25SNS Remington Industries	25SNS 25 AWG MAGNET WIRE, ENAMEL	49
16H200P.5 Remington Industries	16H200P.5 MAGNET WIRE, ENAMELED	43
30SNS Remington Industries	30SNS 30 AWG MAGNET WIRE, ENAMEL	46
32H200P Remington Industries	32H200P 32 AWG MAGNET WIRE, ENAM	49
44SNSP.25 Remington Industries	44SNSP.25 44 AWG MAGNET WIRE, EN	45
28H200P Remington Industries	28H200P MAGNET WIRE, ENAMELED CO	45
24HNSP Remington Industries	MAGNET WIRE, HEAVY BUILD ENAMELE	48
44SNS2.5 Remington Industries	MAGNET WIRE, ENAMELED COPPER WIR	47
41SNSP Remington Industries	41SNSP 41 AWG MAGNET WIRE, ENAME	50
28H200 Remington Industries	28H200 MAGNET WIRE, ENAMELED COP	49
42HFVP.5 Remington Industries	42HFVP.5 42 AWG HEAVY BUILD MAGN	49
26H200P.125 Remington Industries	MAGNET WIRE, ENAMELED COPPER WIR	42

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.