Magnetic Wire

Part Number	Description / PDF	Quantity
8049 Belden	MW-28C SL 18AWG	25114
8073 Belden	MW-35C HY 14AWG	66134
8052 Belden	MW-28C SL 24AWG	2848
8079 Belden	MW-35C HY 26AWG	3
8055 Belden	MW-28C SL 30AWG	2189
8078 Belden	MW-35C HY 24AWG	265
8058 Belden	MW-28C SL 36AWG	287
8076 Belden	MW-35C HY 20AWG	24
8075 Belden	MW-35C HY 18AWG	96
8057 Belden	MW-28C SL 34AWG	27236
8083 Belden	MW-35-C HVY 34AWG	5
8081 Belden	MW-35C HY 30AWG	1
8050 Belden	MW-28C SL 20AWG	1137
8051 Belden	MW-28C SL 22AWG	1413
8054 Belden	MW-28C SL 28AWG	12
8085 Belden	MW-35C HY 38AWG	7
8053 Belden	MW-28C SL 26AWG	21
8056 Belden	MW-28C SL 32AWG	51202
8074 Belden	MW-35C HY 16AWG	9
8077 Belden	MW-35C HY 22AWG	11

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.