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Magnet wire (also known as motor wire or winding wire) is a type of wire used for winding in electrical devices. In its most basic form, magnet wire is used to exchange electrical energy for magnetic energy.
The most common magnet wire is copper insulated wire used in electric motors, which rank with the wheel and light bulb as one of the greatest inventions of all time. Magnet wires are classified into three types: enameled wire, covered (or served) wire, and combinations of the two.
Magnet wire types can be fairly diverse, however they will all have the essential characteristics:
(a) insulation uniformity,
(b) excellent electrical qualities such as dielectric strength and insulation resistance,
(c) mechanical stress resistance, and
(d) chemical and solvent resistance, as well as
(e) thermal resistance and
(f) high thermal life.
Any magnet wire should have strong qualities in at least one of these areas. Each variety has advantages and cons, but the basic concept is that an electric current creates a magnetic field. As a result, the operating circumstances must be considered while selecting a wire type for every given application.
The essential concept is that an electric current generates a magnetic field. They may strengthen this magnetic field by increasing the current or by connecting several loops.
To produce a robust, continuous insulating layer, modern magnet wire often employs one to build thicknesses (in the case of quad-film type wire) or polymer film insulation, frequently of two distinct compositions.
Magnet wire insulating films are made of polyvinyl formal (Formvar), polyurethane, polyamide, polyester, polyester-polyimide, polyamide-polyimide (or amide-imide), and polyimide (in that order). Continuous operation is possible using polyimide insulated magnet wire.
The insulation of thicker square or rectangular magnet wire is sometimes supplemented by wrapping it with a high-temperature polyimide or fiberglass tape, and finished windings are frequently vacuum coated with an insulating varnish to increase insulation strength and winding long-term dependability.
Self-supporting coils are made of wire that has been coated with at least two layers, the outermost of which is a thermoplastic. Other insulating materials used in diverse applications such as transformers and reactors include fiberglass yarn with varnish, aramid paper, craft paper, mica, and polyester film.
A silver wire and several other insulators, such as cotton (often impregnated with some form of coagulating agent/thickener, such as beeswax) and polytetrafluoroethylene (Teflon), may be found in the audio industry.
Cotton, paper, and silk were once popular insulating materials, but they are now only viable for low-temperature applications (up to 105°C).
Some low-temperature magnet wire contains insulation that may be removed by soldering heat for simplicity of manufacture. This implies that electrical connections may be made at the ends without first removing the insulation.
Aluminum has the advantage of being lighter for the same ampacity as copper, as well as being significantly cheaper on an equivalent ampacity basis. That’s all. However, when it comes to automobiles, especially EVs, being cheaper and lighter are two highly appealing characteristics.
Aluminum’s drawbacks can be avoided – or at least minimized – by using appropriate application and termination strategies. Aluminum, for example, is a suitable choice for higher-current wires such as those connecting the traction battery, inverter, and motor, but it is a bad choice for low-current or signal-level wires due to the difficulty of producing a solid termination and fatigue cracking from vibration/movement.
Welding is the preferred method of termination for aluminum wire, however traditional methods such as GMAW (aka TIG) are too costly.
The Global EV Aluminum Magnet Wire Market accounted for $XX Billion in 2023 and is anticipated to reach $XX Billion by 2030, registering a CAGR of XX% from 2024 to 2030.
Essex Furukawa has the technological competence to satisfy any standard as a partner to some of the world’s leading electric vehicle manufacturers and suppliers.
They provide the magnet wire components that power the traction motors, regenerative braking, autonomous driving, and sensors used in the future generation of automobiles, as well as the classic creature comforts present in all vehicles.
To guarantee improved efficiency and dependability in Traction Motors and Belt Started Generators, global automotive OEMs and Tier 1 suppliers rely on components that are electrically, thermally, and mechanically robust, such as Allex and UltraShield Plus.
Many companies have collaborated with MagForceX Innovation Centres to develop revolutionary technologies to aid in the launch of their next product line.ssex Furukawa is a vertically integrated firm, which not only gives more control over supply chain, but also allows it to be more flexible in innovation at every stage.
A relationship enables clients to better monitor the efficiency and performance of their products throughout the whole manufacturing process, with low chance of schedule delays.
EIS offers a variety of Magnet Wire that is designed to fulfill a wide range of industrial applications. Magnet Wire is available in a variety of forms and materials, including round, rectangular, square, copper, aluminum, and other speciality varieties.
thermal class ranges and wire are available in a wide range of insulation options, including enamel or the use of insulated tapes, poly-fiber yarns, and papers. Litz Wire and varnishes, as well as round wire ranges from AWG 4 to AWG 56, millimetric diameters, and rectangular and square variants, are available on request. Magnet Wire is supplied by EIS from high-quality industrial vendors.
