It is an insulated copper or aluminum conductor commonly used to wind electromagnetic devices like motors and transformers. The insulation may consist of a thin varnish film, known as enamel, a fibrous polyester or fiberglass yarn, or a combination of both enamel and fibrous materials. The fibrous insulation may be impregnated with varnish to secure it to the conductor and improve thermal endurance. Additionally, other materials such as copper and nickel alloys, pure nickel, precious metal-plated copper, and pure precious metals can also be coated with film insulation for specialized applications.

Raw copper / aluminum is drawn to meet specific size requirements based on the National Electrical Manufacturer’s Association (NEMA), IEC, JIS and GB standards.

Build is the measurement of insulation obtained by subtracting the bare wire diameter from the overall (insulated) diameter. Build is equal to two insulation wall thicknesses measured 180º apart on the circumference of the wire. For acceptance purposes, the measurement for insulation build is the average of three measurements made at 120º intervals around the wire circumference. There are four different builds: single, heavy, triple, and quadruple. Insulation build is directly correlated to dielectric strength.

There are a number of film insulation types ranging from temperature Class 105 to Class 240. Each film type has its own unique set of characteristics to suit specific needs of the user.

The formula for current carrying capacity in amperes for copper magnet wire wound into a coil is: Diameter Squared X 4869.48 (d = diameter in inches). This formula is pretty conservative, and formulas from other sources based on straight lengths of solid or stranded conductors in ambient air may indicate greater current carrying capacity than this one.

LP Industry stocks a variety of wires with insulation types ranging from Class 180 to Class 220. There are also a variety of sizes, conductors, and insulation builds to consider. Especially transformer and motor winding wire is double build polyimide Class 180 or 200 with a polyamide. It is stocked in range sizes 0.21mm to 3.5mm and is a good general-purpose insulation for people that don’t know exactly what they want. Armored polyester (APT) insulation is another option when a higher temperature class is desired.

Square wire is useful where space constraints are concerned. When formed into a coil an equivalent amount of square wire put in a coil can be placed in a tighter coil configuration than the same amount of round wire.

The mechanical properties of nylon are advantageous due to its lubricity and low coefficient of friction. It makes magnet wire more durable and easier for machines and people to handle without damaging the conductor or primary insulation coating. However, nylon is hygroscopic, meaning it can absorb moisture from the surrounding environment, which can lower the dielectric strength of the film insulation.

Bondable wire has a thermoplastic adhesive film superimposed over standard film insulation. When activated by heat or solvent the bond coating cements the winding turn-to-turn to create a self-supporting coil. The use of bondable wire can eliminate the need for bobbins, tape or varnishes.

A lubricant is applied to film coated magnet wire to ensure compact winding and ease of de-reeling for the user. Lubricants commonly used are very dilute solutions of paraffin wax or mineral oil in a volatile solvent. Isoparaffinic fluids have also been used in certain applications. Without the application of lubricant the winding on the spool may be ‘spongy’ or become tangled and difficult to de-reel. However, special orders can be manufactured without lube on request.

Magnet wire shelf life is not established in commercial specifications. As long as the wire has been carefully stored it may be usable for years to come. Bondable wire should not be stored at temperatures exceeding 100°F.

Electrolytic tough pitch copper (ETP Copper, UNS C11000) exceeds 99.9% purity and is the most widely used type for magnet wire production. It is intentionally oxygenated (200-400 ppm) to achieve the best combination of conductivity, capacity for being cold worked and economy. LP Industry can also supply wire made from (99.99%) OFHC Copper.

Basic Requirements:
Our enameled wires are made with aluminum containing ≥99.5% purity (industrial pure aluminum, corresponding to grade 1350 alloy).
For high-performance applications, enameled wires are made with ≥99.7% aluminum purity (close to EC-grade aluminum).

Standards:

• IEC 60317-30: Specifies that aluminum conductors must meet the 1350 alloy requirements outlined in IEC 60104 (aluminum wire for electrical use) with Al content ≥99.5%.

• ASTM B230/B230M: Requires 1350-O/H19 aluminum wire to have a resistivity ≤28.264 nΩ·m (20°C, equivalent to 61% IACS).

• Chinese Standard GB/T 3954-2014: Electrical round aluminum wire (LY9 grade) must have aluminum content ≥99.5%.

Testing Includes:

• Spectroscopic analysis (OES) to confirm Al% and impurities.

• Resistivity test (conducted at 20°C).

• Elongation and tensile strength data

The overwhelming majority of magnet wires produced and supplied by LP Industry are in compliance with Directive 2015/863 amending Annex II of the European Parliament. We will continue to supply solder plated wire containing lead to our customers that want and need these products. All products sold exceeding RoHS threshold levels of lead carry a RoHS non-compliance statement on the packing slip, certification and invoice so any customer can determine if they have purchased a product containing lead above the threshold level.

The enamel on the magnet wire surface is very stable in ambient environments. Storage in any dry, room temperature environment will ensure the best shelf life.

Zhengzhou LP Industry offers enameled copper wire (0.21–3.5 mm) in stock, featuring a 180°C temperature rating.

• Minimum Order Quantity (MOQ): 500 kg per gauge

• Customization: Available for enameled aluminum wire and other specifications.

• Key Advantage: Ready stock ensures fast delivery for standard sizes.

Magnet wire is bare copper wire coated with insulation to prevent shorting of wound coils. The insulation comes in various thicknesses based on the need of the product being wound. Single build is a standard, where as heavy build adds double the amount of insulation to further protect the wire from shorting out. Plain enamel and heavy formvar insulations are used mainly for the guitar pickup industry, and closely resemble the enamel coating used in vintage instruments.

The temperature class of magnet wire can range from 105°C to 240°C. Each temperature rating is suited to certain applications, with 180°C and 200°C being the most common.

Yes – we can wind spools based on your specifications of weight or length. All wire sizes are available as custom spools. Please contact us with your requirements, and we will respond as soon as we can.

AWG – or American Wire Gauge – is a standardized sizing system for electrically conducting wire. Increasing gauge numbers represent a decrease in wire diameter.

SWG (Standard Wire Gauge): A British wire measurement system, also known as “Imperial Wire Gauge.” Like AWG, higher SWG numbers denote thinner wires.

Samples of insulated wire are made into twisted pairs and aged at a series of temperatures significantly higher than the expected temperature class rating of the insulation. The twisted pairs are periodically proof tested at 300 to 1200 volts depending on the wire diameter. Sample failures are recorded and an average life at each temperature is calculated in accordance with procedures established in ASTM D2307. From these values a regression line is calculated to determine the temperature at 20,000 hours of aging. This temperature must be equal to or greater than the proposed temperature class for the insulation.

The conductivity of electrical conductor grade aluminum wire (Alloy 1350-0) is 61.8% of the equivalent cross-sectional area of annealed ETP copper. Therefore aluminum wire must have 1.6 times the cross sectional area for a given copper wire in order to achieve a comparable DC resistance.

Aluminum is lighter and less costly per pound than copper. However, the disadvantages include electrochemical decomposition, lower fatigue strength, and the buildup of a hard sapphire oxide coating. In addition, resistivity is higher at 16.782 ohms/cmf compared with 10.371 for copper.

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LP Industry holds valid certification (Certificate No. 15/25E5661R31), officially registered with the Certification and Accreditation Administration of the People’s Republic of China (CNCA).
Verification portal: www.cnca.gov.cn

Yes, all our products are compliant.

yes, EU RoHS Directive (EU) 2015/863 amending Annex II to Directive 2011/65/EU -Lead, Mercury. Cadmium,Hexavalent chromium,Polybrominated biphenyls (PBB),Polybrominated diphenyl ethers (PBDE), Bis(2-ethyIhexyl) phthalate (DEHP),Butyl benzyl phthalate (BBP),Dibutyl phthalate(DBP) and Diisobutyl phthalate (DIBP)

Test Method:
With reference to IEC 62321-4:2013+AMD1:2017, IEC 62321-5:2013,IEC 62321-7-1:2015, IEC 62321-6:2015 and IEC62321-8:2017, analysis was performed by ICP-OESIAAS, UV-Vis and GC-MS.