coatedwire

Coated wire refers to an electrical conductor that carries an insulating or protective layer over its conductive core. The term typically describes copper or aluminum wires with either an exterior jacket or an enamel-like coating, each serving different applications and performance requirements.

Two common forms are insulated wired with a polymer outer jacket and magnet wire with a thin enamel coating. Insulated wires use jackets made from materials such as PVC, polyethylene, cross-linked polyethylene, or fluoropolymers, offering environmental and mechanical protection as well as insulation for higher voltage circuits. Magnet wire employs a thin polymer or resin enamel that provides electrical insulation while allowing tight winding in coils for transformers, motors, and inductors. Enamel compositions include polyamide-imide, polyurethane, and other high-temperature resins.

Manufacturing involves drawing the conductor to size, then applying the coating. Jacketed wires are extruded with the chosen outer material, while magnet wires are enameled and cured to form a durable insulating layer. Quality control includes insulation resistance tests, dielectric strength tests, and checks for coating integrity.

Key properties include insulation thickness, dielectric strength, voltage rating, and temperature rating. The coating protects against short circuits, moisture, abrasion, and chemical exposure, while allowing the conductor to carry current. Safety and compatibility depend on the material, with some coatings offering halogen-free formulations for building safety or high-temperature performance for industrial equipment.

Common applications encompass general electrical wiring, automotive and consumer electronics, transformers, motors, audio equipment, and electronic assemblies. Coated wire choices depend on operating voltage, temperature, environmental conditions, and mechanical requirements.