Next-generation automotive magnet wires

Solvay, a supplier of speciality polymers, together with Essex Furukawa Magnet Wire Europe (EFMWE), has won recognition from Magna Powertrain for the development of next-generation automotive magnet wires.

Magna had invited suppliers to submit ideas for innovations capable of advancing demanding challenges in the production of automotive electric and hybrid motors.



The jointly developed winning concept combines EFMWE’s High Voltage Winding Wire (HVWW) technology for electric traction motors and an insulation coating using Solvay’s KetaSpire PEEK polymer.

As one of only seven innovation concepts that made it through to the second round of the competition, the joint entry by Solvay and EFMWE was awarded first prize by Magna’s Innovation Committee.

The KetaSpire PEEK wire insulation is applied using an extrusion process and allows the magnet wires to attain unprecedented performance levels.

Notably, the coated enamel wires exhibit greatly enhanced heat and chemical resistance and can operate at higher voltages – above 600V.

This, in turn, enables more compact motor designs with subsequent space and weight savings as well as overall higher system efficiency.

The technology also reduces the number of assembly steps versus conventional high-performance electric traction motors.

“This collaborative achievement underscores our committed approach to helping customers optimise their technology and speed up their innovation process,” says Andreas Lutz, Area Development Manager, Automotive Europe for Solvay’s Specialty Polymers global business unit. “We are very pleased about the success of our industry leading PEEK polymer in this important application, which is an excellent example of real value created by our focused partnership with our customers.”

The new technology demonstrates the benefits gained by industry leaders collaborating to overcome existing constraints by enabling more durable, efficient and downsized large electric traction motors running at higher voltages and currents.

It also speeds the time-to-market of major advances in automotive engineering.

Electrified powertrains are among the main drivers of automotive innovation that will bring significant changes to the design and manufacture of vehicles, particularly hybrid and fully electric models.