Connection Technologies for Litz Wires

The connection technology of litz wires often poses a challenge. The following table advises the connection technologies which are generally applicable. Only the most important factors of influence have been classified. Many others, such as enamel type and insulation thickness of the single strands, heat resistance of the additional insulation, the stranding construction (tight/compact or wide/flexible), have been left unconsidered.

  

Litz wires without additional insulation

Litz wires with additional insulation

 

overall diameter < 1.0 mm

 

 

overall diameter ≥ 1.0 mm

 

Serving

Extrusion

Taping

 Connection  

 technology

many fine single

strands*

few heavy

 strands**

many fine

single strands*

few heavy

strands**

 Soldering

dip/flow/hand/wave

soldering

dip/flow/hand/wave

soldering

dip/flow

soldering

dip/flow

soldering

dip/flow soldering

dip/flow soldering

dip/flow soldering

 Mechanical skinning

-brushing-brushing

taking off serving,

brushing if necessary

stripping off coating,

brushing if necessary

off/opening the tape,

brushing if necessary

 Crimping (pre-stripped)

possible

possible

possible

possible

possible

possible

possible

 Welding                      

 

 - thermocompression

 - resistance

 - ultrasonic sound

thermo-compression,

ultrasonic sound

thermo-compression,

ultrasonic sound,

resistance

thermo-compression

thermo-compression,

ultrasonic sound,

resistance

thermocompression

(nylon)

thermocompression

mechanical removal

of additional insulation recommeded

  

* nom. diameter ≤ 0,100 mm

** nom. diameter > 0,100 mm

 

In case conductor materials from alloys are used, please contact us.

Please contact us directly for further questions assistance.

 

 

Determination of Winding Tension on Litz Wire

The following table shows the max. applicable winding tension on the single litz wire strands. The max. feasible winding tension for litz wires can be calculated by multiplying the number of single strands by the appropriate winding tension of the single strand. Regardless of this calculation, for litz wire diameters thicker than 5 mm tension limits of (420N) for hard metals and (270N) for copper and soft metals are recommended.

 

These values are guidelines and can deviate significantly depending on the manufacturing process.

 

Max. winding tension on single litz wire strands

Cu, Cu/Ag
[mm]AWGnom. [cN]± 20 % [cN]
0.018531.60.3
0.01952.51.70.3
0.020521.90.4
0.02151.52.10.4
0.022512.30.5
0.02350.52.50.5
0.02450.52.60.5
0.025502.90.6
0.026503.10.6
0.02749.53.30.7
0.028493.50.7
0.03048.54.00.8
0.032484.50.9
0.035475.41.1
0.036475.71.1
0.040467.01.4
0.045458.81.8
0.0504410.92.2
0.0564312.42.5
0.06042.514.32.9
0.0634215.73.1
0.0714119.84.0
0.0804024.95.0
0.0903931.16.2
0.1003838.08.0
0.1123747.09.0
0.12036.553.011.0
0.1303662.012.0
0.1403571.014.0
0.15034.580.016.0
0.1603491.018.0
0.17033.5101.020.0
0.18033113.023.0
0.19032.5125.025.0
0.20032137.027.0
0.21031.5150.030.0
0.22031164.033.0
0.23030.5178.036.0
0.24030.5193.039.0
0.25030209.042.0
0.26030225.045.0
0.27029.5241.048.0
0.28029259.052.0
0.29029276.055.0
0.30028.5295.059.0
0.31028314.063.0
0.32028333.067.0
0.33027.5353.071.0
0.34027.5374.075.0
0.35027395.079.0
0.36027417.083.0
0.37026.5439.088.0
0.38026.5462.092.0
0.39026486.097.0
0.40026510.0102.0
0.42025.5560.0112.0
0.43025.4586.0117.0
0.45025639.0128.0
0.47024.5695.0139.0
0.48024.5724.0145.0
0.50024783.0157.0