Connection Technologies for Litz Wires
Due to the many stranded nature of litz wires, terminating them often poses a challenge. The following table advises the connection technologies which are generally applicable for various insulations. 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 not been addressed.
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 recommended |
* nom. diameter ≤ 0.100 mm
** nom. diameter > 0.100 mm
Please contact us if the conductor metals are alloys.
Please contact us directly for further assistance.
Determination of Winding Tension on Litz Wire
The following table shows the maximum applicable winding tension on the single litz wire strands. The maximum 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] | AWG | nom. [cN] | ± 20 % [cN] |
0.018 | 53 | 1.6 | 0.3 |
0.019 | 52.5 | 1.7 | 0.3 |
0.020 | 52 | 1.9 | 0.4 |
0.021 | 51.5 | 2.1 | 0.4 |
0.022 | 51 | 2.3 | 0.5 |
0.023 | 50.5 | 2.5 | 0.5 |
0.024 | 50.5 | 2.6 | 0.5 |
0.025 | 50 | 2.9 | 0.6 |
0.026 | 50 | 3.1 | 0.6 |
0.027 | 49.5 | 3.3 | 0.7 |
0.028 | 49 | 3.5 | 0.7 |
0.030 | 48.5 | 4.0 | 0.8 |
0.032 | 48 | 4.5 | 0.9 |
0.035 | 47 | 5.4 | 1.1 |
0.036 | 47 | 5.7 | 1.1 |
0.040 | 46 | 7.0 | 1.4 |
0.045 | 45 | 8.8 | 1.8 |
0.050 | 44 | 10.9 | 2.2 |
0.056 | 43 | 12.4 | 2.5 |
0.060 | 42.5 | 14.3 | 2.9 |
0.063 | 42 | 15.7 | 3.1 |
0.071 | 41 | 19.8 | 4.0 |
0.080 | 40 | 24.9 | 5.0 |
0.090 | 39 | 31.1 | 6.2 |
0.100 | 38 | 38.0 | 8.0 |
0.112 | 37 | 47.0 | 9.0 |
0.120 | 36.5 | 53.0 | 11.0 |
0.130 | 36 | 62.0 | 12.0 |
0.140 | 35 | 71.0 | 14.0 |
0.150 | 34.5 | 80.0 | 16.0 |
0.160 | 34 | 91.0 | 18.0 |
0.170 | 33.5 | 101.0 | 20.0 |
0.180 | 33 | 113.0 | 23.0 |
0.190 | 32.5 | 125.0 | 25.0 |
0.200 | 32 | 137.0 | 27.0 |
0.210 | 31.5 | 150.0 | 30.0 |
0.220 | 31 | 164.0 | 33.0 |
0.230 | 30.5 | 178.0 | 36.0 |
0.240 | 30.5 | 193.0 | 39.0 |
0.250 | 30 | 209.0 | 42.0 |
0.260 | 30 | 225.0 | 45.0 |
0.270 | 29.5 | 241.0 | 48.0 |
0.280 | 29 | 259.0 | 52.0 |
0.290 | 29 | 276.0 | 55.0 |
0.300 | 28.5 | 295.0 | 59.0 |
0.310 | 28 | 314.0 | 63.0 |
0.320 | 28 | 333.0 | 67.0 |
0.330 | 27.5 | 353.0 | 71.0 |
0.340 | 27.5 | 374.0 | 75.0 |
0.350 | 27 | 395.0 | 79.0 |
0.360 | 27 | 417.0 | 83.0 |
0.370 | 26.5 | 439.0 | 88.0 |
0.380 | 26.5 | 462.0 | 92.0 |
0.390 | 26 | 486.0 | 97.0 |
0.400 | 26 | 510.0 | 102.0 |
0.420 | 25.5 | 560.0 | 112.0 |
0.430 | 25.4 | 586.0 | 117.0 |
0.450 | 25 | 639.0 | 128.0 |
0.470 | 24.5 | 695.0 | 139.0 |
0.480 | 24.5 | 724.0 | 145.0 |
0.500 | 24 | 783.0 | 157.0 |