Abbreviations

Abbreviations

Abbreviations 
AConductor,Litz = total conductor cross section of litz wire
Ages,Litz = total cross section of litz wire
ODLitz = outer diameter of litz wire
ODBundle = outer diameter of bundle
nsw = number of single wires
Øsw = nominal diameter of single wire
VF = bunching factor
SL = length of lay (bunching length)
SR = pitch (bunching) direction
RDC = DC resistance
RAC = AC resistance
f = frequency
ρ = specific resistance of conductor
µO = permeability of free space
δ = skin depth
J = current density
UBDV = breakdown voltage
b = width of winding window
h = height of winding window
NW,tot = total number of windings
NL = number of winding layers
NW,L = number windings per layer
FillLitz = copper filling factor of litz wire
FillWin = copper filling factor of winding window
ne = recommended total number of single wires
n1,max = number of single wires of basic bundle in 1st bunching step
k = constant according Ch. R. Sullivan

Smartbond

Smartbond Litz Wire

General

Products for multimedia applications are increasingly equipped with wireless charging devices. ELEKTRISOLA's Smartbond OSP18 has been developed to meet the needs of these specific charging systems. This self-bonding litz wire combines excellent bond strength with good windability, fast soldering, and very good hot air bonding characteristics.

The hot air bonding process is environmentally friendly compared to solvent bonding process, allows faster winding, and has potential for process automation. Very thin coils can be produced with Smartbond`s unique construction giving additional space for designers or to help to achieve miniaturization goals.

Features and benefits of Smartbond litz wires

  • excellent bonding strengths with hot air bonding
  • high winding speed
  • solderable without pre-stripping of insulation
  • environmentally friendly automated process due to elimination of solvents
  • thin walled overcoat allows small coils
  • customized wall thickness possible per customer specification

Technical properties of Smartbond litz wire

Standard Litz Wire Served Litz Wire Selfbonding Litz Wire Smartbond
Stability of coil - good medium good
Flexibility / windability soft more stiff soft soft
Bonding process - solvent hot air hot air
Mechanical protection avg good avg good
Surface and haptic - rough avg smooth
Second adhesion step
without additional adhesion		 no no limited yes

Diameter of litz wire and copper fill factor

Dimensions
Diameter of single wires 0.020 - 0.500 mm
Outer diameter of litz wires 0.500 - 3.500 mm

Applications

  • transmitter coil for wireless charging
  • receiver coil for wireless charging
  • wireless power charger
  • coreless coils in different applications

Served

Served Litz Wire

General

High frequency litz wire served with natural silk, polyester, or nylon is characterized by increased dimensional stability and mechanical protection. The optimized serving tension ensures high flexibility and splicing- or spring up prevention during the process of cutting the litz wire. This splicing effect can cause handing and contacting of the wire ends more difficult in post processing.

Features and benefits of served litz wires

  • Additional protection against mechanical stress
  • Excellent dimensional and physical stability
  • High flexibility
  • Splicing prevention
  • Good solderability above temperatures of 410 °C
  • Improved impregnation
  • Optimization of winding capacity
  • Serving material allows optimization of insulation distances

Technical properties of served litz wires

Technical values of serving material

Serving materials1) Silk Nylon Polyester*
Thermal properties
Recommended permanent use temperature 110 120 120 °C
Melting temperature - 250 - 260 250 - 260 °C
Elektrical properties
Dielektric constant ℇr 1.4 3.4 3.2
Mechanical properties
Elongation at break (dry) 13 - 25 25 - 46 20 %
Moisture absorption (65% rel. humidity, 21°C) 9 2.5 - 4 0.2 - 0.5 %
Other
Color white, green white white

Dimensions

Serving materials1) Silk Nylon Polyester*
Diameter of single wires2) 0.020 - 0.300 0.020 - 0.300 0.020 - 0.300 mm
Number of single wires3) 2 - 25,000 2 - 25,000 2 - 25,000 pcs
outer diameter of litz wires 0.071 - 4.0 0.071 - 10.0 0.071 - 4.0 mm
Number of layers (typ.) 1 - 2 1 - 2 1 - 2

* Available in Asia only
1) customized solution on demand (thermo adhesive yarns)
2) other diameters on demand
3) depending on number of single wires

Applications

  • HF transformers
  • HF in-/converters
  • HF transceivers
  • HF chokes
  • Inductive charger

With Strain Relief

Litz Wire with Strain Relief

General

Some of the ultrafine litz wires are impacted by high mechanical forces during further processing and over their lifetime. Litz wire constructions starting from an available single conductor diameter of 0.01 mm (AWG 58) can be designed implementing strain reliefs to improve the resistivity of the litz wire against tensile stress. It is typically used in applications where litz wire is used not wound in a coil, but used like a cable.

Features and benefits of litz wires with strain

  • Excellent increase of tensile strength and flex life performance
  • Different strain relief materials can be selected for individual applications
  • Protection of super fine litz wires against mechanical stress
  • Strain reliefs can be used in all other litz wire constructions

Properties of litz wires with strain relief

Comparison of properties with a typical litz wire

Technical values of strain relief materials

Materials Polyester
PES		 Polymer
LCP		 Polyamide
Aramide
from
Gram per 10,000 m dtex 30 110 110
Tensile strength N 1.5 29.6 26.7
Elongation % 9.8 3.3 3.9
to
Gram per 10,000 m dtex 450 440 420
Tensile strength N 29.4 99.2 49.7
Elongation % 12.4 3.4 4.2

Dimensions of litz wire with strain relief

Dimensions
Diameter of single wire 0.020 - 0.500 mm
Number of single wires 2 - 5,000 pcs
Outer diameter of litz wire 0.020 - 2.5 mm

Profiled

Profiled Litz Wire

General

Profiled (mechanically shaped) litz wires allow optimal utilization of available winding space due to the superior filling factor of  rectangular or square litz wire cross sections. In comparison to a standard round cross section construction, profiled litz wire can increase the filling factor up to 20%.

The design advantages of profiled litz wire can only be fully realized using products with consistent and precise dimensions. This dimensional stability is only possible with exact control of each process step.

Features and benefits of profiled litz wires

  • Increased filling factor of up to 20 %
  • Constant winding performance requiring tight dimensional tolerance and good flexibility
  • Profiled dimensions to customer specification
  • Profiling also possible with outer insulation

Technical properties of profiled litz wires

Increasing filling factor by profiling

Available insulation materials of profiled litz wires

For served litz wire:

Nylon

For taped litz wire:

Polyester (PET)

Polyethylene Naphthalate (PEN)

Polyimide (PI)

Dimensions
Smallest sizes (width x height) 1.2 x 1.2 mm
Biggest sizes 15.0 x 15.0 mm
Ratio (width x height) 1:1.7 mm
Tolerance (±) 0.1 mm
Diameter of single wires 0.050 - 0.500 mm

Other dimensions and materials on demand.

Applications

  • Wireless charging
  • Induction cooking hobs
  • HF transformers
  • HF transducers
  • E-motors

Taped

Taped Litz Wires

General

Taped high frequency litz wire constructions are mainly suitable for applications requiring high break down voltage. Taping improves the capability to withstand flexing and mechanical stress. Adhesive taped litz wire can be achieved by using thermally sealed or self adhesive tape. This ensures protection against re-opening during and after manufacturing processes and thus secures the compliance with defined creepage distance. 

Some tapes can be thermally sealed when used in conjunction with certain wire enamel types.

Excellent adhesion and bonding characteristics to the individual wires are possible. A wide range of thermally sealable tapes can be selected for special applications all promoting various degrees of flexibility and mechanical protection for the litz wire construction.

Features and benefits of taped litz wires

Variants Dielectric strength Flexibility Splicing Contacting
Standard high very good good very good
Thermally Sealed elevated medium very good very good
Self-Adhesive very high good very good good

Technical data sheet of different tapes

Taping materials PET PEN PI
Description Polyester Polyethylene Naphtalate Polyimide
Color transparent transparent brown
Standard PET PEN PI
Insulation class (UL) °C 105 (A) 180 (H) 200 (C)
Insulation class (VDE) °C 130 (B) - 200 (C)
Dielectric constant ℇr 3.3
(VDE 0345)		 2.8
(JIS C 2318)		 3.4
(ASTM D 150-92)
Flammability 400
(VDE 0345)		 VT-M
(UL 94)		 V-0
(IEC 60695-11-10, UL 94)
UL-file no., tapes E53895 E206562 E39505
Processing fusible fusible mechanical stripping
Thermally Sealed
Insulation class (UL) °C 13 - 25 - 20
Insulation class (VDE) °C 9 - 0.2 - 0.5
Dielectric constant ℇr 3.25
(ASTM D 150-81)		 - 3.4
(ASTM D 150-92)
Flammability n.a. - V-0
(IEC 60695-11-10, UL 94)
UL-file no., tapes E93687 - E39505
Processing fusible fusible mechanical stripping
Self Adhesive
Insulation class (UL) °C 130 (B) 180 (H) 180 (H)
Dielectric constant ℇr 3.2
(JIS C 2318)		 2.8
(JIS C 2318)		 3.3
(JIS C 2318)
Flammability - flame retardant
(internal test acc. UL 510)		 flame retardant
(internal test acc. UL 510)
UL-file no., tapes E515235 E515235 E515235
Processing fusible fusible mechanical stripping
Custom materials can be arranged

Degree of overlapping

The degree of overlapping of two adjacent tape windings is defined by the gradient angle between tape and litz wire during the taping process. The overlapping determines the number of tape layers located on top of each other and thus the thickness of the insulation.


Dimensions
Diameter of single wires 0.040 - 0.700 mm
Outer diameter of litz wire 0.5 - 20.0 mm
Overlapping (typical) 50 or 67 %
Number of tapes (typical) 1 - 2

Applications

  • EV (Electric Vehicles)
  • OBC (Onboard charger)
  • DC/DC converter
  • Wireless charging
  • Charging piles
  • SMPS (Switch Mode Power Supplies)
  • HF transformers
  • HF transducers
  • HF chokes

Special constructions with VDE-approval for high voltage applications available:

GotoEFOLIT®-product family

Calculating Tools

Fully Insulated Wire

FIW Quick Selection

For the selection of the right FIW wire

key in the Nominal Diameter (in mm) and the FIW Grade in the input fields underneath to calculate the Length, Weight and minimal Breakdown Voltage (acc. to IEC 60317-56) of the specified FIW wire (line 1),

or key in the Nominal Diameter (in mm) and the required minimal Breakdown Voltage (acc. to IEC 60317-56) to get the corresponding FIW Grade of the FIW wire (line 2).


1. Nominal Diameter [mm] Grade
Length [km/kg] ???
Weight [kg/km] ???
min. Breakdown Voltage [V] ???
2. Nominal Diameter [mm] min. Breakdown Voltage [V]
Length [km/kg] ???
Weight [kg/km] ???
Grade ???

FIW Length/Weight Calculator

Length in km per 1 kg and weight in kg per 1 km for FIW can be retrieved along with the breakdown voltage, too, using the FIW quick selection on the dimensions page. The weight for an arbitrary length and vice versa can be retrieved using the Length/Weight Calculator underneath.

After specification of the considered FIW by picking a nominal diameter and an FIW grade from the tables offered, any weight can be typed in and the length is calculated immediately and the other way around.


Nominal Diameter [mm] Grade
Length [km] Weight [kg]

Technical Data

Fully Insulated Wire

Technical values of FIW acc. to IEC 60317-56

IEC 60317-56 describes a full Enamelled Wire Specification with diameters, outer diameters, mechanical, electrical, thermal and other characteristics like soldering.
Test parameter Test method Specification values for 0.30 mm FIW 6 Typical values for 0.30 mm FIW 6
Mechanical
Elongation IEC 60 851-3.1 ≥ 23 % 56 %
Tensile strength IEC 60 851-3.2 not specified 310 N/mm²
Springback IEC 60 851-3.4.1 not specified 68°
Solderability
at 390 °C IEC 60 851-4.5 ≤ 4 sec ≤ 3.0 sec
Thermal values
Temperature index IEC 60 172 ≥ 180 °C 192 °C
Heat shock EC 60 851-6.3.1.1 ≥ 200 °C 220 °C/6 mm mandrel
Cut through IEC 60 851-6.4 ≥ 245 °C ≥ 260 °C
Breakdown voltage (cylinder)
Volt min. 10032 V > 15 kV
V/µm at room temperature IEC 60 851-5.4.3.2 min. 76 V/µm > 100 V/µm
at 180°C IEC 60 851-5.4.3.2 min. 53 V/µm 74 V/µm
(Volt per µm increase of insulation)

Test conditions for FIW acc. to UL 2353 (UL 60950)

UL 60950 will be replaced by UL 62368
UL 2353, rather similar to expired IEC 60950 Annex U, gives mainly electrical properties which mostly are rather short-term tests.
Test conditions acc. to UL 2353
No.		 Typical values for 0.30 mm FIW 6
U2.1Electrical strength 9 6000 Vrms 1 min (twisted pair)
U2.2Adherence and flexibility 10 3000 Vrms 1 min (mandrel)
U2.3Heat shock
225 °C x 30 min for class B 12 3000 Vrms 1 min (mandrel)
U2.4Retention of electric strength after bending 11
 3000 Vrms 1 min (mandrel)

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    To enable the display of certain fonts on our website, a connection to the Google server in the USA is established whenever our website is accessed.

    The legal basis is Art. 6 Para. 1 lit. f) GDPR. Our legitimate interest lies in the optimization and economic operation of our site.

    When you access our site, a connection to Google is established from which Google can identify the site from which your request has been sent and to which IP address the fonts are being transmitted for display.

    Google offers detailed information at

    https://adssettings.google.com/authenticated

    https://policies.google.com/privacy

    in particular on options for preventing the use of data.

    Model Data Protection Statement for Anwaltskanzlei Weiß & Partner

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