| ELEKTRISOLA

LW Basic

Basic Litz Wire

General

Litz wire made of enameled magnet wires is either used for high frequency or heating related applications. Ultra fine litz wires provide solutions for both technologies regardless of frequency or impedance range. Electrical, mechanical and cost aspects need to be considered carefully during the design phase.

Features and benefits of litz wire for high frequency applications

Reduction of high frequency losses
Cost effective design
Resistance or frequency related construction
Increased tensile strength by using additional strain relief
Flexibility for high conductor cross sections

Features and benefits for heating applications

Precise resistance related manufacturing
Very broad field of application (drying, heating, warming up)
Different conductor materials available with excellent mechanical properties
High thermal stability

Technical properties of basic litz wires

Properties	For high frequency applications	For heating applications
Conductivity	high	medium
Resistance	medium	high
Tensile strength	low - medium	high
Looping behaviour	low	high
Splicing	medium	high
Bending cycle performance	high	high
Typical conductor material	copper	copper, alloys
Typical wire insulation	polyurethane, polyester-imide	polyurethane

Diameter of single wire	0.010 - 0.700	mm
Number of single wires	2 - 25,000	pcs
Outer diameter of litz wire	0.095 - 20.00	mm
Typical length of lay: Single step Multiple step	2.00 - 26.00 20.00 - 60.00	mm mm

Applications

HF transformers
Chokes
Switching power supplies
Hearing aids
Sensors
Ballasts
Resistance wires for heating applications
Motors

Taped

LW Extruded

Extruded Litz Wires

General

Extruded coatings applied to high frequency litz wires support increased flexibility, mechanical robustness, resistance to chemical substances, as well as electrical insulation. The flex life performance of extruded litz wire is improved considerably in comparison to standard constructions. Extrusion materials, wall thickness tolerance, and litz wire construction details can be selected and combined for optimal performance in a wide range of applications.

Features and benefits of extruded litz wires

High resistance to mechanical stress
Excellent flexibility
Good resistance against oil and grease
High dielectric strength
Solderable above 410°C

Technical properties of extruded litz wires

Extrusion materials

	PA-F	PA-M	PA-T	PB-A	PB-B	TPE-E	TPE-F	TPE-S
	mod. Polymide	mod. Polymide	mod. Polymide	Polyether Block Amide	Polyether Block Amide	Polyester- Elastomer	Polyester- Elastomer, flame retardant	Polyester- Elastomer
Melting temperature, °C	170 - 180	175 - 185	170 - 180	155 - 165	165 - 175	205 - 230	205 - 230	125
Max. usage temperature, °C	90	90	115	100	120	140	140	90
Min. breakdown voltage, kV *	4	3	3	3	3	3,5	3	3
Color	transparent	transparent	transparent	transparent	transparent	transparent	white	white

* at wall thickness of 0.2mm

Dimensions


Diameter of sigle wires	0.032 - 0.50	mm
Outer diameter of litz wire	0.5 - 3.5	mm

Applications

Resistance wires for heating applications
Smart Textiles
Hearing Aids

Taped

Profiled

FIW Calculator 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]

FIW 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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The information including but not limited to technical data and graphics contained in this website are for general information and guidance only and is not intended to form part of any contract or to be a guarantee or warranty of any kind of and is subject to change without prior notice.
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Per Art. 4 No. 1 of Regulation (EU) 2016/679, i.e. the General Data Protection Regulation (hereinafter referred to as the "GDPR"), "processing" refers to any operation or set of operations such as collection, recording, organization, structuring, storage, adaptation, alteration, retrieval, consultation, use, disclosure by transmission, dissemination, or otherwise making available, alignment, or combination, restriction, erasure, or destruction performed on personal data, whether by automated means or not.

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Our privacy policy is structured as follows:

Information about us as controllers of your data
The rights of users and data subjects
Information about the data processing

I. INFORMATION ABOUT US AS CONTROLLERS OF YOUR DATA

The party responsible for this website (the "controller") for purposes of data protection law is:

Elektrisola Dr. Gerd Schildbach GmbH & Co. KG
Zur Steinagger 3
51580 Reichshof-Eckenhagen
Deutschland

Tel: +49-2265-12-0
Fax: +49-2265-12-22

webinfo(at)elektrisola.de

The controller's data protection officer is:

Herr Luca Saggiomo
Zur Steinagger 3
51580 Reichshof-Eckenhagen
Deutschland

datenschutz@elektrisola.de

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With regard to the data processing to be described in more detail below, users and data subjects have the right

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In addition, the controller is obliged to inform all recipients to whom it discloses data of any such corrections, deletions, or restrictions placed on processing the same per Art. 16, 17 Para. 1, 18 GDPR. However, this obligation does not apply if such notification is impossible or involves a disproportionate effort. Nevertheless, users have a right to information about these recipients.

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III. INFORMATION ABOUT THE DATA PROCESSING

The following explanations are intended to inform you in particular about the type, scope, purpose, and duration for the processing of such data either under our own control or in conjunction with others. Additionally, for citizens or residents of the European Union (EU) or the European Economic Area (EEA) the legal basis of the processing of personal data is described. We also inform you below about the third-party components we use to optimize our website and improve the user experience which may result in said third parties also processing data they collect and control.

Your data processed when using our website will be deleted or blocked as soon as the purpose for its storage ceases to apply, provided the deletion of the same is not in breach of any statutory storage obligations or unless otherwise stipulated below.

SERVER DATA

For technical reasons, the following data sent by your internet browser to us or to our server provider will be collected, especially to ensure a secure and stable website: These server log files record the type and version of your browser, operating system, the website from which you came (referrer URL), the webpages on our site visited, the date and time of your visit, as well as the IP address from which you visited our site.

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The basis for this storage is Art. 6 Para. 1 lit. f) GDPR. Our legitimate interest lies in the improvement, stability, functionality, and security of our website.

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Your data will be deleted once we have fully answered your inquiry and there is no further legal obligation to store your data, such as if an order or contract resulted therefrom.

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Through certification according to the EU-US Privacy Shield

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The Google Analytics service is used to analyze how our website is used. The legal basis is Art. 6 Para. 1 lit. f) GDPR. Our legitimate interest lies in the analysis, optimization, and economic operation of our site.

Usage and user-related information, such as IP address, place, time, or frequency of your visits to our website will be transmitted to a Google server in the United States and stored there. However, we use Google Analytics with the so-called anonymization function, whereby Google truncates the IP address within the EU or the EEA before it is transmitted to the US.

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including options you can exercise to prevent such use of your data.

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Google guarantees that it will follow the EU's data protection regulations when processing data in the United States.

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.

If you access the Google Maps components integrated into our website, Google will store a cookie on your device via your browser. Your user settings and data are processed to display our location and create a route description. We cannot prevent Google from using servers in the USA.

The legal basis is Art. 6 Para. 1 lit. f) GDPR. Our legitimate interest lies in optimizing the functionality of our website.

By connecting to Google in this way, Google can determine from which website your request has been sent and to which IP address the directions are transmitted.

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Google guarantees that it will follow the EU's data protection regulations when processing data in the United States.

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Google offers detailed information at

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concerning the general handling of your user data.

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We use conversion tracking to provide targeted promotion of our site. The legal basis is Art. 6 Para. 1 lit. f) GDPR. Our legitimate interest lies in the analysis, optimization, and economic operation of our site.

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If the cookie is still valid and you visit a specific page of our website, both we and Google can evaluate that you clicked on one of our ads placed on Google and that you were then forwarded to our website.

The data collected in this way is in turn used by Google to provide us with an evaluation of visits to our website and what visitors do once there. In addition, we receive information about the number of users who clicked on our advertisement(s) as well as about the pages on our site that are subsequently visited. Neither we nor third parties who also use Google AdWords will be able to identify you from this conversion tracking.

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in particular information on how you can prevent the use of your data.

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Through certification according to the EU-US Privacy Shield

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Google guarantees that it will follow the EU's data protection regulations when processing data in the United States.

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.

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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.

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in particular on options for preventing the use of data.

Model Data Protection Statement for Anwaltskanzlei Weiß & Partner

Impressum

Name and Address

Elektrisola Dr. Gerd Schildbach GmbH&Co. KG
Zur Steinagger 3
D - 51580 Reichshof-Eckenhagen
Deutschland

Easy Contact

Tel   +49-2265-12-0
Fax   +49-2265-12-22
e-mail   sales@elektrisola.de

Representatives

Dr. Detlef Schildbach
Dr. Oliver Schildbach
Peter Schildbach

Commercial Register

Elektrisola Dr. Gerd Schildbach GmbH&Co. KG
HRA 3950
at the local district court AG Siegburg
Complementary: Dr. Gerd Schildbach GmbH
HRB 7415
at the local district court AG Siegburg

Tax Office

Local Tax Office
Gummersbach
VAT Identification Number
DE122535202

Copyright

All rights reserved. No part of this publication (text, pictures, graphs) may be reproduced or transmitted in any form without permission in writing from Elektrisola. This copyright is held by Elektrisola Dr. Gerd Schildbach GmbH&Co. KG

EW Info

Enamelled Wire

General

Enamelled wire is a metallic conductor insulated with a varnish and generally used for electrical applications. Most times it is wound in different shapes of coils to generate magnetic force for motors, transformers, magnets etc. Elektrisola produces over 30,000 different types of enamelled wire with the most important differences of characteristics as follows:

Conductor Material

Copper is the standard used conductor material with excellent conductivity and very good windability. For low weight and larger diameters Aluminum sometimes can be used. Because of the difficult contacting of Aluminum wire with problems of oxidation Copper Clad Aluminum can help to compromise between Copper and Aluminum. For special applications a wide variety of conductor materials is offered, such as Brass, Silver, Nickel, Gold, Stainless Steel, or alloys of copper for special characteristics like higher mechanical strength or bending performance. In addition, the core conductors can be plated with different materials such as Silver or Nickel.

Metals

Bare Wire Diameter Range

Elektrisola specializes in fine diameters, starting with 0.008 mm (8 microns), and going up to a diameter of 0.50 mm. Beside the standardized diameters a big variety of special diameters is produced according to customer’s specification. Bare wire tolerances are very important as they have direct impact on the resistance what again determines the variance of the final coil resistance.

Technical Data by Size

Comparison of 0.010 mm wire with human hair

Outer Diameter

International standards like IEC group enamelled wires according to ranges of specific outer diameters. IEC groups the insulation in Grade 1, 2, or 3, NEMA in single, heavy, or triple, and JIS in class 0, 1, 2, or 3. The tolerances in these standards can be further restricted if necessary to design and optimize the wound coils and final products.

Technical Data by Size

Outer diameter control by laser

Selfbonding Layer

In addition to the base coat insulations described separately, a selfbonding layer can be applied, by which the wire will be bonded together for example for bobbinless coils, such as voice coils.

Selfbonding Wire Types

Transmitted light photo of selfbonding wire 0.09 mm AB15 green

V=200 X

Spool Types

Spool types have to fit to the wire size. Finer sizes are wound on smaller spools, while for heavy sizes very large spools can be used. They are important for productivity as larger spools require less spool changes on the winding machines.

Spools & Packaging

The wire length on one spool can be very long:

0.018 mm on spool 99L: up to 417 km
0.05 mm on spool 199L: up to 1143 km
0.30 mm on spool 400/630: up to 277 km

Insulation Types

Elektrisola offers a wide range of different insulations. Polyurethane has the advantage of easy direct contacting by soldering, while Polyester insulations are more resistant against higher temperatures. Thin top coats as Nylon or Polyamidimide may improve certain desired characteristics like mechanical or chemical strength.

Enamelled Wire Types

Colors

Colors may be used to differentiate wire types or diameters, but have the disadvantage of lower technical properties and higher costs.

Lubrication

A defined very low amount of lubrication – mostly special types of paraffin – is applied to achieve excellent windability of the wire in all winding processes without wire breaks.

Our Product Line

Elektrisola specializes in fine diameter and offers a wide range of products from 0.008 mm (8 microns) to 0.50 mm with many different enamel types on different conductor materials.

Diameters

For copper: 0.008 mm – 0.50 mm
For other metals: Please inquire

Specifications

Elektrisola produces enamelled wires according to many different specifications. The most important worldwide used specification is IEC, besides NEMA in North America and JIS in Asia.

Technical Data by Size

Enamel Types

Polyurethane
is a varnish which is easy for direct contacting by soldering, welding or crimping. Especially for fine wire the easy soldering is the most advantage of this enamel type. Polyurethanes are available with Temperature Index 155 °C (Polysol^© 155) and Temperature Index of 180 °C (Polysol^© 180). This enamel is available from 0.008 to 0.50 mm on all of our conductor materials.

Polyesterimides
are more resistant against higher temperatures and beside the pure Polyesterimide (Estersol^© 180) not usable for direct soldering. Under this enamel type also Theic-modified Polyesterimide (Amidester^© 200) or (Amidester^© 210) are listed.

Polyamidimides and Polyimides
have the highest temperature and chemical resistance and you will find them as I220 or ML240^© at ELEKTRISOLA product portfolio.

Enamel Wire Types

Based on the above mentioned enamel types, you can combine all these enamels with a self bonding coat such as Polyvinylbutyral, Polyamide or Polyester.

Selfbonding Wire Types

Selfbonding wire can be bonded by different methods

Bonding Methods

Production Process

Drawing process

For copper wires an 8 mm copper rod (5/16″ in USA) is used as raw material, which, through drawing dies, is drawn to the required bare wire size in several stages. The copper rod has to be of high purity and consistenly high quality to manufacture fine and ultrafine wires of sizes below 10 µm. ELEKTRISOLA uses only pure electrolytic copper ETP1 (copper content min. 99.99 %) from pre-approved high quality vendors.

The drawing process is carried out sequentially through several groups of machines producing specific diameter ranges. The wire is elongated in several stages through dies, so that the larger wire is permanently becoming thinner and longer during the drawing process while the volume remains unchanged.

Multiple drawing with cones

The quality of the copper, the fine tuning between the different drawing stages, and especially the quality of the drawing dies, are all of high importance to achieve a high quality final bare wire. The bearing surfxes of the wire drawing dies consist of natural or artificial diamonds or, for heavy wire production, of carbide.

Cross section of a drawing die

Enamelling Process

All wires are enamelled on special enamelling machines which are developed and produced by ELEKTRISOLA for our exclusive use. Enamelling is a continuous process, mainly consisting of the annealing process, enamel application, curing process, lubricant application, tension control and spooling.

1. Annealing Process
During the drawing process the bare wire’s grain structure has been changed through cold deformation. Annealing will re-crystalize the copper and make it soft again. This thermal stress relief process is carried out under protective atmosphere in order to avoid oxidizing the wire surface, which would interfere with good adherence of the initial coating of insulation later in the process. Softness of the wire is an important criteria for good windability, in particular significantly reducing the number of wire breaks.

2. Enamel Application
There are 2 main application systems for enamelling of winding wires, i.e felt application and die application, whereas felt application is mainly used in fine wire production, while die application is mainly used in heavy wire production. The enamel coating should always be applied in as many single layers as possible rather than fewer and thicker layers to achieve better mechanical and electrical properties.

3. Curing Oven
Solvents contained in the liquid enamel are driven out in the curing oven at high Temperature and then are burnt catalytically by using the thermal energy in an environmentally friendly way. Temperature control is very important: if the temperature is too low, too many solvent residues will be left in the enamel layer, leading to poor adhesion and reduced mechanical and electrical properties. If the temperature is too high, the enamel coating will be hard and brittle, leading to cracks in the insulation coating resulting from mechanical stress.

4. Lubrication
A defined amount of lubricant is precisely applied to the insulated wires surface. Lubrication is necessary to achieve consistent winding properties and failure-free winding of the wire even at high winding speeds.

5. Diameter Control
ELEKTRISOLA continuously monitors the Outer Diameter of all wires after the final pass by laser.

6. Tension Control
A continuous wire tension control during the enamelling process results in a consistently uniform spooling onto the spool. With effective tension control, elongation of the wire is avoided and thus a change in resistance. Furthermore, good de-reeling properties at the customer can be guaranteed.

7. Spooling
The wire pitch and the spool’s rotational speed are spooling process variables closely to be controlled. This results in consistently good wire de-reeling performance and minimizes other problems like trapped and tangled wires.

8. Monitor
The monitor informs the operator about all important parameters of the process.

Applications

Automotive

Appliances

Industrial Electronics

Audio and Video

Computer

Watches

Mars Rover

Technical data

Enamelled Wire

Enamelled Wire Types

There are different enamels available worldwide at Elektrisola. In addition, there are a few types available in selected continents.

Technical Data by Size

The most important technical data of enamelled copper wire are controlled by the resistance and outer diameter of the enamelled wire. These and other values are important as engineering support. Different standards specify these values differently, therefore the three major world standards are shown by size. IEC (International Electrical Commission) is the harmonized worldwide basic standard. NEMA and JIS still maintain additional elements of their older standards into their national standard.

Europe / Asia IEC 60317

Asia JIS C3202

America MW 1000C (inch)

America MW 1000C (metric)

Selfbonding Wire

Selfbonding Wire Types

For our self bonding wires there are typical enamel types available for the different markets, depending on the different standards and also on different main applications for the markets.

Europe

Asia (standard)

Asia (high performance)

America

Technical data by Size

The most important technical data of enamelled copper wire are controlled by the resistance and outer diameter of the enamelled wire. These and other values are important as engineering suport. Different standards specify these values differently, therefore the three major world standards are shown by size. IEC (International Electrical Commission) is the harmonized worldwide basic standard. NEMA and JIS still maintain additional elements of their older standards into their national standard.

Europe / Asia IEC 60317

Asia JIS C3202

America MW 1000C (inch)

America MW 1000C (metric)

Conductor Materials

For most of the applications copper is used as conductor material but for special applications like voice coils, actuator coils, or other special applications high performance metals are needed.

ELEKTRISOLA has a wide range of special conductor material, like low weight, high mechanical or bending performance metal. In addition, plated conductors are available which show superb characteristics for special applications.

Please contact us for metals not shown in the table.