Litz Wire Types & Applications - Metalitz
Simple Twisted (Type 1)
Type 1 Litz wire is the simplest and most commonly used variety in applications where reducing losses is a priority. This design involves individually insulated strands twisted together, offering better current distribution and reducing resistance at higher frequencies.
Construction
- Strands: The number of strands is determined based on the current capacity and frequency.
- Standard Insulation: Typically insulated with enamel, but materials like silk or polyurethane can also be used.
- Customized Insulation: Depending on specific requirements, insulation materials like PTFE, nylon, or polyester can be added for enhanced durability and performance.
- Applications: Ideal for use in small transformers, RF inductors, and other high-frequency AC applications.
Grouped Twisted (Type 2 )
Type 2 Litz wire improves upon Type 1 by grouping multiple twisted strands together, making it more suitable for higher frequencies. This construction minimizes the skin effect and proximity effect more effectively, offering higher efficiency.
Construction
- Construction: Bundles of twisted Type 1 strands are further twisted together for better surface area and current distribution.
- Strands: Made up of individually insulated strands that are grouped for high-frequency use.
- Standard Insulation: Common materials like enamel or polyurethane.
- Customized Insulation: Insulation options like silk, textile yarn, or extruded compounds can be added for additional mechanical or thermal protection.
- Applications: Frequently used in power inductors and high-frequency transformers.
Multi Grouped Twisted (Type 3)
Type 3 Litz wire is more complex, suitable for high-power and high-frequency applications. It offers a more refined design to reduce AC losses in systems like motors and power inductors.
Construction
- Construction: Multiple Type 2 bundles are twisted together in a hierarchical arrangement for enhanced performance.
- Strands: Each strand is individually insulated, improving current distribution and reducing overall resistance.
- Standard Insulation: Typically insulated with polyurethane or polyimide.
- Customized Insulation: For high-temperature applications, PTFE, polyester, or silk insulation can be used.
- Applications: Commonly used in high-frequency motors, inductors, and RF circuits where power loss reduction is essential.
Braided (Type 4)
Type 4 Litz wire handles extremely high frequencies and is optimized for current-carrying capacity. It is widely used in applications where efficiency at high frequencies is crucial.
Construction
- Construction: It consists of multiple twisted Type 3 bundles, providing optimal performance.
- Strands: Insulated strands ensure maximum efficiency at high frequencies.
- Standard Insulation: Materials like PTFE, polyimide, or polyurethane are used to provide strong thermal and electrical insulation.
- Customized Insulation: Can be upgraded with extruded compounds or yarn for better performance in challenging environments.
- Applications: Ideal for RF transformers, power inverters, and wireless charging systems.
Group Braided (Type 5)
Type 5 Litz wire is designed with a central fiber core for added mechanical strength. It is often used in heavy-duty applications, such as in the aerospace and automotive sectors, where structural durability is critical.
Construction
- Construction: Bundles of Type 2 Litz wire are twisted around a fiber core, offering increased mechanical integrity.
- Strands: The core supports the structure, ensuring stability.
- Standard Insulation: Textile yarn, tape, or extruded compounds can be used for outer insulation.
- Customized Insulation: Nylon, polyester, or PTFE insulation can be provided for enhanced performance in harsh conditions.
- Applications: Used in automotive systems, aerospace components, and high-frequency transformers.
Multi-Grouped Braided (Type 6)
Type 6 Litz wire combines the high-frequency efficiency of Type 4 with the structural benefits of a fiber core. It’s designed for use in environments where space constraints are significant.
Construction
- Construction: Bundles of Type 4 wires are twisted around a central core, creating a round geometry.
Strands: Highly flexible with the ability to carry large currents in compact spaces. - Standard Insulation: Options include nylon, polyester, or PTFE for added mechanical protection.
- Customized Insulation: Insulation materials like polyimide or silk can be added based on the environmental conditions.
- Applications: Ideal for wireless power transfer, wireless charging, and other compact, high-frequency systems.
Insulated Strands (Type 7)
Type 7 Litz wire has a unique rectangular profile, making it perfect for applications where efficient use of space is critical. This wire is commonly used in grounding and specialized inductor designs.
Construction
- Construction: Braided, film-insulated magnet wire, formed into a rectangular shape.
- Strands: Provides a high aspect ratio with a lower copper fill factor, typically between 45% and 55%.
- Standard Insulation: Textile yarn or extruded compounds for added protection.
- Customized Insulation: Additional materials like tape, PTFE, or polyimide can be chosen based on space, heat, and mechanical requirements.
- Applications: Widely used in grounding applications and high-frequency systems where space is a limiting factor.
Customized Specification Type 8
Type 8 Litz wire is designed for high-frequency applications that require a compact form factor and excellent copper density. It’s ideal for use in applications with space constraints, such as medical devices and power supplies.
Construction
- Construction: Strands are twisted and compressed into a rectangular or oval profile, maximizing copper density.
- Strands: Copper density ranges between 60% to 75%, providing high-efficiency current flow.
- Standard Insulation: Textile yarn, tape, or extruded compounds provide protection from environmental factors.
- Customized Insulation: Polyimide, PTFE, or silk can be added to meet high-performance and specific environmental demands.
- Applications: Commonly used in high-frequency medical devices, power supplies, and space-constrained systems.
