Latest Breakthrough of Litz Wire 0.025mm*28 OFC Conductor

Being an outstanding player in the advanced magnet wire industry, Tianjin Ruiyuan hasn’ t stopped for a second on the way to improve ourselves, but keep on pushing ourselves for innovation of new products and design to continuously provide services for realizing our customer’ s thoughts. Upon receiving a new request from our customer, bundling super fine enameled copper wire 0.025mm to form 28 strands litz wire, we face several challenges due to the delicate nature of the materials of 0.025mm oxygen free copper conductor and the precision required in the process.

The primary difficulty lies in the fragility of the fine wires. Super fine wires are prone to breaking, tangling, and kinking during handling, making the bundling process delicate and time-consuming. The thin enamel insulation on each wire is also susceptible to damage. Any compromise in insulation can lead to short circuits between strands, defeating the purpose of Litz wire.

Achieving the correct stranding pattern is another challenge. The wires must be twisted or braided in a specific way to ensure even current distribution at high frequencies. Maintaining uniform tension and consistent twists is crucial but difficult when working with such fine wires. Additionally, the design must minimize proximity effect and skin effect** losses, which requires precise positioning of each strand.

Handling these wires while retaining flexibility is also tough, as improper bundling can lead to stiffness. The bundling process must maintain the required mechanical flexibility without compromising electrical performance or damaging the insulation.
Furthermore, the process demands high levels of quality control, especially in mass production. Even minor variations in the wire diameter, insulation thickness, or twist pattern can degrade performance.

Lastly, termination of Litz wire—where multiple fine wires must be properly connected—requires special techniques to avoid damaging the strands or insulation, while ensuring good electrical contact.

These challenges make our bundling super fine enameled copper wire into Litz wire a complex, precision-driven process. With the help of our advanced equipment and experienced professional staff, we have successfully completed the production of such litz wire of 0.025*28, made by oxygen free copper conductor and have received approval from our customers.