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Connect litz wire to copper blade

Discussion in 'Electronic Basics' started by [email protected]_KB-PM, Aug 27, 2003.

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  1. Hi,
    I'm trying to find a way to connect a AWG24 litz wire to a copper current
    blade 4.5 x 0.75 x 0.1 inch. Soldering by using a standard solder bolt doesn
    't
    work properly because of the copper heat conductivity/capacity.
    I wonder if resistance welding or soldering might be a possible way?
    The process should be capable for large scale production.
    Appreciate your ideas!
    Thanks, Michael
     
  2. Michael wrote...
    We treat the litz-wire ends in a solder pot. It's necessary
    to coat the litz wire first with flux, no success otherwise.
    Once the litz is tinned you can use conventional methods...

    Thanks,
    - Win
     
  3. Gary Coffman

    Gary Coffman Guest

    Each strand of Litz wire is separately insulated (that's what makes it
    Litz wire). You have to strip that insulation off before it will take solder.
    There are chemical dips you can use to do this with some insulation
    formulations. Consult the wire manufacturer for the recommended
    stripping method.

    To handle the heatsink issue, use a torch (or hot plate) to preheat
    the copper before attempting to make the joint. The whole thing
    doesn't have to be brought to soldering temperature. It just has to
    be hot enough to reduce its ability to sink soldering heat away from
    the joint. You don't want to heat it so much that it oxidizes. Since
    heat flow is proportional to the fourth power of temperature difference,
    250 F should be plenty of preheat.

    Gary
     

  4. Since I didn't have a clue as to what Litz wire was, here's more than you
    ever wanted to know about Litz wire:
    http://www.mwswire.com/litzmain.htm
    The term litz wire is derived from the German word litzendraht meaning
    woven wire. Generally defined, it is a wire constructed of individual film
    insulated wires bunched or braided together in a uniform pattern of twists
    and length of lay.

    The multistrand configuration minimizes the power losses otherwise
    encountered in a solid conductor due to the "skin effect", or the tendency
    of radio frequency current to be concentrated at the surface of the
    conductor.

    In order to counteract this effect, it is necessary to increase the amount
    of surface area without appreciably increasing the size of the conductor. It
    is also essential to position each individual strand in the litz
    construction in a uniform pattern moving from the center to the outside and
    back in a given length.

    Even properly constructed litz wires will exhibit some skin effect due to
    the limitations of stranding. Wires intended for higher frequency ranges
    require more strands of a finer gauge size than litz wires of equal cross
    sectional area but composed of fewer and larger strands.

    Polyurethane is the film most often used for insulating individual strands
    because of its low electrical losses and its solderability. Other
    insulations can also be used. Litz wires are generally further insulated
    with a single or double wrap or serving, of a textile-typically nylon-but
    are also available unserved.

    r/

    Steve

    Bremerton, WA
     
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