Litz and Formed Cables

In 1898, New England Wire became the first company in the United States to manufacture Litz wire on a commercial basis. Since then, we have designed and manufactured thousands of constructions for use over the E.L.F. through H.F. frequency ranges. Typical applications for Litz conductors include high frequency inductors and transformers, inverters, communication equipment, ultrasonic equipment, sonar equipment, television and radio equipment and induction heating equipment. We have also provided cabling, insulating and other services to the superconductor industry since its inception in the early 1960s. Our products are also integrated into all the major accelerator projects, ore separator magnets, NMR magnets and superconducting magnetic energy storage magnets.

New England Wire works closely with our suppliers and leverages our own expertise to provide magnet wire materials that meet the needs of the specific applications. We routinely supply Litz Constructions using magnet wires with standard NEMA and IEC enamels. We have also designed and manufactured Litz both rounded and shaped using bondable, PTFE, Ceramic or glass fiber magnet wire. See charts in technical details for more information on magnet wire films.

Theory: Typically the design engineer requiring the use of Litz knows the operating frequency and RMS current required for the application. Since the primary benefit of a Litz conductor is the reduction of A.C. losses, the first consideration in any Litz design is the operating frequency. The operating frequency not only influences the actual Litz construction, but is also used to determine the individual wire gauge. Click here for additional information and formulas.

Types & Constructions: Litz constructions Types 1 through 6 are all designed to be round and vary from a simple bunch of conductors (Type 1) to complex designs utilizing multiple cores and several manufacturing operations (Type 6). Type 7 and Type 8 Litz constructions are used where special designs require high aspect ratio conductors or high fill factor and copper density.

Formed & Compacted: New England Wire has pioneered the development of formed and compacted Litz designs including square, rectangular, and keystone-shaped configurations. Click here for design considerations.

NEWind® Winding Wire: We have solved the problem of insulation loss between winding turns, separate windings and between the winding and the ground by insulating our custom wire and cable in single-end, stranded and Litz wire multiconductor cable configurations. The result is motors and transformers that can be manufactured without additional insulation using our propriety NEWind® Winding Wire, thus reducing their cost and size.

NE-F1 Insulation System: Electrical insulation systems are invaluable to coil and transformer designers as they eliminate the need for long term component testing. Combining the regulatory approvals of NE-F1 with the capabilities and experience of New England Wire Technologies at producing high performance winding wire products allows us to provide unique solutions to meet design challenges associated with today's winding needs.

Custom Options: We have a multitude of magnet wire enamels and gauge sizes available as well as fiber, tape and extruded insulations to suit your specific application requirements.

Click here for our Litz Wire Termination Guide.

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