Product Introduction
Rectangular Litz Wire is the profiled flat variant of Litz wire: multiple individually insulated fine copper strands are bundled, fully transposed during production, then compacted into a neat rectangular flat cross-section. The transposition design ensures every strand evenly distributes high-frequency current, effectively suppressing eddy current and proximity losses. Its biggest advantage is the adjustable thickness-width (T/W) ratio (max up to 20:1), which greatly improves the slot fill factor of motor stators and transformer coils compared with round Litz wire, boosting equipment power density and heat dissipation efficiency.
Our rectangular Litz Wire has been successfully applied to stator coil projects of China Aerospace Science and Industry Corporation's high-speed maglev & vacuum tube train, with mature mass production technology for rail transit, new energy vehicle motor, wireless charging and other high-end high-frequency fields.
Core Product Parameters
1. Production Range
- Single strand spec: φ0.1mm~φ1.0mm fine insulated strands, classic configuration φ1.000mm/78 strands available
- Cross-section customization: Thickness-width ratio adjustable from 1:1 to max 20:1, exact dimension matched to motor stator slot size
- Strand layout: Parallel arranged strands with full cyclic transposition before compression forming
2. Conductor Base Material
- Standard: High-purity oxygen-free copper wire
- Upgrade options: Tin-plated copper (easy soldering for terminal processing), silver-plated copper (high oxidation resistance for long-term high-temperature operation)
3. Insulation System
- Strand inner insulation: Polyester film enamel, polyamide enamel, multi-layer polyester composite film, thermal class B/F/H optional
- Optional outer reinforced wrapping: Polyester tape, polyimide tape for enhanced dielectric strength and mechanical protection in severe slot installation scenarios
4. Structural & Processing Features
Each copper strand completes full position transposition in the bundling stage; multi-strands are arranged in dense parallel rows, then precision pressed into flat rectangular ribbon structure, maintaining strand insulation integrity without damage during compaction.
Core Product Advantages
1. Industry-Leading Slot Fill Factor
Flat rectangular shape fits stator slot inner contour seamlessly, fill factor can reach 70%-75% (round Litz wire only 45%-55%), which allows motors to output higher power under the same core volume, or miniaturize motor size at equal power.
2. Stable Ultra-Low High-Frequency Loss
Full-process strand transposition eliminates unbalanced current distribution, eddy current loss remains extremely low even under variable high-frequency working conditions, long-term operation temperature rise is 8-12℃ lower than round wire windings.
3. Excellent Heat Dissipation Performance
Large flat contact surface closely fits the iron core, heat conduction path is more direct and uniform, avoiding local hot spots in coils, extending insulation service life significantly.
4. Strong Customization Compatibility
Adjust T/W ratio, strand count, insulation grade and total width/thickness to perfectly match different motor slot widths, winding pitches and voltage grades; support mass standardized production and small-batch customized R&D orders.
5. Proven High-End Project Reliability
Validated in national maglev train stator coil projects, adapting to vibration, wide temperature fluctuation and long-cycle continuous operation in rail transit scenarios.
Complete Production Flow
- Fine insulated copper strand feeding & pre-bundling
- Cyclic transposition for each strand to realize cross-section position switching
- Parallel dense arrangement of transposed strand bundles
- Precision cold pressing into rectangular flat profile with controlled T/W ratio
- Optional outer insulation tape wrapping
- Online inspection: dimension tolerance, insulation breakdown voltage, DC resistance, transposition consistency
- Meter counting & spool take-up
- Shockproof moisture-proof export packaging
Typical Application Fields
- Maglev train & high-speed rail traction motor stator coils
- New energy vehicle drive motor stators
- High-power wireless charging transmitting/receiving coils
- Large high-frequency power transformer windings
- Industrial high-efficiency permanent magnet motors
- Aerospace electromagnetic winding components
Packing & Logistics
Packaging Options
- Inner spools: Cylindrical wooden/plastic spools, tapered plastic spools for flat wire orderly winding
- Outer export packing: IPPC fumigated wooden pallets & wooden cases; domestic conventional wooden pallets
- Independent foam isolation for each spool to prevent flat cross-section extrusion deformation during transport
Shipping Methods
Available via sea, air, road and container logistics, global door-to-door delivery service supported.
Frequently Asked Questions
Q1: What's the maximum thickness-width ratio you can achieve?
A: Our mature technology supports max T/W ratio up to 20:1, we optimize the ratio according to your slot space and loss requirements.
Q2: Can rectangular Litz Wire be bent during winding?
A: It has excellent flexible performance for flat-direction repeated bending; we provide bending parameter suggestions to avoid cross-section deformation and insulation damage.
Q3: What insulation temperature grades can you offer?
A: Polyester (Class B 130℃), Polyamide (Class F 155℃), multi-layer polyester composite (Class H 180℃) for selection.
Q4: Do you offer free test samples for motor slot matching?
A: Standard samples are free, you only cover shipping cost; we can tailor sample dimensions for your slot trial winding.
Q5: How to clean the rectangular Litz Wire surface?
A: Use dry soft cloth to wipe dust, never use corrosive organic solvents to prevent insulation layer erosion.
Q6: Can I customize the number of strands?
A: Fully customizable, we adjust strand quantity and single wire diameter to balance loss performance, flexibility and slot filling rate.
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