Litz Wire Conductors differ from typical conductors in that each strand of conductor material is individually insulated with a thin enamel coating that must be removed prior to termination and use in the end application. As each Litz Wire Conductor construction and application is unique, there is no single, best process and you may need to experiment with different processing set ups to determine the ideal termination method for your process.

The information below is intended to provide you with ideas and general recommendations for determining which process will best suit your application and manufacturing operation. Once properly prepared, Litz Wire Conductors can be terminated using any standard crimp, soldering or ultrasonic method suitable for use with typical stranded copper conductors.

Solderable Enamels

Most Litz Wires are manufactured using enamels with a thermal class rating from 155°C to 180°C and an enamel coating derived from either a polyurethane or polyester based system. These coatings are designed to be directly soldered and immersion into a solder pot is an effective method for terminating Litz Conductors. It is generally recommend that you select a solder pot with the ability to maintain the solder temperature up to 500°C. A pot with a capacity of 5 lbs (2,2 kg) is recommended for litz conductors with diameters up to .250” (6,3mm). Contact your solder pot supplier for proper sizing requirements for larger constructions and solder composition.

Enamel Thermal Class

Recommended Solder Temperature

Immersion Time seconds [OD range]

155°C 415°C—430°C 5—20 [.020” – .250”]
180°C 470°C—485°C 10—25 [.020” – .250”]

Soldering in properly ventilated area along with the use of a heat sink is always recommended to ensure operator safety. Follow all manufacturer guidelines for
operation and safe handling of materials. The use of flux during soldering may also improve overall solder quality for larger diameter constructions with very high strand counts and designed with higher thermal class enamels.

Additional Resources for Terminating Litz Wire Conductors

Mechanical The Eraser Company
Chemical Ambion Corportation
Molten Salt The Eraser Company (Dip Strip®)
Brazing Oweld S.n.C
Wire Fusing Strunk Connect Automated SoluƟons
Joyal—div. of Alliance Winding Equipment

Non‐Solderable Enamels

Most higher thermal class enamels, those designed to operated at temperatures above 180C, require that enamel be removed from the individual wires prior to termination.

For larger diameter wires, a mechanical method such as fine-grit sandpaper or a rotating brush system can prove to be very effective in removing the enamel coatings.

The use of chemical stripping agents or molten salts, along with proper cleaning steps typically prove most effective when dealing with litz conductors with fine wire diameter and high strand counts.

Additionally, Brazing and Wire Fusing techniques have also be shown to be effective for preparing litz wire for terminating.

The adjacent table lists additional resources that can assist you determine the best method for preparing litz wire conductors for termination in your application.