Flat HF Transformers
Specialized Litz Wires for Flat Windings in Aerospace
PACK LitzWire, together with an aviation manufacturer, developed an HF litz wire solution for extremely flat transformers that safely conducts high currents and remains reliable even under extreme conditions.
The Challenge
For an aircraft transformer, PACK LitzWire worked on a high-frequency optimized, flat winding that also had to safely conduct high currents.
The challenge was to meet the stringent low-profile constraints, avoid hotspots in the inner windings, and withstand extreme aerospace conditions such as vibrations, shocks, and moisture.
Flat-designed high-frequency transformer with profiled HF litz wires, designed for high currents and a particularly low construction profile.
Detail of the profiled RUPALIT® Planar litz wire with high copper fill factor for uniform current distribution in flat windings.
Solution Strategy
PACK LitzWire recommended the use of RUPALIT® Planar, a profiled HF litz wire with a rectangular cross-section. This profile enabled a high copper fill factor and could be ideally integrated into flat coils. The angled arrangement of the individual wires minimized hotspots. A resistant polyimide coating also ensured mechanical stability, insulation, and thermal resistance under demanding aerospace conditions.
Result
Thanks to these solutions, the manufacturer was able to realize a significantly more compact transformer that complied with strict safety clearances and streamlined the certification process. The pre-tested materials and optimized litz wire construction accelerated the certification process and ensured the high safety and efficiency of the application.
RUPALIT® Planar
This elegant geometry minimizes stray inductances and enables field-compensated windings for high-performance applications. Ideal for transformers with high output current and induction heating up to the kW range.
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