Extremely Robust HF Litz Wires for Military Electronics
PACK LitzWire Consulting in the Defense Sector
For a manufacturer in the defense industry, an HF litz wire solution was developed that operates reliably even under extreme stresses such as shocks, vibrations, and EMC influences.
The Challenge
In a project for military transformers and filters, an HF winding was developed that met the high requirements for currents, thermal loads, and mechanical stresses. Despite limited space, the components had to deliver stable performance and function reliably even under EMC-relevant conditions.
The compact ferrite core assembly with highly insulated HF litz wire is designed for extreme mechanical, thermal, and electromagnetic loads and supports reliable use in military electronic applications.
The multi-insulated HF litz wire with dense bundling and precise routing through the ferrite core underscores the robust insulation and EMC concept for highly reliable military systems.
Solution Strategy
Highly insulated RUPALIT® litz wires with triple-layered silicone insulation were used for this purpose. The fine litz structure distributed the current evenly, preventing hotspots and minimizing AC losses. At the same time, the multilayer insulation provided both mechanical strength and high dielectric strength. The design took into account requirements for the litz wire regarding an EMC-optimized winding arrangement and specially matched ferrite cores to optimize magnetic flux guidance.
Result
The final HF winding achieved exceptional robustness and reliability. Even under extreme military conditions, such as high switching currents, vibrations, or temperature fluctuations, the transformer demonstrated consistent stability and efficiency.
RUPATEX® Litz Wire
Maximum resilience for demanding windings. Wherever standard high-frequency litz wires reach their mechanical or electrical limits, extruded litz wires offer the optimal solution. By sheathing with high-quality thermoplastics, these cables combine excellent high-frequency properties with the protection of a robust outer skin.
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