Conductive Flexibility: Highly Resilient Litz Wires for Smart Textiles
Wearables & Sensor Technology
PACK LitzWire supported a manufacturer of functional sensor clothing in developing extremely flexible, miniaturized litz wires that withstood high bending cycles and washing processes without compromising the basic textile structure.
The Challenge
Conventional copper wires failed in this application: they broke quickly under constant movement and bending cycles. PACK LitzWire therefore recommended the use of copper litz wire and high-strength alloys such as copper-silver, which significantly increased splice and tensile strength without substantially reducing conductivity. Due to extremely fine individual wires (0.025 mm), the litz wire could be designed with maximum flexibility, so that it was perfectly integrated into the fabric.
Conductive textile modules with integrated litz wires for smart textile applications. The flexible conductor structures are suitable for wearables and sensor systems and enable reliable signal and energy transmission with high mechanical resilience.
Solution Strategy
The conductors were provided with a highly resistant polyurethane lacquer, supplemented by an extrusion coating to repel sweat, detergents, and corrosion. Nylon covering ensured the necessary mechanical stability.
Result
The result was a textile litz wire that far exceeded the required bending cycle and splice strengths. The customer was able to bring a smart textile to market that was fully washable and perceived by the end customer as comfortable clothing.
RUPALIT® Plus
RUPALIT® Plus offers reinforced electrical protection for demanding high-voltage applications while optimizing HF losses. The integrated multi-layer insulation allows for space-saving designs without compromising safety.
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