Patient Safety First: Standard-Compliant Transformer Windings according to IEC 61558
PACK LitzWire supported a manufacturer of medical devices in developing HF litz wires for isolation transformers that meet the highest insulation standards while saving space.
The Application
For a medical technology manufacturer, PACK LitzWire accompanied the optimization of isolation transformers in high-frequency surgery equipment and imaging systems. The goal was to design the windings in such a way that patient protection (MOPP) and maximum dielectric strength were guaranteed without sacrificing miniaturization and efficient construction.
The Challenge
The challenges lay in strict compliance with the IEC 61558 and IEC 60601 standards. The transformers had to maintain large creepage and clearance distances to ensure reinforced or double insulation, while remaining compact. Conventional windings required too much space for tape layers and could not utilize the installation space optimally.
The HF-optimized isolation transformer shows a compact winding design in which reinforced insulation and patient protection according to IEC standards are already implemented at the conductor and winding level.
The multi-insulated HF litz wire enables high dielectric strength and safe creepage distances without requiring additional space for tape layers – a central prerequisite for MOPP-compliant medical technology.
Solution Strategy
PACK LitzWire recommended litz wires with multiple extruded insulations (Triple Insulated Wire concepts) and foil insulation, which enabled reinforced insulation directly on the conductor. This measure allowed for more efficient use of the winding space. In addition, PACK LitzWire supported the customer in material selection, provided complete data sheets and UL approvals, and advised on the winding process to avoid micro-cracks in the insulation.
Result
Thanks to these solutions, the manufacturer was able to realize a significantly more compact transformer that complied with strict safety clearances and was easily certified. The pre-tested materials and optimized litz wire construction accelerated the certification process and ensured the high safety and efficiency of the medical device.
RUPALIT® Plus with Extrusion
Extrusion with fluoropolymers achieves the highest chemical resistance and individually adjustable insulation thicknesses for demanding environments.
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