Maximum Efficiency at Every Frequency

RUPALIT® is the gold standard among high-frequency litz wires. By optimally stranding up to several thousand thin, enamelled copper strands, the effective surface area is maximized while loss effects are minimized. The results: significantly reduced eddy current losses, lower heat generation in demanding applications, and substantially higher efficiency. RUPALIT® litz wires enable both size reduction and long-term component reliability. With cross-sections ranging from fine wires to several hundred mm², we tailor our solutions to your specific technical requirements.

Key Advantages:

• Increased overall component efficiency due to lower power loss.
• Improved heat dissipation within the winding.

Our aluminum litz wires are the ideal solution for applications requiring reliable electrical conductivity combined with minimum weight. By utilizing high-purity aluminum strands and precise stranding technology, we ensure constant electrical properties, high flexibility, and a cost-effective alternative to copper-based conductors. With individual cross-sections and customized designs, our litz wires offer a reliable foundation for modern electrical engineering applications.

Key Advantages:

• Significant weight reduction compared to copper conductors.
• Good electrical conductivity (approx. 62% IACS).
• Excellent formability and flexibility.
• Good corrosion resistance.
• Economical solution for high-current applications.

RUPALIT® Plus enhances our proven technology with specialized insulation coverings. This additional outer layer significantly improves dielectric strength and breakdown voltage (kV) – ideal for high-voltage applications and safety-critical systems. RUPALIT® Plus combines the HF efficiency of our standard litz wire with reinforced electrical protection. It was designed for engineers who refuse to compromise on safety or performance.

Key Advantages:

• Increased dielectric strength – up to 10× higher than standard RUPALIT®.
• Eliminates the need for separate interlayer insulation (direct winding), saving material costs and assembly time.
• Reduced EMC susceptibility.
• Enhanced durability in humid or chemically aggressive environments.
• Continuous quality monitoring of insulation during manufacturing.

RUPALIT® Safety revolutionizes transformer and inductor design through a sophisticated triple-insulated structure. The HF litz wire is protected by a reinforced, taped foil insulation – an innovative design that defines industry standards. This construction eliminates the need for separate interlayer insulation or potting. The result: 50% size reduction, 65% weight savings, and up to 70% faster winding processes. RUPALIT® Safety is VDE-certified (IEC 60950) and provides essential safety for critical applications.

Key Advantages:

• VDE-certified breakdown strength up to 1000 Vrms (14140 Vpeak).
• Eliminates interlayer insulation, saving assembly time and material costs.
• Integrated clearance and creepage distances meet safety standards.
• Significant reduction in transformer size and weight.
• Ready for immediate use – no impregnation or potting required.
• Also available as RUPATEX® Litz Wire – with a further reduced outer diameter.

RUPALIT® Profile utilizes a square or rectangular cross-section instead of the traditional round shape – developed in 1985 as a groundbreaking response to customer requirements. This geometry has a powerful effect: it optimally exhausts the available winding space. The copper fill factor increases, the number of layers decreases, and the power density per component rises significantly. RUPALIT® Profile is the preferred choice for maximizing volume efficiency without compromising electrical performance or HF effectiveness.

Key Advantages:

• Reduces the number of turns for an identical copper cross-section.
• Maximum space utilization – more copper in the same component volume compared to round litz.
• Compact design allows for bobbinless winding, reducing manufacturing costs.
• Higher efficiency due to optimized fill factor and reduced specific losses.
• Available as RUPALIT® Safety Profile for safety-critical applications.
• Fully automated winding capability increases reproducibility and lowers unit costs.

RUPALIT® Plus Profile is the answer to the challenge of achieving maximum dielectric strength within extremely tight installation spaces. By combining precision outer insulation with a profiled geometry, we optimize the winding window to the fullest. The additional insulation improves breakdown strength by up to 10× compared to standard litz wires.

Key Advantages:

• Fewer turns required due to superior space utilization.
• Eliminates the need for separate interlayer insulation (direct winding).
• Increased power density and improved thermal dissipation.

RUPALIT® Safety Profile combines VDE-certified safety with the extreme packing density of a profiled geometry. The square or rectangular profile ensures every millimeter of available space is utilized, while the sealed foil insulation guarantees dielectric strength up to 1000 Vrms.

Key Advantages:

• Size reduction up to 50% with an improved fill factor.
• No impregnation or potting required; ready for immediate use after winding.
• Significant weight reduction and up to 70% faster winding processes.

RUPALIT® Planar is the solution for high-current and high-power applications where conventional round litz wires reach their limits. Multiple RUPALIT litz wires are arranged in parallel on a single plane rather than being wound on top of each other. This geometry minimizes stray inductance, reduces hot spots through uniform current distribution, and enables field-compensated windings. With cross-sections up to 150 mm², it is specifically designed for high-output transformers and induction heaters.

Key Advantages:

• Drastic reduction in stray inductance via field-compensated parallel arrangement.
• High current capacity with minimal outer profile.
• Simplified manufacturing for multi-conductor transformers – more reproducible than multi-layer windings.