Conventional solid conductor winding technologies show its shortcomings as electrical vehicles develop towards high power, speed and efficiency. When operating frequencies raise up, significant AC losses in motor windings will often happen due to skin effect and proximity effect, which reduces overall drivetrain efficiency. Developed as a proven solution to these challenges, litz wire design enables modern traction motors to achieve good performance demanded by next-generation powertrains.

One of advantage of litz wire is its ability to mitigate high-frequency losses. Due to skin effect, AC current is toward surface as frequency increases, generating resistive losses and heat. Litz wire, made of multiple strands of single wire can distribute current evenly across each strand, considerably reducing AC resistance and enabling motors to operate more efficiently at high speeds. Research shows that hybrid rectangular litz wire winding can reduce AC losses by a round 34% compared to solid hairpin designs, about 37.2% loss reduction in high-power-density traction motors.

Except for loss reduction, rectangular profiled litz wire saves space for compact motor designs, heat dissipation and higher continuous power output performance is better than single turn.

In terms of different applications, various types of serving materials can be chosen, mostly nylon, polyester, fiberglass, natural silk etc.

Nylon yarns provides excellent mechanical protection, abrasion resistance, and a low friction efficient that is good for winding process. Thermal class up to 180°C, litz wire with nylon serving is an ideal option for high frequency transformers, EV charging station, and motor windings.

Fiberglass has super high-temperature performance, with some constructions rated for continuous operation at temperatures 350°C+. Glass insulation is particularly suitable for heavy-duty commercial vehicle traction motors and aerospace powertrain.

While natural silk offers outstanding flexibility and dimensional stability, with excellent dielectric properties, super for hf transformers, inductors, and precision winding applications. It works reliably in electrical environments because of its inherent strength and elasticity.

As powertrains evolve into higher switching frequencies, the requirements for winding conductors tend to become more important. No matter what properties you require, mechanical properties of nylon, thermal resilience of glass silk, or the precision of natural silk, we can offer a wide range of solutions to address the most demanding powertrain challenges.