Triple Insulated Litz Wire-ETFE FEP and FPA insulation optional

Triple insulated Litz wire is increasingly recognized for its ability to enhance performance.Especially micro litz wire,such as 30AWG-40AWG,big size (such as 13AWG avaible too).tripple insulation enhance its electronic performance and mechanical performance .

Not only mirco litz wire need to be triple insulated. Big section area litz wire can also use 3 layers insulation to enhace their performance

Understanding Triple Insulated Litz Wire

Triple insulated Litz wire consists of  one single conductor or multiple insulated conductors twisted together, surrounded by three layers of insulation. This construction significantly reduces energy losses and minimizes signal distortion, making it ideal for applications such as transformers, motors, and high-frequency communication devices.

Triple insulated Litz wire presents a powerful solution for high-frequency applications, balancing the challenges of design and production with significant benefits. As a manufacturer specializing in this technology（only only triple insulated litz wire,double insulated litz wire available too ）, we offer customized solutions using ETFE, PFA, and FEP insulation materials, along with free samples to help you make informed decisions. By choosing triple insulated Litz wire, you can enhance the performance and reliability of your electrical systems.

Following are some Single insulated,Double insulated and triple insulated litz wire

Insulation Thickness:

• PFA:0015″ min per layer
• FEP:002″ min per layer
• ETFE:0015″ min per layer

Voltage Rating:

• single layer 600 Vpk
• Double layers 1000 Vpk
• Triple layers 1000 Vpk

Temperature Rating:

• PFA:UL/VDE Class H 180℃
• FEP:UL/VDE Class H 180℃
• ETFE:UL/VDE Class F 155℃

Dielectric Strength:

• PFA:2000V/mil nominal
• FEP:2000V/mil nominal
• PFA:1800V/mil nominal

PFA insulated conductor Litz wire
FEP insulated conductor Litz wire
ETFE Insulated conductor Litz wire
PFA insulated conductor Litz wire

Conductor				Single Insulated		Double Insulated		Triple Insulated
AWG	OD(m m)	DC Resistance		Part Num ber	OD(mm)	Part Number	OD(mm)	Part Number	OD(mm)
		Bare	Tinned
18	1.02	6.516	6.995			YL18D1.5PXXTC1A	1.176	YL 18T 1.5PXXXTC1A	1.252
19	0.912	8.211	8.815			YL19D1.5PXXTC1A	1.064	YL 19T1.5PXXXTC1A	1.140
20	0.813	10.33	11.09			YL20D1.5PXXTC1A	0.965	YL 20T1.5PXXXTC1A	1.041
21	0.724	13.03	13.99			YL21D1.5PXXTC1A	0.876	YL 21T1.5PXXXTC1A	0.952
22	0.643	16.53	17.75	YL22S1.5PXTC1A	0.719	YL22D1.5PXXTC1A	0.795	YL 22T1.5PXXXTC1A	0.871
23	0.574	20.72	22.24	YL23S1.5PXTC1A	0.65	YL23D1.5PXXTC1A	0.7 26	YL 23T1.5PXXXTC1A	0.802
24	0.511	26.19	28.12	YL24S1.5PXTC1A	0.587	YL24D1.5PXXTC1A	0.663	YL 24T1.5PXXXTC1A	0.739
25	0.455	33.03	35.46	YL25S1.5PXTC1A	0.531	YL25D1.5PXXTC1A	0.607	YL 25T1.5PXXXTC1A	0.683
26	0.404	41.86	44.94	YL 26S1.5PXTC1A	0.48	YL26D1.5PXXTC1A	0.556	YL 26T 1.5PXXXTC1A	0.632
27	0.361	52.48	56.34	YL27S1.5PXTC1A	0.437	YL27D1.5PXXTC1A	0.513	YL 27T1.5PXXXTC1A	0.589
28	0.32	66.66	71.56	YL28S1.5PXTC1A	0.396	YL28D1.5PXXTC1A	0.472	YL 28T1.5PXXXTC1A	0.548
29	0.287	82.88	88.97	YL29S1.5PXTC1A	0.363	YL29D1.5PXXTC1A	0.4 39	YL 29T1.5PXXXTC1A	0.515
30	0.254	105.8	113.6	YL30S1.5PXTC1A	0.33	YL30D1.5PXXTC1A	0.406	YL 30T1.5PXXXTC1A	0.482
31	0.226	133.9	143.8	YL31S1.5PXTC1A	0.302	YL31D1.5PXXTC1A	0.378	YL 31T1.5PXXXTC1A	0.454
32	0.203	166.2	178.4	YL32S1.5PXTC1A	0.279	YL32D1.5PXXTC1A	0.355	YL 32T1.5PXXXTC1A	0.431
33	0.18	211.7	228.2	YL33S1.5PXTC1A	0.256	YL33D1.5PXXTC1A	0.332	YL 33T1.5PXXXTC1A	0.408
34	0.16	269.8	289.6	YL34S1.5PXTC1A	0.236	YL34D1.5PXXTC1A	0.312	YL 34T1.5PXXXTC1A	0.388
35	0.142	342.8	368.1	YL35S1.5PXTC1A	0.218	YL35D1.5PXXTC1A	0.294	YL 35T1.5PXXXTC1A	0.37
36	0.127	431.9	463.7	YL36S1.5PXTC1A	0.203	YL36D1.5PXXTC1A	0.279	YL 36T1.5PXXXTC1A	0.355
37	0.114	535.7	575.1	YL37S1.5PXTC1A	0.19	YL37D1.5PXXTC1A	0.266	YL 37T1.5PXXXTC1A	0.342
38	0.102	681.9	732	YL38S1.5PXTC1A	0.178	YL38D1.5PXXTC1A	0.254	YL 38T 1.5PXXXTC1A	0.33
39	0.089	897.1	963.1	YL39S1.5PXTC1A	0.165	YL39D1.5PXXTC1A	0.241	YL 39T1.5PXXXTC1A	0.317
40	0.079	1152	1237	YL40S1.5PXTC1A	0.155	YL40D1.5PXXTC1A	0.231	YL40T1.5PXXXTC1A	0.307

FEP insulated conductor Litz wire

Conductor				Single Insulated		Double Insulated		Triple Insulated
AWG	O D(m m)	DC Resistance		Part Number	OD(mm)	Part Num ber	OD(mm)	Part Number	OD(mm)
		Bare	Tinned
18	1.02	6.516	6.995	YL 18S2.0FXTC1A	1.12	YL 18D2.0FXXTC1A	1.22	YL 18T2.0FXXXTC 1A	1.32
19	0.912	8.211	8.815	YL 19S2.0FXTC1A	1.012	YL 19D 2.0FXXTC 1A	1.112	YL 19T2.0FXXXTC 1A	1.212
20	0.813	10.33	11.09	YL 20S2.0FXTC 1A	0.913	YL 20D2.0FXXTC1A	1.013	YL 20T2.0FXXXTC 1A	1.113
21	0.724	13.03	13.99	YL 21S2.0FXTC 1A	0.824	YL 21D2.0FXXTC 1A	0.924	YL 21T2.0FXXXTC 1A	1.024
22	0.643	16.53	17.75	YL 22S2.0FXTC 1A	0.743	YL 22D2.0FXXTC1A	0.843	YL 22T2.0FXXXTC 1A	0.943
23	0.574	20.72	22.24	YL 23S2.0FXTC 1A	0.674	YL 23D 2.0FXXTC 1A	0.774	YL 23T2.0FXXXTC 1A	0.874
24	0.511	26.19	28.12	YL 24S2.0FXTC 1A	0.611	YL 24D 2.0FXXTC 1A	0.711	YL 24T2.0FXXXTC 1A	0.811
25	0.455	33.03	35.46	YL 25S2.0FXTC1A	0.555	YL 25D 2.0FXXTC1A	0.655	YL 25T2.0FXXXTC 1A	0.755
26	0.404	41.86	44.94	YL 26S2.0FXTC1A	0.504	YL 26D 2.0FXXTC1A	0.604	YL 26T2.0FXXXTC 1A	0.704
27	0.361	52.48	56.34	YL 27S2.0FXTC1A	0.461	YL 27D 2.0FXXTC1A	0.561	YL 27T2.0FXXXTC 1A	0.661
28	0.32	66.66	71.56	YL 28S2.0FXTC 1A	0.42	YL 28D2.0FXXTC1A	0.52	YL 28T2.0FXXXTC 1A	0.62
29	0.287	82.88	88.97	YL 29S2.0FXTC 1A	0.387	YL 29D 2.0FXXTC1A	0.487	YL 29T2.0FXXXTC1A	0.587
30	0.254	105.8	113.6	YL 30S2.0FXTC1A	0.354	YL 30D 2.0FXXTC 1A	0.454	YL 30T2.0FXXXTC 1A	0.554
31	0.226	133.9	143.8	YL 31S2.0FXTC 1A	0.326	YL 31D 2.0FXXTC 1A	0.426	YL 31T2.0FXXXTC 1A	0.526
32	0.203	166.2	178.4	YL 32S2.0FXTC 1A	0.303	YL 32D 2.0FXXTC 1A	0.403	YL 32T2.0FXXXTC 1A	0.503
33	0.18	211.7	228.2	YL 33S2.0FXTC 1A	0.28	YL 33D 2.0FXXTC 1A	0.38	YL 33T2.0FXXXTC 1A	0.48
34	0.16	269.8	289.6	YL 34S2.0FXTC1A	0.26	YL 34D 2.0FXXTC 1A	0.36	YL 34T2.0FXXXTC 1A	0.46
35	0.142	342.8	368.1	YL 35S2.0FXTC1A	0.242	YL 35D 2.0FXXTC 1A	0.342	YL 35T2.0FXXXTC1A	0.442
36	0.127	431.9	463.7	YL 36S2.0FXTC 1A	0.227	YL 36D 2.0FXXTC 1A	0.327	YL 36T2.0FXXXTC1A	0.427
37	0.114	535.7	575.1	YL 37S2.0FXTC 1A	0.214	YL 37D2.0FXXTC1A	0.314	YL 37T2.0FXXXTC 1A	0.414
38	0.102	681.9	732	YL 38S2.0FXTC 1A	0.202	YL 38D 2.0FXXTC 1A	0.302	YL 38T2.0FXXXTC 1A	0.402
39	0.089	897.1	963.1	YL 39S2.0FXTC 1A	0.189	YL 39D 2.0FXXTC 1A	0.289	YL 39T2.0FXXXTC 1A	0.389
40	0.079	1152	1237	YL 40S2.0FXTC1A	0.179	YL 40D2.0FXXTC1A	0.279	YL 40T2.0FXXXTC1A	0.379

ETFE Insulated conductor Litz wire

Conductor				Single Insulated		Double Insulated		Triple Insulated
AWG	OD(mm)	DC Resistance		Part Num ber	OD(mm)	Part Number	OD(mm)	Part Number	OD(mm)
		Bare	Tinned
18	1.02	6.516	6.995	YL18S1.5EXTC1A	1.096	YL18D1.5EXXTC1A	1.172	YL18T1.5EXXXTC1A	1.248
19	0.912	8.211	8.815	YL19S1.5EXTC1A	0.988	YL19D1.5EXXTC1A	1.064	YL19T1.5EXXXTC1A	1.14
20	0.813	10.33	11.09	YL20S1.5EXTC1A	0.889	YL20D1.5EXXTC1A	0.965	YL20T1.5EXXXTC1A	1.041
21	0.724	13.03	13.99	YL21S1.5EXTC1A	0.8	YL21D1.5EXXTC1A	0.876	YL21T1.5EXXXTC1A	0.952
22	0.643	16.53	17.75	YL22S1.5EXTC1A	0.719	YL22D1.5EXXTC1A	0.795	YL22T1.5EXXXTC1A	0.871
23	0.574	20.72	22.24	YL23S1.5EXTC1A	0.65	YL23D1.5EXXTC1A	0.726	YL23T1.5EXXXTC1A	0.802
24	0.511	26.19	28.12	YL24S1.5EXTC1A	0.587	YL24D1.5EXXTC1A	0.663	YL24T1.5EXXXTC1A	0.739
25	0.455	33.03	35.46	YL25S1.5EXTC1A	0.531	YL25D1.5EXXTC1A	0.607	YL25T1.5EXXXTC1A	0.683
26	0.404	41.86	44.94	YL26S1.5EXTC1A	0.48	YL26D1.5EXXTC1A	0.556	YL26T1.5EXXXTC1A	0.632
27	0.361	52.48	56.34	YL27S1.5EXTC1A	0.437	YL27D1.5EXXTC1A	0.513	YL27T1.5EXXXTC1A	0.589
28	0.32	66.66	71.56	YL28S1.5EXTC1A	0.396	YL28D1.5EXXTC1A	0.472	YL28T1.5EXXXTC1A	0.548
29	0.287	82.88	88.97	YL29S1.5EXTC1A	0.363	YL29D1.5EXXTC1A	0.439	YL29T1.5EXXXTC1A	0.515
30	0.254	105.8	113.6	YL30S1.5EXTC1A	0.33	YL30D1.5EXXTC1A	0.406	YL30T1.5EXXXTC1A	0.482
31	0.226	133.9	143.8	YL31S1.5EXTC1A	0.302	YL31D1.5EXXTC1A	0.378	YL31T1.5EXXXTC1A	0.454
32	0.203	166.2	178.4	YL32S1.5EXTC1A	0.279	YL32D1.5EXXTC1A	0.355	YL32T1.5EXXXTC1A	0.431
33	0.18	211.7	228.2	YL33S1.5EXTC1A	0.256	YL33D1.5EXXTC1A	0.332	YL33T1.5EXXXTC1A	0.408
34	0.16	269.8	289.6	YL34S1.5EXTC1A	0.236	YL34D1.5EXXTC1A	0.312	YL34T1.5EXXXTC1A	0.388
35	0.142	342.8	368.1	YL35S1.5EXTC1A	0.218	YL35D1.5EXXTC1A	0.294	YL35T1.5EXXXTC1A	0.37
36	0.127	431.9	463.7	YL36S1.5EXTC1A	0.203	YL36D1.5EXXTC1A	0.279	YL36T1.5EXXXTC1A	0.355
37	0.114	535.7	575.1	YL37S1.5EXTC1A	0.19	YL37D1.5EXXTC1A	0.266	YL37T1.5EXXXTC1A	0.342
38	0.102	681.9	732	YL38S1.5EXTC1A	0.178	YL38D1.5EXXTC1A	0.254	YL38T1.5EXXXTC1A	0.33
39	0.089	897.1	963.1	YL39S1.5EXTC1A	0.165	YL39D1.5EXXTC1A	0.241	YL39T1.5EXXXTC1A	0.317
40	0.079	1152	1237	YL40S1.5EXTC1A	0.155	YL40D1.5EXXTC1A	0.231	YL40T1.5EXXXTC1A	0.307

Challenges in Design and Production

1. Material Selection: Choosing the right insulation materials is crucial. Common materials include ETFE, PFA, and FEP, each offering unique properties but also requiring careful consideration of performance under high temperatures and frequencies.
2. Layer Adhesion: Ensuring strong adhesion between insulation layers is vital to prevent delamination during operation, which can lead to failure.
3. Manufacturing Complexity: The production process for triple insulated Litz wire is more intricate than for simpler wire types, necessitating specialized equipment and precise process control.
4. Cost Implications: The increased complexity and higher-quality materials can lead to higher production costs, necessitating a balance between performance and affordability.

Key Considerations for Users

1. Electrical Performance: Users must assess whether the enhanced electrical isolation and reduced losses justify the investment in triple insulated Litz wire.
2. Safety Requirements: For applications in sensitive environments (e.g., medical or aerospace), the increased safety from additional insulation can be a deciding factor.
3. Long-Term Reliability: The durability and reduced maintenance needs offered by triple insulated designs can lead to cost savings over time.

Advantages of Triple Insulated Litz Wire

1. Superior Electrical Performance: The three layers of insulation provide excellent electrical isolation, drastically lowering energy losses in high-frequency applications.
2. Enhanced Safety: Thicker insulation layers significantly decrease the risk of short circuits and electrical failures, making it a safer choice for demanding applications.
3. Extended Equipment Lifespan: The reliability of triple insulated Litz wire contributes to a longer operational lifespan for devices, ultimately reducing replacement and repair costs.

Disadvantages and User Perspectives

While there are several advantages, users must also consider some potential disadvantages:

1. Increased Cost: The complexity of production and high-quality materials can lead to a higher price point.
2. Reduced Flexibility: The additional insulation may decrease the wire’s flexibility, making it less suitable for applications requiring frequent bending.
3. Weight Considerations: The added insulation can increase the overall weight of the wire, which may not align with lightweight design requirements in certain applications.

Despite these drawbacks, users often choose triple insulated Litz wire for its superior performance in specific applications, particularly where efficiency and safety are paramount.

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