Coated-Strand Litz Wire for Multi-Megahertz Frequency Applications

Substantial induced eddy-current losses and the need for skin-depth-size strands leave litz wire out as an option for inductive applications at multi-megahertz frequencies. To address this, we analyze and minimize the litz-wire eddy-current losses by adding a coating layer to each strand while keeping the wire dimensions and packing factor constant. The skin and proximity effects of isolated and in-bundle coated strands are studied for various coating properties and dimensions. A new method is proposed for calculation of proximity losses inside coated-strand litz wire, which enables simple systematic approach for proximity loss and ac resistance (Rac) determination. Three types of pure copper (Cu), silver-coated copper (Ag/Cu), and nickel-coated copper (Ni/Cu) strands are studied in isolation and inside a litz wire. The litz wires associated with these strands are fabricated and their power dissipations are measured. Analytical results followed by finite-element modeling and experimental results show 26% reduction in Ni/Cu litz wire Rac, and 3% reduction in Ag/Cu litz wire Rac at 13.56 MHz compared with same-size Cu litz wire.