A Heat Sink is used to prevent soldering heat from migrating up the cable and affecting the litz wire strength and flexibility. The heat sink is sized to the wire and clamped onto the wire just above the portion to be immersed. Pliers with brass jaws or bars will work.
The use of Flux to ease the tinning process may be beneficial for applications that contain:
High Temp Magnet wire with polyester base materials, 0.250" or larger constructed litz wire, increased soldering cycle times, and highly compacted designs.
In general the use of flux is NOT required for polyurethane based materials.
High temp flux formulated for soldering magnet wire is available. Traditional Type R non activated flux, or type RA fully activated flux may also be used. The end of the cable should be immersed no more than the length of cable to be tinned.
Non-Solderable Litz Wire
Non-Solderable classes of magnet wire must first be stripped of the enamel. The constructions can then be soldered or mechanically terminated.
SN-Fusing - This process uses a combination of heat and pressure to replace the enamel with tin/solder. The terminals are also attached in the same process.
Mechanical Method - Physically abrade the enamel material off the magnet wire strands with sand paper or wire brushes depending on the AWG size and # of ends.
Chemical Method - This is a chemical magnet wire insulation stripper available in both a Jell and Liquid. Litz wire is dipped into the chemical solvent until the enamel is dissolved, then wiped clean.
Dip Strip contains caustic soda. DO NOT take internally. Avoid direct contact with skin and clothing. DO NOT inhale dust or allow contact with eyes. If accidental contact does occur, flush freely with water and obtain medical attention.
Sodium hydroxide (NaOH), also known as lye, caustic soda and (incorrectly, according to IUPAC nomenclature) sodium hydrate, is a caustic metallic base. Sodium hydroxide forms a strong alkaline solution when dissolved in a solvent such as water, however, only the hydroxide ion is basic. It is used in many industries, mostly as a strong chemical base in the manufacture of pulp and paper, textiles, drinking water, soaps and detergents and as a drain cleaner. Worldwide production in 1998 was around 45 million tonnes. Sodium hydroxide is a common base in chemical laboratories.
Pure sodium hydroxide is a white solid; available in pellets, flakes, granules and as a 50% saturated solution. It is deliquescent and readily absorbs carbon dioxide from the air, so it should be stored in an airtight container. It is very soluble in water with liberation of heat. It also dissolves in ethanol and methanol, though it exhibits lower solubility in these solvents than potassium hydroxide. It is insoluble in ether and other non-polar solvents. A sodium hydroxide solution will leave a yellow stain on fabric and paper.