Electronic – Best way to terminate fine gauge polyurethane magnet wire

soldering

I am winding custom coils with AWG 32 polyurethane coated magnet wire and need to solder the coil leads to ~AWG 24 standard insulated wire so that they can be connected to a terminal block.

What are the best practices to solder the wires and also provide some strain relief?

Best Answer

To strip the fine wires (AWG32 is not all that fine) with polyurethane insulation you can usually use a small solder pot. Set it a bit hotter than you would a bench soldering iron. If you use one of the very inexpensive ones, it helps to put a small thermocouple into the pot to monitor the temperature. A bit of peanut oil on the top will prevent too much oxidation from occurring. Something with a 1-2" (25-50mm) inside diameter is adequate.

If the insulation won't burn away, you can use mechanical or chemical stripping.

Typically you'd tape some sturdy insulation material to the outside of the finished coil, splice the wires, insulate the joint if necessary, and then wrap more tape around the outside to secure the joint. Leave adequate slack on the fine wire so that it won't be drawn taut by thermal expansion.