In the realm of high-frequency transformer design, the choice between copper tape and Litz wire for winding coils plays a pivotal role. Presently, the absence of flat copper tape in domestic high-frequency transformers is notable. The use of flat copper tape demands meticulous precision in manufacturing to ensure optimal flatness, a challenging feat. The complexity arises due to the potential surge in eddy current losses at high frequencies if the tape is not impeccably flat.

Enter Litz wire, a common choice at high frequencies to mitigate eddy current losses. However, the decision to use Litz wire or copper tape hinges on various factors, including the size of the magnetic core and the magnitude of the current. Typically, Litz wire is favored for low current applications, while copper tape steps in for high current scenarios.

The simplicity of the Litz wire manufacturing process is a notable advantage, but it comes with a trade-off. When the current exceeds a certain threshold, employing numerous Litz wire strands becomes a necessity, potentially escalating the overall manufacturing cost beyond that of copper tape. In essence, the choice between these two methods involves a delicate balance of factors, with considerations for process complexity, current magnitude, and cost implications.