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Everything to Know about Micro-Coil Winding Method

The coil winding method is the foundation of the micro-coil production process. This process involves the twisting or winding of an electrically conductive wire in order to produce electromagnetic coils. Depending on the type of winding, the shape of the electromagnetic coils or micro-coils can be different, such as a helix, spiral, or coil. Behind this different shape and size, the main determinant factor is the application purpose. Manufacturers consider three major elements while shaping the coils, such as resistance, magnetic field strength, and inductance. 

When there is a need for developing an interconnection between a magnetic field and an electric current, electromagnetic coils are essential for those applications. For this reason, to produce transformers, sensors, inductors, and electromagnets, these coils are useful. To build this interaction, you can either use an electric current for the generation of a magnetic field or apply a magnetic field for the development of an electric current.

Machinery Requirements:

The micro-coil winding method can not be conducted using hands. In fact, manufacturers need specialized machinery to work with tiny wires during the winding process. Automated machinery and mass production facility are also essential during this process to eliminate human errors and produce the coils in a large quantity. The micro-coil winding method can be of different types and offer different geometrical shapes, for instance, helical, orthocyclic, and jumble.

In the case of producing helix coils, manufacturers switch the directions to create different layers. Therefore, the machines involved in the production of helix coils should have the ability to move backward and forward. Nevertheless, ultra-fine wires are essential to produce any type of coil, otherwise, the micro-coils will appear in a very tight structure after certain layers.

The most efficient and ideal method for the micro-coils is the orthocyclic winding method. In this method, manufacturers place the upper-layer wires into the channel of the lower-layer wires so that the structure takes minimum space and becomes more efficient. This method can distribute the heat and the strength of the magnetic field properly. 

Challenges for the Winding Method:

The most crucial challenge that the manufacturers face during the winding method is the physical size constraint. As micro-coils are placed into small medical devices, the use of ultra-fine wires for the winding process becomes important. The ultra-fine wires also result in some critical challenges. The other major challenges are-

  • Insulation of the wires to avoid reaching the breaking point 
  • Limited space for winding the micro-coils
  • The need for the high-speed machinery
  • Handling twisted or curl wires

Micro-Coil Winding Method:

During the winding process, manufacturers twist or wind the wires around a core with about 2000 turns. While providing this maximum number of turns, manufacturers also need to maintain the small size of the coils. For that, the application of ultra-fine wires with 8 to 9 microns diameter becomes essential. As far as it is about connecting two ultra-fine wires for the production of electromagnetic coils, modern manufacturers use thermal compression bonding technology, instead of relying on the traditional methods. Apart from using this technology, manufacturers also require specialized equipment and state-of-the-art methods for the micro-coil winding method.