The winding method is the basis of the manufacturing of the micro-coils. Through this process, an electrically conductive wire is wound in the shape of a spiral, helix, or coil. However, one can decide the size and shape of the micro-coils based on the purpose of use. Different shapes and sizes are responsible for offering different inductance, resistance, and strength of the magnetic field. Thus, depending on your requirements of these parameters, you can also determine the desired shape and size.
Electromagnetic coils are crucial for applications where an electric current interrelates with a magnetic field. The major applications of micro-coils are transformers, electromagnets, sensors, and inductors. In these applications, manufacturers either use an electric current to produce a magnetic field or use a magnetic field to generate an electric current.
Machinery Requirements for Winding Method of Micro-Coils:
You can not use your hands to wind the tiny micro-coils. To handle very tiny wires in the coil winding process, you require special machinery. You also have to rely on automated machinery to produce the micro-coils in a huge quantity through mass production. The micro-coils can also be prepared with different geometrical shapes and types, such as jumble, orthocyclic, and helical.
For the preparation of a helix coil, the manufacturers have to create layers by switching directions. Therefore, the machines that can move forward and backward are effective for the winding of helix coils. However, for any type of micro-coil, ultra-fine wires are necessary, otherwise, with normal wires, the structure will become very tight after certain layers.
The orthocyclic winding method is the most ideal method where the wire of the upper layer takes place in the channel of the wires of the lower layer. This manufacturing process helps to minimize the required space and makes the coil more efficient. This method is also useful for the proper distribution of heat conditions and electric field strength.
Winding Method Challenges:
The most important challenge for the winding method is the size constraint. Manufacturers have to place the micro-coils into the tiny medical devices. Therefore, they need to wind the coils with ultra-fine wires, and this is challenging.
Dealing with ultra-fine wires is challenging for various reasons, such as
- The ultra-fine wires require proper insulation to evade reaching the breaking point.
- There is always a limited space for the winding of the coils.
- The machines should have high-speed manufacturing ability.
- Curl wires are difficult to deal with.
Micro-Coil Winding Method:
In the winding process, manufacturers require to wind the coil with about 200 turns. However, as the coils need to be very tiny, thus, the manufacturers should minimize the thickness of the wire as much as possible. To deal with this, modern manufacturers use ultra-fine wires that are about 8 to 9 microns in diameter. Handling and connecting these wires is a very difficult job and when it comes to connecting two ultra-fine wires, you should always rely on the thermal compression bonding technology. State-of-the-art methods and specialized equipment are also necessary for the winding process.