In today’s world, the demand for miniaturized and microscopic parts for components such as sensors and transducers is increasing. These components are often used in manufacturing state-of-the-art micro-motion control and positioning systems. Many of these tiny components require miniaturized coils, but the creation of such coils, which involves connecting ultra-fine wires, presents substantial manufacturing difficulties.
Moreover, winding microscopic coils with ultra-fine wire is a significant challenge, especially if the expected size or shape of the coil is constrained by numerous physical and environmental factors. Coils may also have to meet ultra-strict tolerance requirements.
This means traditional coil winding techniques are insufficient. Companies that have produced regular coils in the past often lack the technology or manufacturing processes needed to produce coils small enough to meet current requirements. For this reason, if you require specialized micro coils, you should consult with a specialist micro coil manufacturer such as Benatav.
To overcome the various problems presented when manufacturing miniaturized coils, Benatav has spent over 20 years developing the necessary techniques and processes which allow us to produce such coils at very competitive rates.
As mentioned above, one of the problems encountered when producing miniature coils is leaving the insulation layer that covers the conducting wire unharmed undamaged due to ultra-fine tooling sets.
Another major problem is the difficulty in joining the ultra-fine wires that are used to wind the coils.
The ultimate answer to these connectivity challenges was found in the form of an innovative, thermo-pressure bonding technology refined by Benatav to meet the standards of the ultra-fine wire field. Our unique thermo-compression process allows us to join ultra-fine wires which may be as small as 9 microns, (0.00035″ 8–10 times thinner than a human hair).
Advantages of micro compression bonding include:
Thermo-pressure bonding can connect:
The molecular connections formed by this thermo-pressure bonding technology provide highly reliable, corrosion-free, and strain-free joints. The process is also more economical than traditional soldering or welding, which lowers manufacturing costs. We have extensively tested thermo-pressure bonding in a wide variety of customer environments and implemented it in several production processes. The process has proven suitable for both disposable and long-life products, for example, permanent implant
Whatever your micro coil requirements, due to our extensive specialist experience in micro coil technology, chances are that we have already solved any issues that may prevent us from producing your coils at highly competitive rates.
The following is a list of some applications that benefit from micro coil and ultra-fine wire connectivity technology:
Benatav’s specialist technologies open up a limitless range of new possibilities to designers of miniaturized medical equipment and other industries.
Find out about the benefits gained using Benatav’s thermo-pressure technology to mass-produce high-quality, miniature coils at a reasonable cost. As designers become more aware of our thermo-compression bonding, we foresee that the variety of applications of its use will become increasingly widespread.
Call Benatav on +972-3-9345951 to discuss how our unique technologies can benefit your business. You can also contact us via this contact form.