Electromagnetic coils are produced by winding a conducting wire in the shape of a coil, spiral, or helix. The shape and dimensions of a coil are designed to fulfill a particular purpose. Parameters such as inductance, resistance, and strength of the desired magnetic field greatly influence the design of coil windings.
Modern equipment is becoming more miniaturized which leads to a demand for micro coils. However, several challenges face the designer of modern equipment which use micro coils:
These size constraints pose multiple challenges, both in the manufacturing and in the connecting of these components to each other and their support systems.
Standard equipment used for regular-sized coils can’t be repurposed for mass-producing micro coils, necessitating specialized equipment. For instance, to manufacture a micro coil with up to 2000 turns, wire thickness must be significantly reduced. Benatav is among the few companies globally working with fine wires as thin as 8.8 microns (0.00034 inches), and we’re even exploring the production of insulated wires smaller than 8.8 microns. A key challenge with miniature coils is maintaining the insulation layer on the conducting wire, which can be damaged by ultra-fine tooling sets.
To connect such fine wires, traditional, solder tin-based connections are not up to the task. Solder-based connecting creates undesired side effects, such as oxidization of the connection and the region, inferior conductivity, low durability, high production costs, and high rates of failure.
To overcome these problems, Benatav has developed a proven, cutting-edge, thermo-pressure technology to produce precise soldering with tight tolerances at very high temperatures. Our thermo-pressure bonding technology allows us to connect ultrafine wires with none of the previously mentioned drawbacks.
The molecular connections formed by this thermo-pressure bonding technology provide highly reliable, corrosion-free, and strain-free connectivity without any soldering, thus simplifying and lowering manufacturing costs. After thorough testing of the technology in a wide variety of customer environments and coupled with its implementation in several production processes, this technology has been integrated into mass serial production processes while continuing to meet the standards required by demanding applications, such as in medical devices.
Manufacturing micro coils and connecting their extremely fine wires can’t be done using traditional technologies and still meet goals such as:
Using in-house engineering, Benatav has developed state-of-the-art methods and robots which allow the winding of micro coils and filling them with ferro-magnetic material (which acts as a core), to an extent that was not possible before. These robotic technologies are not subject to the vagaries of manual production and therefore we can manufacture and connect micro coils on a scale and to standards not previously possible.
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.