Micro-coil production method encompasses the winding of thin insulated conductive wires. The winding method does not involve a single wire. Therefore, you will require to connect two ultra-fine wires during the winding method. So, the question is can you use traditional soldering-based methods to build a connection between the ultra-fine wires? The answer is no. This is because traditional methods can lead to numerous drawbacks and destroy the efficiency of the coils. Then, which connectivity solution is ideal for the micro-coil production process? To know everything about ultra-fine wire connectivity solutions, continue to read this article.
The Problem with the Traditional Methods and the Ultimate Solution:
Traditional welding and soldering methods are popular solutions for joining two metal wires. The welding method involves the melting of the ends of two metals to join them together. On the other hand, the soldering method involves a particular metal with lower melting points that get poured at the joints when melted and joins the metals. However, these two methods become ineffective when the diameters of the wires are too small. The major drawbacks are-
The traditional may lead to oxidization at the wires and joints and thus, the connections will not be durable.
Traditional soldering methods can cause unlimited heat spreading and the destruction of the wires.
Lastly, an extra physical strain can develop at the joints.
This is why traditional methods are not useful in the micro coil production process. To join the tiny ultra-fine wires of approximately 9-micron diameter, thermos-compression bonding technology is useful. This method not only helps to overcome the issues of traditional methods but also helps to build joints that are free from strain and corrosion. More importantly, you can join two wires of dissimilar materials and diameters (even if the difference in the diameter is twelve times). This method is also recognized as the micro-soldering method.
The Importance of the Micro-Soldering Method in Coil Production:
To meet the increasing demand for microscopic components, manufacturers use ultra-fine wires in the production of electromagnetic micro-coils. The tiny size of the wires creates a significant challenge for the makers to handle the wires. The makers need efficient technology and built-in-house equipment to work with ultra-fine wires.
The traditional soldering-based methods also create various issues and constraints when it comes to joining the tiny wires. Manufacturers also have to deal with multiple environmental and physical constraints due to the miniature size of the wires. Above all, they need to maintain ultra-strict tolerance requirements for the final products. Thermo-compression bonding technology helps to resolve all the above-mentioned issues and provides reliable joints for ultra-fine wires.
The Benefits of the Thermo-Compression Bonding Method:
Some major benefits of the micro-soldering method are-
Significant reduction in noise level
Relief of strain on the joints
Lessens the risk of damage
Provides durable oxidization-free joints
Less overall production cost
Ability to integrate into the mass production
Automated manufacturing process.
Considering these benefits, most manufacturers use the micro-soldering method in the micro-coil production process. Traditional methods can not bring these benefits, instead, those methods create various issues.