What is Coil Winding

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An electromagnetic coil is created by winding an electrical conductor, typically a wire, into a coil, spiral, or helix shape. The design and dimensions of a coil are tailored to meet specific purposes. Factors such as inductance, resistance, and the magnetic field strength significantly influence coil winding designs.

Electromagnetic coils are essential in applications where electric currents interact with magnetic fields. They are used in devices such as inductors, electromagnets, transformers, and sensor coils. Depending on the application, either an electric current is directed through the coil's wire to produce a magnetic field, or an external time-varying magnetic field passes through the coil, generating a current in the conductor.

Coil Winding Methods and Machines

When large quantities of coils are needed, manual winding becomes impractical. In traditional coil manufacturing, automated machinery is relied upon for mass production of electromagnetic coils.

Coil winding is classified into various categories based on the coil's type and geometry, including wild or jumble, helical, and orthocyclic winding methods.

Helical winding machines create layers and change directions, moving both forward and backward. However, this technique is limited to a small number of layers; past a specific point, the structure can become too tight to manage, especially with finer wires.

The orthocyclic winding method is recognized as the most efficient way to create coils, as it places the upper layer of wire into the grooves of the lower layers. Engineers constantly strive to enhance the efficiency of coil winding processes by reducing material and spatial requirements. These types of coils exhibit excellent heat conduction, and the electromagnetic field strength is uniformly distributed throughout the windings.

Micro Coil Wire Challenges

One of the primary challenges encountered by designers—particularly those working on invasive medical devices—is fitting the physical dimensions of the device within the constraints of its intended application. This need necessitates the development of micro coils that are significantly smaller than previously manufactured versions.

Designers face numerous challenges such as:

• The breaking point of wire and insulation
• Tight winding spaces
• High-speed operations
• Non-straight wire

Micro Coil Winding

Equipment used for winding standard-sized coils is unsuitable for serial production of micro coils. This situation necessitates the innovation of specialized machinery. Benatav has used in-house engineering to develop cutting-edge methods and machines that enable the creation of micro coils to an unprecedented degree.

Producing a micro coil with numerous turns requires a significant reduction in wire thickness. The thinnest available copper wire currently measures 8 microns (0.00031 inches). Benatav is among the few companies worldwide capable of handling such fine wires, and we are in the process of producing insulated wires that are even thinner than 8 microns.

Utilizing our custom micro-machining technologies, we can manufacture coils with over 1,000 windings that are smaller than a pinhead. However, further challenges arise in connecting these delicate wires.

Ultra-fine wires are so fragile that traditional welding or soldering techniques can damage them. To tackle these difficulties, Benatav has pioneered advanced thermo-pressure technology, allowing for precise soldering with tight tolerances at elevated temperatures.

Applications

Micro coils are vital in applications demanding miniaturization. Here are some specific applications benefiting from our micro coil and ultra-fine wire connectivity technologies:

• Transferring control, monitoring, and logging data to/from miniature implants
• Transferring energy to implants requiring battery charging or electrical input for their operations
• Radiating energy for RF treatments, heat treatments, or electromagnetic pulse therapy to encourage tissue fusion
• In-vivo magnetic navigation using local or external magnetic fields

The Future of Micro Coil Technologies

The application of innovative ultra-fine wire and micro coil winding technologies opens up an extensive range of opportunities for designers in the miniaturized medical equipment industry and beyond. As awareness of these technologies increases, we expect a substantial rise in the variety of applications that will harness them.

To discuss how our micro-coil technology can benefit your business, please contact Benatav at +972-3- or send us an email.

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