Conventional self-adhesive coil and irregular self-adhesive coil foreground

Network communication, consumer electronics, 5G equipment, photovoltaic equipment, new energy fields, these industries with the rapid rise of the domestic economy, as the upstream product chain of self-adhesive coil market demand rises sharply. Every coin has two sides. Theoretically, a big market means a good thing. Although the market is large, it also means that the demand for customization is also increasing. However, during the period when the market rose, the domestic coil faced several problems

(1) Competition between manual and automatic equipment

With the increase of labor costs, China’s demographic dividend is gradually disappearing, and the emergence of automation equipment to many manufacturers of manual winding a lot of pressure. Automatic winding equipment has brought higher production efficiency, higher product quality, and this compared with expensive labor costs, unstable production quality is undoubtedly a fatal punch, automatic winding equipment instead of manual winding is an irreversible trend.

(2) Technical problems caused by the demand for conventional and special-shaped self-adhesive coils

Let’s first understand what a self-adhesive coil is.

Self-adhesive coil is mainly made of self-adhesive insulated wire after heating or solvent treatment. Generally used in: high-power power supply, wireless charging modules, 5G equipment, photovoltaic equipment, new energy fields, common mode filters, multi-frequency transformers, impedance transformers, balanced and unbalanced conversion transformers, personal computers and peripheral devices of USB lines, LCD panels, low-voltage differential signals, and other fields. In a word, as small as your home electrical appliances, as large as aerospace, will be used.

Have a friend asked, such a large range of use, should be very versatile?

Yes, it does, but does the customization of customers match?

With the birth of 5G, customers’ customized demand is increasing. Special-shaped self-adhesive coil is favored by the market for its better environmental specificity than conventional coil due to the lightness of mobile phones, computers, tablets and other electronic devices, and it can effectively protect the insulation layer from damage, and has better inertia.
The good thing is that the market demand means that the industry has income, but the worry is that the industry is subject to technical barriers, low production efficiency, delivery delays caused by the disadvantages of the customer headache.
I have a friend to ask. What is the question? So sad?
There are many factors, a simple example

1. Accuracy of turns

The error of the number of turns will affect the electromagnetic parameters and is not conducive to embedding, it is easy to appear the wrong number of turns when winding more turns, so in the way to solve this problem many manufacturers will choose to buy the turns measuring instrument, or manual turns measuring. And in the 7 S production standard, Huayin electronics also carried on the intelligent upgrade of the workshop, the automatic winding machine.

2, coil shape control

Coil shape to meet the requirements of customers, which requires high quality of forming coil, otherwise it will affect the subsequent processing. While meeting the customized needs of customers, although we are professionals in the industry for more than 10 years, we will also be distressed because of technical barriers.
The rectangular coil in the market is similar to the rectangular coil, for example: “oval coil”, “chamfered rectangular coil” these are similar to the rectangular coil, but not the real rectangle.
So a friend is going to ask, why is that?
The main technical problem with a square coil is the four edges of a rectangle. When winding the coil, the four edges of a square coil do not have the force of the vertical side towards the center of the rectangle, which leads to the tension of the wire itself. If this is the case, it will lead to the edge of the line is not good, after the winding of the coil thickness will be much larger than the thickness of the fillet, will affect the size of the coil and electrical conductivity. Also, racetrack coils have the same problem.

So how do you solve this problem?

There are two ways

First: The use of inward extrusion, extrusion in the side of the square coil, so that the thickness of the coil is consistent. However, there is a problem that if extrusion is carried out after winding the wire, if the line is not neatly arranged, the extrusion will cause damage to the wire, resulting in defective products. If the method of extrusion is used after winding a layer, the structure of the machine will be more complicated and the cost will be higher. Less compatibility.

Second: By extruding outwards, the wound circular coil or oval coil has tight wiring and high precision, and the thickness of each position is the same. By extruding outward from the inner ring through the mold, the circular or oval coil is extruded into a square coil. In this way, the thickness of each position of the square coil is the same, and the conductive performance is the same. The disadvantage is that you can’t squeeze coils that have too many layers or are too thick.

Therefore, when winding the coil, the control of the shape must be accurate, whether it is Angle, or shape, otherwise it will affect the performance of the wire. And in the actual production and processing process, due to the improper operation of the late production and processing, it may cause damage to the insulation layer, and there is a larger quality hazard for the coil performance. So in the production process should be strictly in accordance with the production requirements of the operation. The setting of temperature and tension should take product quality as the center, not blindly seek for speed.

Post time: Feb-02-2023