Will reducing steps, enhancing solder quality and consistency, and maintaining dimensional stability improve overall efficiency?
Are you facing these questions? If yes, then this article has answers to all. Keep reading!
Round and Square Film-Coated Wires
In the context of carbon neutrality, the increasing power requirements of products in the new energy sector, such as new energy vehicles, charging piles, photovoltaics, and energy storage, have led to the widespread use of copper wires with higher current input and output. The rising switching frequency has also increased the demand for litz wire, and product sizes are approaching their limits. As a result, both round and square film-coated wires have emerged.
Currently, the insulation material used for film-coated wires is Class H high-temperature tape. This poses several challenges for transformer and inductor production processes, such as excessively large solder joints that prevent PCB insertion, unstable lead dimensions, and broken strands.
To ensure the dimensional stability and integrity of the solder joints after soldering, as well as high production efficiency and product quality, here is a new soldering process for film-coated square wire.
New Coating Process as a Solution For Soldering Process Issues
By using this process, various issues in the soldering process with film-coated square wire can be avoided.
Design principle and coating ratio of square film-coated wire
Option 1: The overlap ratio of the film coating on the square wire should be more than 50% or 75%.
Option 2: A minimum overlap ratio of 50% or 75% is required for the film coating on the square wire.
This can ensure a smooth coating without bumps, missing spaces, or over-soldering.
Process for improvement of film-coated square wire production
Depending on the transformer, inductor length, and soldering length of lead wire, cut the winding length of the film-coated square wire. The required length of the lead wire should be separated along the square side of the square wire, and the coating on the lead wire should be retained after separation.
After separating the lead wire coating with a blade, the two ends of the square coating are fixed with high-temperature tape to prevent the coating from dispersing after separation by the blade and to ensure that the insulation at the soldering point remains intact.
After cutting the tape to the desired length with a blade, both ends of the film-coated square wire are secured with a soldering furnace at a temperature of 480±10°C. You can adjust the soldering time as needed. After soldering, the high-temperature coating at both ends of the square wire is removed, and the soldered joint is formed.
Finally, high-temperature tape is used to secure the lead wires at the soldered joint to ensure dimensional stability. Once this is done, the required square film-coated wire is cut, and the input and output length are determined.
Final Words
Based on the existing film-coated square wire processing method, the required winding length is cut, and the length of the input and output leads is determined. The blade is used to separate the insulation layer at both ends of the square wire, leaving the insulation layer intact to secure the internal Litz wire at both ends of the lead. Subsequently, the leads are soldered in a high-temperature tin furnace to fix the length and width of the leads. This process completes the soldering of the film-coated square wire without the need for any additional steps. The soldered wires are then directly wound, significantly reducing labor time and improving product consistency and stability, as well as increasing production efficiency.
If you are looking for high-quality, reliable, and reputed film-coated square wires, Jingda is the best choice. Jingda is a reputed seller of film-coated round and square wire or litz wire. We use the best techniques and processes to ensure our wires offer industry-grade performance.
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