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The Thermo compression bonding process is an innovative method for joining the ultra-fine wires to manufacture the micro-coils. Whether it’s about connecting two similar wires, or dissimilar wires of different diameters and metals, this method is the ultimate connectivity solution. You can also use this technology to join a wire with another twelve times thinner wire.
The most common two traditional methods to connect the wires are the welding and soldering methods, however, you can not apply these methods in the case of ultra-fine wires. The ultrafine wires that have about 9 microns diameter are only suitable with the Thermo compression bonding method or micro-soldering method.
In order to deal with the rising demand for microscopic parts, such as transducers and sensors, the need for miniature micro-coils using ultra-fine wires is developing significantly. For the manufacturing of transducers or sensors, manufacturers need to deploy efficient technologies that can deal with the constraints of traditional methods and offer effective connectivity solutions for ultra-fine wires. Manufacturers also require having advanced micro-motion positioning and control systems to wind the ultra-fine wires in the shape of a coil.
Connectivity Challenges:
The major challenges for the ultra-fine wire connectivity solution are the physical and environmental factors that affect the joints and components. Another significant challenge for the manufacturers is the constraints due to the final size and shape of components. In order to make the components suitable for medical devices, the manufacturers should maintain the ultra-strict tolerance requirements. To deal with all these challenges, one can not rely on the traditional methods as these can create several issues.
Thermo Compression Bonding Connections:
In order to build different types of connections, manufacturers can use this method, such as
- To create a connection with ultra-fine wires and miniature thermocouples
- To build metal-to-metal connection using heavier intermediate wires for binding a printed circuit board to the micro-coils
- With the help of metal-plated ends, this technology helps to bind the micro-coils to a supporting system.
Thermo compression bonding process produces strain-free, high reliable, and rust-free joints. This process is significantly economical in comparison to the traditional processes. As the manufacturers can easily integrate this process into mass production, therefore, the overall manufacturing costs with this process are very low. This process is also useful to maintain the high standards for the medical applications and therefore, whether it’s about preparing the disposal or long-life products, the Thermo compression bonding process is the ultimate solution.
Benefits of Thermo Compression Bonding Process:
The major benefits that this process provides are-
- For diminishing the level of noise, this method is effective,
- This process helps to make the connections strain-free,
- You can have durable and oxidation-free joints with this process.
- Compared to the traditional methods, this method is quite safer and therefore, this method removes the risks for the damage of the sensitive components.
- Manufacturers can lessen the overall manufacturing cost with the help of the mass production facility of this process.
- This process involves automated machinery that eliminates human errors.
Traditional Methods:
The most popular traditional methods for joining the wires are-
- Soldering method where the manufacturers use an external heat source and a filler metal to connect the wires.
- Welding method where the manufacturers use an electric current and melt the wires to build a connection.
Apart from the environmental and physical factors, traditional methods can also create several other issues, such as
- There can occur oxidation in the joints of the wires and affect the wires’ durability.
- These methods can cause excessive heat spreading and damage the wires.
- Traditional methods can affect the durability and reliability of the joints by adding extra physical strain.
Applications:
Thermo compression bonding process is useful for numerous applications, such as-
- To manufacture the devices for electrophysiology therapies and electricity-based removals in therapeutic applications.
- In order to build active implants, such as pain management devices, devices for deep brain stimulation, pacemakers, etc.
- For the development of orientation and navigation sensors.
- For the measurement of physiological conditions, such as heart-beat, respiration, blood pressure, blood flow, etc.
- To prepare the devices for dental and orthopedic treatments through pulse electromagnets.
- To build miniature sensor implants for wireless communication.
Considering the enormous number of applications of Thermo compression bonding technology, we can conclude that this technology has definitely opened the door of new possibilities for the manufacturers and designers of medical sensors.