Miniaturised and microscopic component parts like transducers and sensors are in high demand in today’s society. Creating these components necessitates the capacity to combine ultra-fine wires, which are frequently utilised to wound coils needed in the construction of cutting-edge micro-motion control and positioning systems. Micro soldering connects ultra-fine wires as thin as 9 microns, which is 5 – 10 times thinner than human hair.
Undoubtedly, connecting ultra-fine wire is a difficult task, especially when a slew of physical and environmental constraints limits the desired shape or size of the ultimate component. Components might also be required to meet extremely tight tolerance standards. However, connecting ultra-fine wires using traditional methods like Soldering & Welding becomes impossible due to physics limits & these solutions either become ineffective or present additional challenges like:
- Damaging of the wiring due to inaccurate heat spread
- Oxidation in wire and the adjacent region
- Physical strain and decrease in connection reliability
Appropriate Solutions
The ultimate solution to all of these connectivity issues was discovered in the cutting-edge thermo-pressure bonding technology that allows connecting ultra-fine wires to other ultra-fine wires that are either similar in material and diameter or where one wire is up to 12 times thicker and/or made of a different metal.
Thermo-pressure bonding can:
- Enable metal-to-metal micro-coils connections to a printed circuit board with the use of thicker intermediate wires.
- Connect miniature copper thermocouples and ultra-fine wires
- Join micro coils to a support system with the help of metal-plated terminals
Thermo-pressure bonding has demonstrated its competence for incorporation into mass-production processes despite exceedingly high requirements. It creates molecular connections that are exceptionally dependable, strain-free and corrosion-free. Being less expensive than traditional welding or soldering, it also lowers manufacturing expenses. The technique has also been shown to be befitting for both long-life & disposable items.
Applications of Micro Soldering:
- Therapeutic applications – devices in electricity-based ablations (RF & microwave) or electro-physiology treatments (neural or cardiac)
- Active implants – deep brain stimulation components like pain management devices or monitoring or control of implanted pacemakers.
- Diagnostic – wireless communication with miniature sensor implants, whether physiological ( heartbeat or blood pressure) or flow (respiration or blood)
- Navigation and orientation sensors – targeted radiation catheters, targeted drug delivery, highly accurate ablations, stent positioning, implanted markers, and endoscopic manipulation
- Dental & Orthopaedic treatment using pulsed electromagnets
What the Future Holds for Ultra-Fine Wire Technologies?
There is an increasing demand to access high-density regions of the body while interfering as little as possible with the body’s normal functioning. Simultaneously, it is vital for energy consumption reduction and extend the implanted components’ life span, emphasising the necessity of miniaturisation in medical devices. Using innovative ultra-fine wire technologies gives infinite opportunities for designers of miniaturised medical equipment and other industries.
A miniature coil can be utilised in a cardio-vascular catheter as a navigation component to accomplish cardiac ablation. This critical component of a disposable catheter is an instance of the advantages realised by employing the thermo-pressure technique to mass produce high-quality, small components at a low cost. As designers acquire more intricate understanding of micro soldering and the range of applications that can employ it, its use will grow more prevalent.
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