How to Select Wires in the Preparation Process of Integrated Molding Power Choke

Wires are one of the crucial raw materials in the preparation of integrated molded inductors. Selecting appropriate wires exerts a significant impact on their manufacturing process. The following content will provide a brief introduction to wire selection for integrated molded inductors.

1. Role of Wires

Wires are one of the three core raw materials for integrated molded inductors. The coils wound from wires are key elements for the inductor to generate electrical properties, and they serve as important filling components of the product.  

2. Wire Categories and Standards

The application scope of common integrated molded inductors, divided according to the stress test certification standards of AEC-Q200 passive components, is shown in Table 1:

[Table 1 Temperature Table of AEC - Q200 Passive Component Stress Test Certification]

As can be seen from Table 1, the common operating temperature ranges for inductors are twofold: -40~+125°C and -50~+150°C (including self-heating), which impose different temperature and characteristic requirements on the required wires.

Enamel-coated copper wires are commonly used wires for integrated molded inductors. According to the currently commonly used mainstream wire classification, see Table 2 below: the commonly used wires for integrated molded inductors are round and flat enamel-coated copper wires. Round copper wires are preferentially selected due to their advantages,such as flexible winding methods, easy shaping, and firm structure. Flat wires, with a single winding method, high filling rate, small parasitic capacitance, and obvious characteristic advantages, are often used in the design of high-performance inductors.

[Table 2 Classification Table of Enamel - coated Wires]

3.Key Points for Selection

Through the practice of selecting wires for integrated-molded inductors, the main influencing factors are summarized as follows: The selection of wires for the production line will affect the winding process, coil thickness, product appearance, electrical characteristics, etc. Appropriate considerations can be made according to customer requirements. For example, if the application voltage of the product exceeds 48V, the thickness of the enamel coating, voltage resistance, and abrasion-resistant properties should be given priority consideration. If the product size is relatively small, the self-adhesiveness of the enamel coating and the attachment method should be the main concerns. For processes that require high efficiency, such as using a hot-air gun, the attachment method, cross-sectional area, and enamel coating thickness need to be considered. For high-temperature resistance requirements, such as-50~150°C, wires of grade 200 or 220 are preferably selected. For inductors used in complex environments such as aerospace, wires of grade 240 are preferably chosen first. If the wire is directly used as an electrode, solderability is preferred. When making a selection, pay attention to the close correlation among characteristics, dimensions, and the manufacturing process.

For integrated molded inductors produced by CODACA, such as CSAB/CSAC/CSEB/CSHB/VSAB series, key considerations include the impact of wire types and enamel coatings on characteristics and manufacturing processes. Standardized selection, optimization of raw material suppliers, and focused control over the environmental friendliness and stability of the manufacturing process have all passed strict reliability tests and verification.