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Author Archives: Chris Mayville

  1. Bridging the Gap Between Innovation and Efficiency With Electrical Coil

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    Electrical coils are insulated wire wound into a coil or spiral shape. They are used in a variety of applications across different industries, playing a crucial role in electrical and electronic systems. Their primary purpose is to generate magnetic fields or store energy as inductance when an electric current passes through them.

    This article delves into the evolution of electrical coils, shedding light on key advancements that have paved the way for energy-efficient designs.

    The Evolution of the Electrical Coil

    Let’s explore the key stages in the evolution of electrical coils:

    1. Early Exploration (19th Century)

    The development of electrical coils can be traced back to the 19th century when visionaries like Michael Faraday and Joseph Henry experimented with electromagnetic induction. This early research paved the way for the practical application of coils in various electrical devices.

    2. Rise of Induction Coils (Late 19th Century)

    The late 19th century saw the beginnings of induction coils, which played a crucial role in early telecommunication systems. They were instrumental in transforming weak electrical signals into stronger ones, enabling long-distance communication via telegraph systems.

    3. Transformer Revolution (Early 20th Century)

    This era marked a revolutionary phase in the electrical coil industry. Engineers like Nikola Tesla made groundbreaking contributions to the design and understanding of transformer technology. The use of iron cores in these systems improved efficiency, causing the widespread adoption of transformers in power distribution networks.

    4. Miniaturization and Advanced Materials (Mid to Late 20th Century)

    Advancements in materials and manufacturing processes led to the miniaturization of electrical coil components. These smaller coils with enhanced performance were developed using new materials such as ferrites and advanced polymers. This era also saw the development of inductors and transformers for electronic devices, including radios and televisions.

    5. Integration Into Microelectronics (Late 20th Century to Present)

    As technology advanced, coils found their way into various consumer electronics, computers, and communication devices. Surface mount technology (SMT) further facilitated the compact design and integration of coils into densely populated circuit boards.

    6. Specialization and Advanced Applications (21st Century)

    With the continuous demand for smaller and more efficient electronic devices, the 21st century has seen the development of specialized coils for specific applications. Industries such as automotive, aerospace, and telecommunications have driven innovations in electrical coil design, incorporating advanced materials and manufacturing techniques to meet stringent performance requirements.

    Latest Advancements Revolutionizing Electrical Coils

    Technology has revolutionized how electrical coils are manufactured and used. Here are some key advancements in the industry:

    Superconducting Coils

    Superconducting coils have revolutionized electrical coils by enabling zero-resistance conductivity. When cooled to extremely low temperatures, they exhibit unique electrical properties, reducing energy losses and enhancing efficiency in various applications.

    High-Temperature Superconductors (HTS)

    Traditional superconductors require extremely low operating temperatures, limiting their practical applications. HTS can function at higher temperatures, making them more feasible for a broader range of applications, including power transmission and magnetic resonance imaging (MRI).

    Nanomaterials

    Using nanomaterials in coil construction has allowed for precise winding and miniaturization. This advancement is particularly notable in manufacturing inductors for electronics, enabling the creation of smaller, high-performance coils.

    3D Printing

    3D printing technology has brought a new level of customization and complexity to electrical coil design. Engineers can now create intricate coil structures with specific geometries, enhancing performance and tailoring coils to meet the demands of unique applications.

    Smart Coils and IoT Integration

    The incorporation of smart technologies and Internet of Things (IoT) connectivity has transformed electrical coils into intelligent components. Smart coils can adjust their properties dynamically, optimizing performance based on real-time data and environmental conditions. This is particularly beneficial in applications like power distribution and energy management systems.

    Advanced Winding Techniques

    Innovations in winding techniques, including computer-controlled winding machines, have improved the precision and uniformity of coil winding. This ensures consistent performance and reliability, especially in high-frequency and high-power applications.

    Get Top-Notch Electrical Coil Winding Solutions at Endicott Coil Company

    Endicott Coil Company specializes in crafting custom electrical coil winding assemblies tailored to your unique specifications. Utilizing CNC winding equipment, we ensure precision windings with tolerances as tight as .002 inches. Moreover, our coils are constructed with 48 to 10 AWG-sized wires and boast a variety of configurations to suit your application. These are manufactured at our state-of-the-art facility, complying with UL, CSA, VDE, Mil-Spec, and NRC standards to ensure only the best solutions!

    Contact us or request a quote to explore our custom electric wound coiling capabilities.

  2. The Role of Custom Coils in Elevating Electronic Performance

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    Custom coils are pivotal in ensuring optimal performance and reliability of electronics. These are specialized electromagnetic components designed and manufactured to meet unique electrical specifications and application requirements. They can vary in size, shape, and configuration to accommodate diverse applications ranging from small portable devices to more complex configurations for specialized electronic equipment.

    In this blog, we will delve into how custom coils are created and the reasons behind their increasing demand in electronic manufacturing.

    How Custom Coils Are Designed and Crafted

    Custom coils are typically crafted by skilled engineers and manufacturers who collaborate closely with clients to understand their needs. It starts with a comprehensive analysis of the specific electrical requirements of the application. Various factors are carefully considered to ensure that the product meets the desired performance outcomes.

    Once the specifications are defined, advanced computer-aided design (CAD) software comes into play. Engineers use these tools to create detailed schematics and simulations, allowing them to visualize the coil’s behavior under different conditions. Prototyping follows, enabling real-world testing and fine-tuning before mass production.

    The production begins with the precision winding of copper wire. It is often automated for consistency to ensure the correct number of turns and alignment, which are crucial for the coil’s electrical properties. Then, insulation materials are carefully chosen to withstand the application’s operating temperatures and environmental factors. Lastly, each coil undergoes meticulous inspection to guarantee that it meets the highest standards before reaching the client.

    Why Custom-Made Coils Are in High Demand

    Currently, there’s a growing trend of businesses and professionals opting for tailored solutions in the field of electronics. Here are the key reasons behind the increasing demand for custom coils:

    Precise Electrical Specifications

    Unlike off-the-shelf coils with standard specifications, custom-made components are tailored to match the exact requirements of an application. This precision ensures optimal performance since it is designed to operate within the specified voltage, current, and inductance parameters.

    Compatibility With Bespoke Equipment

    Electronic systems often consist of bespoke equipment designed for specialized tasks. Custom coils are engineered to seamlessly integrate with these components, ensuring compatibility for the smooth operation of the entire system.

    Improved Performance

    Custom coils are optimized to deliver superior performance and efficiency. By tailoring its specifications to the application’s unique requirements, these solutions can enhance efficiency, reduce energy consumption, and minimize heat generation. These optimizations improve the overall functionality of electronic systems while contributing to prolonged lifespan and reliability.

    Flexibility in Design and Form Factors

    Standard or stock coils may not always fit the available space in intended applications. On the other hand, custom options can be designed in unique shapes and sizes to match specific spatial constraints and dimensions within electronic devices or systems.

    Elevate Your Projects With Custom Coils From Endicott Coil Company

    At Endicott Coil Company, we understand the critical role that custom coils play in shaping the future of electronic engineering. For over 65 years, we have been at the forefront of providing top-quality components to a diverse range of OEMs. We specialize in crafting custom-wound copper coils for magnetic coils, transformers, solenoids, and various other applications.

    Let us empower your electronic applications with tailored, high-performance components crafted with precision and dedication! Contact us today to discuss your requirements or request a quote to get started.

  3. Unveiling the Versatility of Industrial Coils in Various Applications

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    In the dynamic landscape of technology and innovation, industrial coils silently serve as the backbone for a wide array of applications. Industrial coils are indispensable components that power an array of industries, and they are engineered to excel in diverse and often demanding environments.

    Industrial Coil Applications:

    Industrial coils find applications in an extensive range of industries, from oil extraction to high-speed transportation and power generation. These coils are meticulously designed to meet the unique demands of each application, ensuring seamless operation in a variety of extreme conditions.

    Coil Materials Selection:

    Selecting the right materials is paramount in crafting exceptional industrial coils. Endicott Coil works closely with customers to ensure that the materials they choose align with their specific project requirements. These coils are built with a range of materials, including thermoset and thermoplastic epoxy compounds, to guarantee that the coils manufactured are not only efficient but also durable.

    Industrial Coil Performance Metrics:

    The performance of industrial coils is governed by strict adherence to industry standards. Quality assurance is a fundamental aspect, guaranteeing that products consistently perform admirably, even when faced with the most challenging conditions.

    Coil Efficiency Optimization:

    Efficiency is at the heart of industrial coil manufacturing. This is achieved through rigorous quality control, precise winding techniques, and meticulous attention to detail. The engineering behind these coils is geared towards maximum performance and reliability.

    Industrial Coil Manufacturing Processes:

    Whether your project calls for low or high-volume applications, or multi-spindle solutions, there are various manufacturing processes which are adaptable to your requirements.

    Industrial Coil Quality Assurance:

    Quality is the cornerstone of successful coil manufacturing. With ISO 9001-2015 certification, the emphasis is on consistently delivering high-quality products on time, ensuring that customer satisfaction remains a top priority.

    Environmental Durability of Coils:

    Industrial coils often operate in harsh environmental conditions. These coils are designed to withstand extreme elements, making them the preferred choice for applications where reliability is non-negotiable.

    Customized Solutions to Your Specifications:

    In the realm of custom manufacturing, the challenges of relying on a universal solution are widely recognized. It’s imperative to have seasoned engineers at your disposal, ready to collaborate with your team, and take your project from conceptualization to production. The ability to work closely with you in crafting coils that align precisely with your unique specifications is essential.

    Industrial Coil Prototyping:

    Prior to advancing to full-scale production, the inclusion of prototyping enables customers to assess and appraise the performance of their coils. This pivotal step ensures that the coils seamlessly conform to the exact project requirements.

    With a legacy of over 65 years in the industry, a relentless focus on quality assurance, a diverse range of manufacturing capabilities, and a dedication to meeting your unique needs, Endicott Coil stands as the top choice for industrial coil solutions. Trust in our expertise, quality, and innovation to power your industry with unparalleled coil solutions.

  4. Custom Transformers: The Edge of Tailored Solutions in Electrical Transmission

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    A transformer is a device that regulates voltage and current levels in electrical circuits. It plays a crucial role in power distribution, ensuring electricity is delivered efficiently and safely from power plants to homes and businesses. Generic transformers have been used for decades and are designed for a wide range of applications. However, they may not always meet the specific requirements of a particular electrical system. This is where custom transformers come into play.

    Unlike one-size-fits-all solutions, custom transformers are precisely engineered to provide optimal performance, efficiency, and reliability for specific conditions or requirements. In this article, well take a look at how they are revolutionizing modern electrical transmission and key considerations when designing these tailored solutions.

    The Benefits of Custom Transformers

    Customized transformers offer numerous benefits thanks to their tailored design and ability to meet specific requirements. Here are their key benefits:

    Improves Efficiency

    Custom transformers are optimized for their intended use to work more efficiently. They are precisely engineered to match voltage and current requirements, ensuring they operate at their optimal load and reducing energy wastage. Through careful design and material selection, custom transformers also minimize energy losses. This results in reduced heat generation during operation, which in turn improves efficiency.

    Enhances Reliability

    When transformers are tailored to specific needs, they are less likely to fail or malfunction. This enhanced reliability is critical for maintaining a consistent and uninterrupted power supply, especially in critical application settings like hospitals and data centers.

    Saves Costs

    While custom transformers may have higher upfront costs due to their specialized design, they can prove more cost-effective over time. Their efficiency and reduced maintenance requirements translate into lower operational expenses in the long run.

    Ensures Safety

    Custom transformers can incorporate advanced safety features and monitoring systems, such as overcurrent protection, temperature sensors, and fault detection. These safeguards help prevent accidents and ensure hitch-free operation.

    Accommodates Future Changes

    As electrical systems evolve, custom transformers can be adapted or redesigned to accommodate new technologies and changing requirements. This future-proofing ensures that the electrical infrastructure remains reliable and efficient in the long term.

    10 Key Design Considerations for Custom Transformers

    Creating tailored transformers involves a meticulous design process. There are numerous factors to consider to ensure optimal performance, safety, and reliability:

    1. Load Requirements

    Engineers must determine the expected voltage and current levels the transformer will handle to ensure it can deliver the necessary power without overloading or underperforming.

    2. Core and Winding Materials

    Different materials have varying magnetic properties, significantly impacting the transformer’s performance. Materials like iron and various alloys are commonly used for transformer cores.

    Meanwhile, the choice of winding materials depends on factors like cost, weight, and specific electrical properties required. Copper and aluminum are frequently used due to their excellent electrical conductivity.

    3. Cooling Systems

    Transformers generate heat during operation, leading to overheating if not managed properly. Engineers must design effective cooling systems such as oil-filled tanks or forced-air cooling — to dissipate heat and maintain optimal operating temperatures.

    4. Size and Weight Constraints

    Depending on the application, there may be limitations on the size and weight of the transformer. Designers must balance meeting electrical requirements and adhering to these constraints.

    5. Safety Features

    Transformers should incorporate safety features such as overcurrent protection, temperature sensors, and fault detection mechanisms to prevent accidents and equipment damage.

    6. Environmental Considerations

    Environmental concerns are increasingly important in transformer design. Designers should use eco-friendly materials and minimize environmental impact during manufacturing. They should also ensure that the transformer can be recycled or disposed of responsibly at the end of its life cycle.

    7. Maintenance and Monitoring

    Custom transformers often include advanced monitoring systems with sensors that track parameters like temperature, oil level, and load conditions. This data facilitates predictive maintenance, helping to identify and address issues before they lead to failures.

    8. Regulatory Compliance

    Designers need to ensure that their custom transformers adhere to relevant safety and performance standards to avoid legal and safety issues.

    Power Your Electrical Transmission Systems With Endicott Coil Company

    Endicott Coil Company is your trusted manufacturer of top-quality magnetic coils, transformers, and more! We are a leader in manufacturing custom transformers, including power, isolation, flyback, and autotransformers. Moreover, our expert engineers specialize in tailored electric coil winding assemblies and can cater to both prototype-stage production and high-volume orders. With over 60 years of industry experience, we guarantee top-notch products and quality solutions to a broad range of industries and OEMs.

    Contact us for more information or request a quote for your custom transformer needs!

  5. The Intricate Art of Coil Winding: How Precision Shapes Power

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    Coil winding involves the strategic arrangement of wire around a core to create coils, which are fundamental building blocks of various components. The process is a delicate balance between the precision of winding machines and the expertise of operators.

    This article delves into the methods and tools that shape a coil’s efficiency and power-handling abilities. Well also talk about challenges during the winding process and the innovative solutions available.

    Methods and Techniques for Precision Coil Winding

    Coil winding is a delicate process that demands careful execution to ensure the reliability and performance of the resulting coils. Here are some fundamental techniques employed to achieve precision:

    1. Linear Winding

    The linear winding method involves wrapping wire around a rotating coil body or device. A wire is threaded through a tube (wire guide) and securely attached to a post. This wire is then wound in layers to create the coil. The wire guide ensures the wire is evenly spread.

    2. Flyer Winding

    This method attaches wires to a rotating part called a flyer. It is positioned at a distance from the coil being created. Clips hold the wire in place as it spins around the coil.

    3. Needle Winding

    The needle winding method uses a needle with a special nozzle to guide wires as they are wound into coils. The needle moves up and down, adding layers of wire in different directions.

    4. Toroidal Winding

    Toroidal winding creates coils in the shape of a circular ring called a toroid. A circular core is placed around which wires are wound. As the core rotates, the machine winds the wires around it to form the coil.

    5. Spiral Coil Winding

    Spiral coil winding involves wrapping wire around a core in a continuous spiral pattern. This technique creates coils that look like a spiral staircase, with each turn of wire placed directly above the previous one. Spiral winding is often used in applications where compact size and efficient use of space are important.

    6. Parallel Coil Winding

    Parallel coil winding involves winding multiple wires side by side in parallel, typically with the same number of turns. This technique results in coils with multiple wire strands running alongside each other. Parallel winding is employed when increased current-carrying capacity or lower resistance is desired.

    7. Orthocyclic Coil Winding

    Orthocyclic coil winding is a specialized technique that creates layers of wire wound at various angles to the coil axis. This method optimizes coil properties for specific applications by carefully controlling the orientation of each wire layer. It is often used in electromagnetic devices to achieve desired magnetic field patterns.

    Precision Tools Used in Coil Winding

    Coil winding requires specialized tools to achieve precision, consistency, and efficiency. Here are some of the tools that assist in various aspects of the winding process:

    Winding Machines

    Winding machines are the backbone of coil winding operations, automating the winding process and ensuring consistent tension, layering, and winding patterns. Advanced winding machines are programmed to follow specific patterns and control parameters, producing coils with high accuracy.

    Tension Control Mechanisms

    Maintaining proper tension in the wire during winding is crucial for uniform layering and preventing wire breakage. Tension control mechanisms include tensioners and dancer arms. These ensure that the wire is fed with the appropriate tension, regardless of changes in spool diameter or wire properties.

    Wire Guides, Spools, and Bobbins

    Wire guides direct the wire onto the core in a controlled manner. They prevent wire tangling and ensure it is laid down evenly, contributing to uniform layering and avoiding gaps between turns. Meanwhile, spools and bobbins hold the wire and guide its movement during winding. They come in various sizes and designs, allowing for organized wire feeding and preventing wire tangling.

    Visual Inspection Tools

    Visual inspection tools, such as magnifying glasses and microscopes, aid operators in checking the quality of winding. They help identify irregularities, wire crossings, and other imperfections that could impact the coil’s performance.

    Challenges During Coil Winding and Innovative Solutions

    Here are some challenges encountered during coil winding and the innovative measures that have transformed the industry:

    Consistent Tension Maintenance

    Variations in wire properties, spool diameter, and winding speed can disrupt tension control. Hence, ensuring consistent wire tension throughout the winding process is critical for uniform layering and preventing defects.

    Advanced tension control systems assist in continuous tension monitoring and automatically adjust feed rates. These systems use sensors to provide real-time feedback, ensuring that the wire maintains the desired tension, regardless of external factors.

    Complex Winding Patterns

    Winding patterns tailored to specific applications can be complex and demanding to achieve accurately. Fortunately, computer-aided design (CAD) software and advanced programming allow engineers to precisely define winding patterns. Modern winding machines can execute intricate patterns highly, reducing human error and ensuring consistency.

    Real-Time Monitoring and Quality Control

    Detecting defects and ensuring quality control during winding can be challenging, especially for large-scale production. Installing real-time monitoring systems equipped with cameras and sensors ensures winding patterns, layer uniformity, and overall quality. In addition, automated quality control guarantees that defective coils are identified and rejected early in the process.

    Unlock the Power Coil Winding With Endicott Coil Company

    Ready to harness the power of precision-wound coils? Consult the experts at Endicott Coil Company! As a leader in this domain, we provide tailored solutions with years of expertise and innovation. We supply magnetic coils, transformers, solenoids, and more to various industries and applications. Whether you require prototyped components or large-scale production needs, you can count on us to deliver reliable and versatile solutions!

    Take the first step and contact us or request a quote today.

  6. Tips for Insulating Bobbin Wound Coils

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    Bobbin wound coils are one of the most efficient and economical methods of producing coils. As a result, they are frequently utilized in manufacturing, medical equipment, and other systems that generate electricity for residential and commercial establishments.

    Two types of plastic materials are used to create bobbin wound coils: thermoplastic and thermoset. Depending on specifications, coils can be insulated with a wide range of materials after being wound on a bobbin. This article will cover the basics of bobbin wound coils and the various tips and techniques for insulating them.

    What Is a Bobbin Wound Coil?

    A bobbin wound coil is created by wrapping a wire around a bobbin to maintain its structure and rigidity. It facilitates winding arrangement within or onto the magnetic core. Furthermore, the diameters of the bobbin change based on the voltage and current levels, the rating, and the working frequency.

    Bobbins are typically hard, pre-formed elements that serve as insulators. As long as a sufficient resistive distance is maintained, they often provide electrical contact between the coil and the connecting core material. They also indicate the features of the coil and the amount of wire utilized.

    Techniques for Bobbin Wound Coil Insulation

    The bobbin material is typically a component for insulation, allowing it to provide an electrical connection between the coil and the nearby core material. This is generally the case so long as the correct creepage distance is utilized.

    There are numerous methods for insulating a coil, including the following:

    Potting or Encapsulating

    Encapsulation is wrapping electric coils in materials such as silicone rubber, polyester, liquid, or thermoformed epoxy. They provide higher protection against extreme weather conditions, grease, and vibrations than molding.

    The main distinction between encapsulated and potted coil techniques is the tooling. Encapsulation uses a reusable mold into which the coil is deposited, filled, and removed after curing. In contrast, the potting process uses a disposable cup, which quickly becomes a finished product component.

    Overmolding or Insert Molding

    For overmolding or insert molding, a synthetic material is used to cover a coil or assembly. This method maximizes the protection of coiled materials against harsh environmental conditions, such as moisture, oil and grease penetration, salt, and vibration. Moreover, overmolded coils feature dielectric characteristics, consistent diameters, and varied stability.

    The overmolding method to insulate bobbin wound coils is often utilized in various industries, including aerospace, electronics, power transmission, and transportation.

    Taping or Thread Covering

    Taping or thread covering is considered the most cost-efficient technique for insulating coils. It often utilizes readily accessible electrical tapes in various materials, adhesives, and temperature specifications. Although taping may not provide the same degree of protection as other coil insulation methods, it often satisfies the requirements of less severe applications at a cheaper cost.

    Vacuum Impregnating

    Vacuum impregnation in transformer coils involves eliminating as much air from the structure as possible and replacing it with epoxy with significantly higher dielectric strength. These epoxies are special adhesives and will link the wires and other components of the construction to create a sturdier assembly.

    Commonly, vacuum impregnation is used to enhance the structural integrity of coils, enhance heat transfer, minimize partial discharge, and strengthen environmental protection. It is also used to reduce winding noises.

    Choose Endicott Coil Company for Exceptional Custom Coils and Transformers

    Endicott Coil Company has been the leading provider of magnetic components to various original equipment manufacturers for over 65 years! We have gained a reputation for value and performance, enabling us to meet and exceed the needs and expectations of our customers. We also provide services and consulting regarding material selection, test settings, and modifying an existing coil design to reduce costs.

    We can design and manufacture any coil, including air core, injection-molded, impregnated, bobbin wound, and sensing coils! Contact us today for additional details about our custom coil services, or request a quote.

  7. What Is an Overmolded Coil?

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    An electromagnetic coil, also known as an electric coil  is an electrical conductor containing a set of conductive wires wrapped around a specified shape and size. This can be a self-supporting (air core) design or include a customer specified core. Electrical coils are simple electronic components that provide inductance in an electromagnetic circuit. There are many coil types to meet the needs of various equipment. Electromagnetic coils can vary by wire gauge, length, coil diameter, core material, and other factors such as Overmolding.

    Overmolding is a multi-step  process where two or more components are molded over top of one another. Overmolded coils are protected from moisture, corrosive chemicals, vibration, explosions, and harsh working environments by being molded in a tough temperature resistant material.

    In addition to additional insulation and dielectric properties, overmolding can improve:

    • Grip or “feel”, while providing a stylish appearance that’s attractive to consumers
    • Reduce shock and vibration
    • Dampen sound
    • Provide electrical insulation
    • Improve chemical/UV resistance
    • Increase product longevity

    Definition of an Overmolded Coil

    Overmolding  requires using a synthetic material to overmold a coil or assembly. This technique optimizes the protection of the winding goods against extreme environmental conditions, such as humidity, oil and grease penetration, salt, and vibration.

    A quality overmolded coil has guaranteed and preserved dimensions through precise molds, the proper choice of materials, a consistent manufacturing process, and quality assurance. It is commonly used in various industries, including transportation, aircraft, electronics, and power transmission. Thus, these coils comply with UL, CSA, military specifications, and other applicable standards.

    Benefits of Overmolded Coils and Assemblies

    Overmolded coils are designed to create components resistant to fluids that would normally compromise the circuit, including solvents,water and oil. This reduces the risk of wire failure in harsh or unstable environments, allowing the completed circuit to continue functioning. Moreover, overmolding of coils enables customer selection of materials with resistance to vibration and other types of degradation based on their specific requirements.

    Endicott Coil Company’s Overmolding of Wound-Copper Coils for the Electronic Industry

    Endicott Coil Company manufactures epoxy molded, wound copper coils for the electronic industry. Depending on the requested coil dimensions, we utilize high-quality presses and carefully selected epoxy compounds, including Farboset, BMC, MH6, and Rynite .

    Choose Endicott Coil Company for Your Custom Coils and Components Needs!

    Since 1954, Endicott Coil Company has been the #1 supplier of magnetic components to various original equipment manufacturers! We have a solid track record for performance and growth, allowing us to meet and exceed the requirements and expectations of our customers.

    Our engineering staff is exceptionally competent and offers expertise in electric coil winding assembly customization. We can  accommodate various coil requirements based on our customers  needs, including self-supported, injection molded, bobbin wound, impregnated, and solenoid.

    Contact us today to learn more about our coil services! You can also request a quote to collaborate with us on your next project.

  8. What Is an Encapsulated or Potted Coil?

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    An electric coil comprises two distinct components: a conductor and a core. The conductor is typically made of solid copper wire wrapped around a metal core. A turn is created each time the wire is looped around the core, while multiple turns are considered a coil. It acts as an electrical conductor, efficiently sending an electrical current to generators, electric motors, electromagnets, and inductors.

    The most common application of an electric coil is as an inductor, which stores energy within its electric field. As a passive electronic component, an inductor has no gain and thus cannot control the directional flow of energy. Instead, it captures energy from the electric current flowing through its body.

    Electrical coils are typically required in industrial manufacturing, medical equipment, and devices used to supply electricity to commercial and residential buildings.

    Definition of an Encapsulated or Potted Coil

    Like any other electrical coil, an encapsulated or potted coil is constructed from a ferromagnetic metal wire wrapped into a specific diameter. It is an electromagnet that is only activated by magnetism when exposed to electric currents. Since most coils use outer casings for protection from harsh environmental conditions — such as salt, water, moisture, and vibration — encapsulated coils are frequently molded into liquid or thermoformed epoxies. This procedure causes the coil to fuse with its casing.

    Both encapsulated and potted coils surround and seal the coil with liquid materials, including silicone rubber, epoxies, and polyesters. These materials are available in temperatures ranging from 105 °C to 190 °C. The only difference between the processes for encapsulated and potted coils is the tooling: encapsulation utilizes a reusable mold into which the coil is placed, filled with material, and then removed after curing. Meanwhile, potting uses a single-use cup, which soon becomes a component of the final product.

    Advantages of Using Encapsulated or Potted Coils

    Encapsulated or potted coils have high dielectric and isolation properties and uniform dimensional and cosmetic characteristics. Thus, they often provide better protection against extreme environmental conditions than molded coils. Besides that, because they are dipped and thermoformed into sealing liquid, epoxies such as silicone rubber provide vibration protection that molded casings do not. Encapsulated coils can also be heat-treated after manufacturing, which sinters the plastic component with the molded coil inside, providing excellent protection.

    Moreover, encapsulation and potting processes aid in transferring heat and protect the components from thermal shock and adverse working environments, such as grease, salt, water, humidity, and gasoline. Finally, they provide a cost-effective alternative to overmolding when a protective outer shell is required, as overmolding tooling can be costly and impractical in small volumes.

    Endicott Coil Company’s Encapsulated Coil Manufacturing

    Endicott Coil Company creates customized encapsulated coils resistant to the harshest environmental circumstances. Depending on the customer’s application, our experts select the best encapsulation material, such as thermoplastics, thermosets, epoxies, silicone rubber, and polyesters.

    We are fully equipped with vacuum chambers, vacuum ovens, and curing ovens to achieve a proper cure regardless of the material used.

    Our company produces encapsulated coils with temperatures ranging from 105 °C to 240 °C. To ensure that all specifications are met, these coils are extensively tested using hi-pot, inductance, resistance, leak, and surge testing.

    High-Quality Custom Coils and Components From Endicott Coil Company

    Endicott Coil Company, Inc. has a long history of providing high-quality custom magnetic components and services. Our company leverages our extensive knowledge, expertise, versatility, and capabilities to meet and fulfill each customer’s specifications. We also offer comprehensive value-added services — such as overmolding, encapsulation, and sub-assembly manufacturing — in addition to our wide assortment of coils and transformers.

    Our facility is RoHS compliant and employs ISO methodologies and procedures throughout the manufacturing process. Furthermore, we have experience with ASTM, CSA, VDE, NRC, Mil-Spec, and UL testing procedures.

    Contact us today to learn more about the products and services Endicott Coil Company offers. You can also request a quote now!

  9. What Is a Self-Supported Coil?

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    An electric coil, also known as an electromagnetic coil, is an electrical conductor composed of wires wrapped around a cylindrical, disk-shaped, or toroidal ferromagnetic core. It is one of the most basic electronic components, providing inductance in an electric circuit. Inductance refers to an electrical property that opposes current flow through the circuit.

    Electric coils are widely used in applications where electric currents interact with magnetic fields. These include the manufacturing, engineering, and medical industries. They are also found in devices and equipment such as electric motors, generators, transformers, inductors, and sensor coils.

    Definition of a Self-Supported Coil

    Self-supported or air core coils are created by coating magnet wire with an adhesive and then wrapping it in an insulating film. Solvents, hot-air heating, and post-baking can all be used to activate the adhesive and secure the adjacent strands of magnet wire. They are also wound on collapsible mandrels, allowing disassembly without damaging the wire insulation. The mandrels can be machined into nearly any shape to accommodate any desired coil configuration.

    These coils are ideal for electronic applications where a bobbin or other coil form is impossible due to dimensional constraints. They reduce bobbin costs while increasing copper content in a given area.

    Presently, bondable magnet wire with fundamental solutions up to 180° is available. However, the strand-to-strand bond typically begins to soften at temperatures 10° to 15° below the insulation rating. A bondable wire is also useful when magnet wire bonding is preferred to prevent movement or wire abrasion in applications where other processes, such as impregnation or varnishing, are not recommended.

    Advantages of Self-Supported Coils

    One of the most significant benefits of a self-supported coil is the low signal loss that occurs at higher magnetic field strengths. Ferromagnetic cores such as iron can become magnetically saturated when the magnetic field is too strong, causing an inductance loss. This is not a problem for self-supported coils as they can carry electromagnetic frequencies up to 1 GHz. Conversely, ferromagnetic core inductors lose efficiency once the frequency exceeds 100 MHz.

    Self-supported coils are also simple to build since they are unaffected by the value of the electric current they transport. If there is no ferromagnetic core, they are more suitable for low-power devices, such as commodity electronic products, computer devices, communication equipment, and other consumer goods.

    CNC Winding of a Self-Supported Copper Coil by Endicott Coil

    Endicott Coil Company, Inc. manufactures a wide range of self-supported coil shapes and sizes for use in various space-constrained electronic applications. Based on customer specifications, the company uses CNC equipment to wind strands of coated 24-48 AWG copper magnet wire to the desired shape. The bondable coating is then activated via a solvent or heat cure to secure the magnet wire strand-to-strand.

    Endicott also solders and trims the finished pieces using in-process gauging to maintain tolerances of less than 0.005 in.

    Partner With Endicott Coil Company for High-Quality Custom Coils and Components

    Endicott Coil Company, Inc. has been the leading supplier of magnetic components to a wide range of OEMs for over 65 years! We have earned a solid reputation for value and performance, enabling us to meet and exceed our customer’s needs and expectations.

    Our company can significantly help with material selection, parameter testing, and cost-cutting redesigns of existing coil designs. Endicott Coil’s engineering team is also exceptionally skilled and specializes in custom electric coil winding assemblies! We can create and construct any coil type, including self-supported, injection molded, bobbin wound, impregnated, and sensing coils.

    For more information on our coil services, contact us right away. You can also request a quote to start your next project with Endicott Coil Company!

  10. What Is A Bobbin Wound Coil?

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    An electric coil is a fundamental type of electronic component which provides inductance in a circuit. In other words, it is an electrical feature that opposes current flow. These coils are classified according to the coil diameter, wire gauges, number of turns and core materials.

    Electric coils are commonly used in manufacturing, medical instruments, and other devices that generate electricity for homes and businesses. They are meticulously designed according to their intended applications. Various electric coils are made up of a core and wiring wrapped around it; one of these is the bobbin wound coil.

    Definition Of A Bobbin Wound Coil

    Bobbin wound coils are created by wrapping a wire around a bobbin to keep its shape and rigidity. It makes winding assembly into or onto the magnetic core easier. The bobbin diameter varies with voltage and current levels, rating, and operating frequency.

    Bobbins are rigid, pre-formed components that typically act as insulators. As long as an adequate resistive distance is used, they provide an electrical connection between the coil and the connecting core material. They also specify the coil’s characteristics and the amount of wire used. Moreover, they aid in determining the coil’s temperature rating, the device’s dielectric properties, and other coil-related features.

    Most bobbins are molded, while others are fabricated. Designs for these frequently include terminals, pins, and surface mount pads for wire termination and printed circuit board mounting.

    Considerations When Designing A Bobbin Wound Coil

    Bobbin wound coils are the most efficient and cost-effective method of producing coils. However, it is critical to choose the most suitable bobbin to achieve the best bobbin and wire combination. The following are some of the most important factors to consider:

    Material Choice

    A critical material consideration is the amount of heat a plastic molded bobbin must withstand; it should be strong enough to endure soldering temperatures for a short period during production. Two types of plastics are used in bobbin molding: thermoplastic and thermoset.

    Thermoplastic materials are the most commonly used in bobbin molding. When mixed with mineral, quartz, or glass fillers, thermoplastic bobbins are economical and can satisfy many heat and flammability requirements. However, these materials are more costly. Still, they provide the highest strength and temperature performance.

    Although DAP and epoxy plastics are suitable for toroid mounts and potting cups, their brittleness makes them unsuitable for bobbin applications. On the other hand, phenolic plastic is ideal as a bobbin because it is stable at high temperatures.

    Cost And Shape

    The square stack lamination sizes E187, E24/25, E375, E21, and E42/15 have the cheapest core and bobbin combination with the greatest availability. However, such leg shapes may need to be protected with copper foil to reduce electromagnetic interference (EMI), increasing the cost.

    You can also consider the newer round center leg cores and bobbin combinations. Common examples of this core style include ETDs, PQs, EFDs, and EPs made of ferrite. These recent combinations are more expensive than the square ones, but they are easier to wind and provide good EMI shielding.

    Orientation Of The Bobbin And Core

    Vertical mount bobbins require less board space but are taller than horizontal mount bobbins. Wire termination is also more complex, and only a few multi-section types are available.

    On the flip side, horizontal mount bobbins are less visible but take up more board space. These types also make wire termination easier, and many multi-section types are available.

    Safety Requirements

    The requirements of the safety agencies apply to the entire process of inductor construction. These regulations address insulation and spacing to prevent thermal aging and an electrical malfunction in the winding from developing over time.

    UL 1446 is the primary specification in the United States that controls the insulation requirements of these products. This standard covers motor, transformer, and coil insulation. Meanwhile, UL 510 is another essential regulation for the flammability of electronic tape, frequently used in the design of a transformer or inductor.

    Tips For Insulating Bobbin Wound Coil

    Coils can be insulated with various materials after being wound on a bobbin to meet your specifications. Some methods for insulating a coil are as follows:

    Tape or Thread Covered

    The most cost-effective method of coil insulation is to use one of the many electrical tapes on the market. These tapes are widely available and come in various materials, adhesives, and temperature ratings. Despite not providing the same level of protection as other options, tapes frequently fulfill the requirements of less stringent applications at a lower cost.

    Vacuum Impregnation

    Impregnation can provide many benefits of molded and encapsulated parts without the expense of dedicated tooling. Impregnants form a bond between the wire and the filler, improving heat dissipation. You can also improve the dielectric properties by selecting the right impregnated coils.

    Encapsulation or Potting

    Encapsulation involves enclosing the electric coils in silicone rubber, polyester, liquid, or thermoformed epoxy casing. They provide better protection from harsh weather, oil, and vibration than molded coils because they are frequently dipped or thermoformed into sealing liquid epoxies.

    Overmolding

    In overmolding or insert molding, a coil is overmolded using a synthetic material in a subsequent process step. This method protects the winding materials from harsh environmental conditions.

    Endicott Coil Company For High-Quality Custom Coils And Transformers

    For over 65 years, Endicott Coil Company, Inc. has been the top supplier of magnetic components to a wide range of OEMs. We have built a reputation for service and quality, allowing us to meet and surpass our customer’s needs and requirements.

    We have a highly skilled engineering team that specializes in custom electric coil winding assemblies. Our expertise and versatility allow us to design and build any coil type, including air core, injection molded, impregnated, bobbin wound, and sensing coils. Endicott Coil Company, Inc. can also help with material selection, test parameters, and redesigning an existing coil design to save money.

    Contact us now for more information on our custom coil services. You can also request a quote and let us make your innovative ideas a reality!