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Pancake coil winding

Discussion in 'Electronic Design' started by Spehro Pefhany, Mar 3, 2008.

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  1. How are flat spiral (pancake) coils wound? How does the machine
    differ from a conventional computer controlled winding machine?

    Best regards,
    Spehro Pefhany
  2. Tim Shoppa

    Tim Shoppa Guest

    Isn't it just the degenerate case of 1 turn per layer?

    But the ridiculous aspect ratio (height of turns : width of turns way
    way bigger than one) will require some sort of bobbin wall.

    I don't know much about "conventional computer controlled winding
    machines" but have run hand-driven Morris coil winders.

  3. Terry Given

    Terry Given Guest

    do they dance with swords?

  4. No! More like one layer per turn-- but how do they get it to stay in
    Best regards,
    Spehro Pefhany
  5. donald

    donald Guest

    Thats SWords.
  6. Jim Thompson

    Jim Thompson Guest


    Chewing gum ?:)

    ...Jim Thompson
  7. Ecnerwal

    Ecnerwal Guest

    Presumably with a bobbin. If you're seeing examples with no bobbin, then
    they were wound with a bobbin (or the moral equivalent - call it a coil
    former, if you like) and then probably varnished or epoxied, IMHO.
  8. Cotton covered and soaked with tacky wax.
  9. Guest

    They might be using self-bonding wire, with comes with a layer of
    thermosetting adhesive on top of the enamel; you wind the coil, then
    run a carefully calculated current through the coil to get it hot
    enough to set the adhesive,then take it out of the bobbin - the
    application notes specify the kind of bobbin materials you can get
    away with and the sort of release agents you have to use on the bobbin
    so that you can take it out of the bobbin.

    Most of the people I've talked with who have built self-supporting
    coils didn't know about self-bonding wire and used slow-setting epoxy
    resin. Here's the first useful web-site that I found with a quick
  10. Guest

    Jim is ever-reliably out of touch.
  11. On Mon, 3 Mar 2008 16:38:13 -0800 (PST), the renowned
    Thanks, Bill, that's very useful information. I think I see how to do
    it now.

    Best regards,
    Spehro Pefhany

  12. Coil dope? That or hard wax. Those are the only two I've seen used.

    Service to my country? Been there, Done that, and I've got my DD214 to
    prove it.
    Member of DAV #85.

    Michael A. Terrell
    Central Florida
  13. Robert Baer

    Robert Baer Guest

    Why not make a PCB with a spiral path?
  14. Robert Baer

    Robert Baer Guest

    A type of glue seems to be used; applied to the wire feeding into the
  15. Robert Baer

    Robert Baer Guest

    Only if it comes from the bottom of movie theater seats...
  16. Robert Baer

    Robert Baer Guest

    How tacky? The wax was more tacky than my dumb jokes...

  17. Not possible.

    Service to my country? Been there, Done that, and I've got my DD214 to
    prove it.
    Member of DAV #85.

    Michael A. Terrell
    Central Florida
  18. JosephKK

    JosephKK Guest

    Currently it is often done with PWB processes (selective plating or
    etching). Previously (about 60 years ago) it was done with litz wire
    and glue.
  19. Tim Williams

    Tim Williams Guest

    I did it in free air. But then, that was 1/4" copper tubing ;-)


    Deep Fryer: A very philosophical monk.
    Website @
  20. That's not really winding-- and I'm not sure that PWB is practical for
    relatively small quantities of coils made with exotic alloys.
    Best regards,
    Spehro Pefhany
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