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Coil Winding Specialist
Self Supported Coils :
Custom Coil Winding Using Small Gauge Wires
 
"We will wind anything for you"

If you can conceptualize it, draw it, sketch it or describe it, we can wind it for you. Of course, if you have an engineering print of it, we can serve you even better.


CWS specializes in very complicated and very delicate custom windings of self supported coils. We can wind extremely small diameter wires, down to 0.04mm ( 1.5 mils) in diameter. These self supported coils are usually wound on self bondable wires, but they can also be wound on non self bondable wires such as the class 200 deg C wires and then bonded with epoxy. CWS also wind large self supported coils over 300mm ( 12 ") in lengths and widths. Application includes sensors, RFIDs, industrial, medical and military. Very low cost, million pieces volume windings are done at our Asian facility.

Examples of custom coil windings from CWS for RFID applications are:

1) Smart Card Coils for 125 kHz or 13.56 MHz: Please see image below for more description.

2) Clamshell Coils: These are thicker coils than the Smart Card coils. The thickness is approximately 1 mm ( 40 mils) . The copper wire diameter ranges from 0.064mm ( 2.5 mils) to 1.0 mm ( 40 mils). Oval or round shaped depending on custom requirements. The coil inductance is designed to match the module inductance for 125 kHz or 13.56 MHz resonance frequency.

3) Proximity Cards Coils: For 125 kHz or 13.56 MHz resonance frequency. Coil inductance designed to match the module capacitance. Thickness of 1.6mm ( 63 mils). Modules includes Hitag, Mifare, Temic or any customized module. The read range is approximately 5 cm to 15 cm depending on the types of reader used. Oval shaped coils are used to maximize the reading distance.

4) Other Services: Coil to module attachment. Coils are soldered to modules using thermo compression welding. Ideal for Smart Card lamination process. No solder is involved to eliminate added height due to solder. CWS also provide complete tag assembly using ultra sonic welding for plastic casing.

See below for examples of custom coil windings. Please call CWS for your requirements - high quality work at a reasonable tooling cost and low cost volume production.

7" x 4" self supported coils using AWG #20 wire.

Built to customer's specifications using Butyl or Epoxy bondable wires.

CWS can also wind these using non bondable wires for extremely high temperature applications.

Smart Card Coils:
Very thin and flat coils for smart card lamination process. Thickness ranging from 0.20mm to 0.30mm. Ideal for ISO card standard. Very fine copper wires with diameters of 0.04mm to 0.15mm are used. Oval or round shape. The coil inductance is matched with the module capacitance for 125 kHz or 13.5 kHz resonance frequency

Round Coils :

Self supported round or oval shaped coils with any wire gauge down to AWG #40. Single wire diameter layer or multiple wire diameter layers. CWS built to customer's specifications.

 

Pan Cake Coils:

Single wire diameter thick coils using AWG #38, 40 and 42 gauges. Fully self supported coils wound with extreme precision

Clam Shell Coils:

Rectangular self supported coils using any wire gauge

Very Fine Windings on miniature ferrite rod:

Rod diameter of 1mm. Length of 5mm. Wire size of 0.04mm. Small antenna receiver applications.
Digitizer Pad Coils Sensor Pad Coils Multi-layer coils forming a copper wire hollow rod

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Need Power Magnetics? Then look no more! CWS delivers the finest in surface mount inductors, standard inductors, Power Transformers, Common Mode Chokes, Ceramic Chip Inductors and Wire Wound Chip Inductors. CWS can supply all of your filtering needs as well, including EMI Filters, RFI Filters, LC Filter Inductors, and Common Mode Filters. From Transmission Line Transformers to power transformers, CWS is the source to call!
We have direct crosses to all major manufacturers including Toko, CoilCraft, Coiltronics, Tokin, J.W. Miller, Arnold, Siemens, TDK, Gowanda, Taiyo Yuden and more! Call for details!

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