Continuous Improvement Efforts in Wire Bonding

Concerns with stripping and soldering copper magnet wire in ignition coils and other related products have led to the investigation of an alternative product and process design, microjoining. This paper describes the initial development occurring during the improvement phase of a Six Sigma project. The use of microjoining with a folded over welding tab terminal design coupled with a parallel gap welding process is developed as a suitable method for joining a tin plated brass terminals to the 0.65mm magnet wire without prior removal of the polyesterimide over-coated polyamideimide insulation.