Flat wire winding is a coil winding method in which the wire or wire is laid flat on a winding bobbin or insulator. It is commonly used for components that require a large number of turns and a wide winding width, such as transformers, inductors and solenoids.

Flat wire winding usually requires the use of a winding bobbin with sufficient strength and stability. The bobbins can be metallic or non-metallic materials such as steel, copper, aluminum or plastic. Flat wire winding requires the use of wires having a flat cross-section. These wires may be copper, aluminum or other conductive materials having good electrical conductivity and heat resistance. The thickness and width of the flat wire can be selected according to the current load and space requirements.
Flat wire winding can be done manually or using automated equipment. During winding, the flat wire is laid flat on a winding skeleton or insulator and wound according to a predetermined number of turns and winding pattern. Insulating varnish or insulating paper is often used to isolate the layers of winding. Flat wires can be wound in different layers, such as single-layer, multi-layer, or staggered. Single-layer winding involves laying the flat wire flat on one layer of the winding bobbin. Multi-layer winding involves laying multiple layers of flat wire on the bobbin at regular intervals. Staggered winding is a way of winding two or more flat wires in a staggered manner on the bobbin.


Once the flat wire is wound, the coil needs to be insulated for electrical safety and reliability. Insulating varnish can be used to coat the entire surface of the coil, or insulation paper or tape can be added to isolate between each layer. In flat wire winding, connections between wires can be made by soldering, crimping, or winding specific connections. These connections require good electrical contact and mechanical strength; quality control is required during flat wire winding, including checking the number of turns wound, insulation quality, connection quality, and cosmetic defects. Electrical testing and performance verification are also required to ensure that the coil meets specifications and requirements.

Flat wire winding offers the advantage of larger winding widths and high turn counts, making it widely used in applications requiring high inductance and low resistance. It provides greater magnetic field and power transfer capability and efficient use of space where space constraints are less.