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

Winding flat wire usually requires the use of a sufficiently strong and stable bobbin. The coil can be made of metallic or non-metallic materials such as steel, copper, aluminum or plastic. Flat wire winding requires the use of flat cross-section wires. These wires may be made of copper, aluminum, or other conductive materials with good electrical conductivity and heat resistance. The thickness and width of the flat wire can be selected based on the current load and available space.



Winding of flat wires can be done manually or using automated equipment. For winding, the flat wire is placed flat on the winding skeleton or insulator and wound according to a predetermined number of turns and winding method. Usually, insulating varnish or insulating paper is used to insulate each layer of the winding. Flat wire can be wound in layers, such as single-layer, multi-layer or staggered winding. Single-layer winding is to lay the flat wire flat on a single layer of the bobbin. Multi-layer winding involves placing multiple layers of flat wire at regular intervals on a bobbin. Interleaved winding involves winding two or more flat wires in an interleaved fashion on a bobbin.

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

Flat wire winding has the advantage of large winding width and high number of turns, and is widely used in applications requiring high inductance and low resistance. It provides greater magnetic field and power transfer capability and efficient use of space with low space constraints.