What is High-Density Plasma Technology?

High-density plasma domes have traditionally been used as decorative objects due to their unique lighting effects, but they are also an integral part of the semiconductor manufacturing industry. This blog will explain high-density plasma domes and their modern applications in further detail.

High-Density Plasma Domes

Also called a plasma globe, a plasma dome is a clear glass ball or container filled with a mixture of different noble gasses and a high-voltage electrode at the center. Plasma forms within the container when you apply voltage. Consequently, plasma filaments extend from the central electrode to the inner walls of the glass insulator. The result is the appearance of several beams of colored light.

Different variations of high-density plasma domes exist. The most common variation is a clear glass sphere filled with gas mixtures at close to atmospheric pressure. These gas mixtures may include neon, krypton, xenon, and argon. 

The globes run on high-frequency alternating current. In most cases, the driving circuit is a type of power inverter, where a lower-voltage direct current supplements the inverter’s output with the help of a high-voltage, high-frequency transformer.

Applications of High-Density Plasma Domes

A high-density plasma dome is a single unit made up of several components, including:

• A ceramic bell jar
• A cooling/RF coil
• Ground tabs/slugs
• Machine parts
• A non-conductive elastomer 

In semiconductor applications, high-density plasma chemical vapor deposition (HDP-CVD) is a technique that creates the crucial layers of insulation that separate and protect the electrical components. High-density plasma domes can be categorized based on the type of gasses they contain and their applications, which typically include RF assemblies and silicon wafers.

In addition to decorative and recreational purposes, high-density plasma globes can be part of an institution’s lab equipment for demonstration purposes. In particular, high-density microwave plasma machines can produce ions and free radical species. In these applications, the machine is made of a plasma source, the circuit, and the applicator.

High-density plasma domes can also be used in silicon wafer and RF assembly applications, where they are susceptible to damage with regular use. That’s why it’s important to partner with a reputable refurbishment and repair company.

When using high-density plasma domes, exercise caution especially in the following conditions:

• Avoid bringing flammable items near the globes.
• The domes may emit certain frequencies that interfere with phone and Wi-Fi signals. Therefore, keep them away from such areas.
• Since they radiate electromagnetic waves, avoid operating the domes near people with pacemakers.

Custom Coils Capabilities

If you’re looking for high-density plasma dome repairs and refurbishments, Custom Coils is here to help. With over 30 years of experience, we are experts at developing high-quality, repeatable production processes for high-density plasma domes. We have shipped over 10,000 high-density bell jar parts, and we remain ready to take on any repair or refurbishment project, no matter how challenging or complex. What sets us apart from other suppliers is that we understand how critical parameters relate to material makeup.

Contact us to learn more about our capabilities, or request a quote to begin your project. 

Real World Applications of Electromagnets

As common as they are, electromagnetic devices are not as widely understood. An electromagnet uses an electrical current to generate a magnetic field. The strength of that field is directly proportional to the level of current supplied to the magnet, and the field’s polarity can be flipped by changing the direction of the electrical current. Electromagnets serve a variety of purposes in many day-to-day technologies, particularly in electromechanical and electronic devices.

We’ll cover some of the most common uses of electromagnets in the world today, both in consumer products and for industrial applications, making many modern technologies possible.

Real World Electromagnet Applications in Electronics

Most people don’t directly see electromagnets in their daily life, but they are no less often used. Electromagnets are found in countless consumer and commercial products, including:

• TVs
• Audio Equipment
• Computers
• Cars
• Elevators
• Copy Machines
• MRI/CT Scan Machines

Real World Electromagnet Applications in Power Generation

Generating power involves converting sources of primary energy into electric power. An electric generator stores mechanical energy in the form of electrical energy by using a wire coil in a magnetic field. This is done by rotating the coil, which induces a current, and industrial-scaled applications accomplish this with a large, rapidly spinning turbine to produce massive amounts of electrical current.

This electrical energy can be stored and converted back into mechanical energy for a variety of purposes – such as running a motor. To do so, an electromagnet is supplied with a reverse current, creating a magnetic field that causes the magnet’s coil to spin, along with anything connected to it.

Electromagnets make it possible to convert mechanical energy into electricity, and then back into mechanical energy. The electromagnetic device that converts these energies is called an actuator, which consists of a stationary and a moving component (such as a rotor), where the magnetic fields produce torque and force that can be harnessed. This same principle makes it possible to use an electromagnet’s induction coil to measure the magnetic field itself, making electromagnets capable of functioning as sensors.

To summarize, electromagnets are used in four different ways in the power generation process:

• Generators
• Motors
• Actuators
• Sensors

Real World Electromagnet Applications in Medicine

Medical devices such as Magnetic Resonance Imaging machines (MRIs), use magnets thousands of times more powerful than your average kitchen magnet to generate signals in the radio-frequency range, which the device then measures and translates into images. This results in highly detailed pictures of bones, organs, and various tissues.

Magnets are also applied in some cancer treatments, where a doctor injects magnetically sensitive fluid into the area around the tumor and uses a powerful magnet to generate heat in the body. The goal is to kill the cancer cells without harming the healthy tissues.

These are just two common medical uses of magnets – others include:

• Scanners
• X-ray equipment
• Dialysis machines
• Disinfectant dispensers
• Electromagnetic therapies

Real World Electromagnet Applications in Aerospace

Aerospace engineers have developed an almost entirely separate field of magnetics. Specialized uses involve sending finely controlled current and voltage to receiving systems to maintain altitude and other flight dynamics. In reverse, this also enables them to track the location and flight path of various aircraft and devices.

Much of aerospace engineering would not be possible without electromagnetic technology. Electromagnets power many standard and specialized aerospace devices, such as:

• Flight control covers for both commercial and combat aircraft
• Missile programs
• Aircraft loudspeakers
• Traveling-wave tube (TWT) radar
• Permanent Magnet (PM) generator rotor assemblies
• Fuel pumps
• Flow regulators
• Cryogenic magnets suited for space environments
• Magnetic holders for aircraft seats
• Position-calibration and speed sensors
• Air-compressor components
• Motorized generators
• Tachometer generators

Electromagnets from Custom Coils

Not many technologies are as ubiquitous to modern life while remaining largely hidden from direct experience as electromagnets. Just as electromagnetic devices have driven much of modern technology forward without being often credited as such, Custom Coils, Inc. has been quietly and dutifully driving the electromagnetic industry forward since 1978.

With a highly customer-centric business model, our expert engineers work closely with every client to design and manufacture precision-engineered electromagnets for a wide variety of end uses. For any questions or to let us know about your electromagnetic needs, don’t hesitate to request a quote or contact us.

Inductors vs. Electromagnets: Applications and Capabilities

Inductors and electromagnets are widely used components in electrical devices such as motors, generators, and transformers. While both components utilize a wire coil to establish a magnetic field, they each have functional differences that influence their suitability for a given application. Here, we highlight their similarities and differences while providing examples of how each is used in various electrical and electromechanical devices.

What are Inductors and Electromagnets?

Inductors

An inductor is a two-terminal electrical component consisting of a wire wound into a coil. When electricity is applied to the coil, a magnetic field forms and gradually increases in strength. This magnetic field eventually collapses and is converted into electrical energy that is released back into the circuit.

The ability of inductors to temporarily store energy in an electromagnetic field makes them useful for: 

• Slowing current surges and spikes in circuits
• Storing and delivering energy to a circuit
• Impedance matching

Inductors are categorized into the following types:

• Coupled inductors featuring two coils connected by electromagnetic induction
• Multi-layer inductors featuring a layered coil wrapped around a core
• Ceramic core inductors featuring a dielectric ceramic core
• Molded inductors created using plastic or ceramic housings

Electromagnets

Like inductors, electromagnets consist of a coiled wire through which electricity flows to produce a magnetic field. The strength of the magnetic field is proportional to the number of turns in the coil. To further increase the magnetic field’s strength, the coil is often wound around a ferromagnetic or iron core.

In contrast to permanent magnets, the strength of an electromagnet’s magnetic field can be adjusted by modifying the amount of current flowing through the coil. The magnetic field can also be “turned off” by removing the electricity source from the magnet. This controllability makes electromagnets ideal for everything from powering electric doorbells to lifting and moving large pieces of metal.

Electromagnets include three main types:

• Resistive electromagnets featuring copper wires twisted around an iron core 
• Superconducting electromagnets featuring cryogenically cooled coils of superconducting wire
• Hybrid electromagnets featuring a combination of resistive and superconducting electromagnets

Applications of Inductors and Electromagnets

Inductors

One of the most well-known uses of inductors is in induction motors, where they generate the magnetic field required to rotate the motor’s shaft. The speed of the shaft’s rotation is directly proportional to the frequency of the power supply. Other inductor applications include:

• Filtering/blocking. In electrical circuits, inductors can filter, choke, or block higher-frequency alternating currents and smoothen output voltages.
• Transformers and converters. Inductors transfer and store energy in transformers and power converters.
• Tuning circuits. In tuning circuits, inductors allow a specific frequency to be selected.
• Sensors. Contactless electronic proximity sensors utilize inductors in the head of the sensor to enable inductive sensing.
• Ferrite beads. When used in ferrite beads, inductors help reduce electromagnetic interference in audio circuits.
• Electromagnetic relays. Electromagnetic relays are automatic switches that use electromagnetic induction to open or close the switch during operation.

Electromagnets

The power and versatility of electromagnets make them an essential component of everything from small consumer electronics to mass-transit systems. In maglev trains, for example, electromagnets line the undercarriage of the train to levitate it above the guideway. Other applications of electromagnets include:

• Motors and generators
• Electric doorbells and buzzers
• Magnetic locks
• Headphones and speakers
• Induction heating systems used in cooking and manufacturing equipment
• Medical equipment such as MRIs and heart monitors
• Magnetic recording technology and data storage devices such as hard disks and tape recorders
• Laboratory research equipment such as mass spectrometers
• Particle accelerators
• Magnetic separation equipment
• Industrial lifting equipment

Custom Inductors and Electromagnets from Custom Coils

Inductors and electromagnets provide essential functions in a range of electrical systems and electronic devices. At Custom Coils, we design and manufacture custom inductors and electromagnets according to specific field requirements and performance expectations. From high-quality materials to expert design recommendations, our in-house resources and experience allow us to create long-lasting products for nearly any electrical application.

To learn more about our inductor and electromagnet design capabilities, please contact us today or request a quote.

Types of Inductors

An inductor is one of the basic electrical components commonly used in electric circuits. Typically, an inductor consists of an electrical conductor wound into a coil, often including an iron core. The inductor stores energy in a magnetic field when current flows through it. This magnetic field induces an electromotive force (in the form of voltage) that opposes any change in current. are common in radio frequency systems, where they conduct currents and reduce feedback and interference. In circuits, inductors are crucial in controlling electrical flow.

Custom Coils produces a wide range of inductors and can work with you throughout the product development life cycle to customize inductors for your application. As you review your options and specifications, consider the following types of inductors.

Types of Inductors

Inductors can follow multilayered, coupled, molded, ceramic, or other designs. Here are more details on the most common inductor types on the market.

Air Core Inductor

Air core inductors are hollow, which gives them low permeability and low inductance. They are most effective in high-frequency settings.

Iron Core Inductor

Also called ferrite core, these inductors have high resistance to electricity, high permeability, and low eddy current losses—all of which results in excellent performance in high-frequency applications.

Toroidal Inductor

These inductors are made of a donut-shaped iron core wrapped in wire. Thanks to its closed-loop, circular shape, toroidal inductors create strong magnetic fields.

Laminated Core Inductor

Laminated core inductors consist of thin steel sheets stacked to form the core. These stacks help block eddy currents and minimize energy loss.

Powdered Iron Core Inductor

These inductors are composed of magnetic iron material with air gaps. This construction allows the core to store more energy than other types of inductors. They also offer low eddy current and hysteresis losses.

Axial Inductor

An axial inductor is made by wrapping copper wire around a dumbbell-shaped ferrite core. A molding procedure then prints colored bands on it, and users can read these bands using a color code chart to determine the inductance value.

Shielded Surface Mount Inductor

The inductor wire wraps around a cylindrical bobbin and is secured in a specially made ferrite housing. These inductors are specifically created for PCB applications since the shielding minimizes EMI and noise from the inductor.

Coupled Inductor

These inductors feature two wires wound around a common core. The wires can be connected in various ways and transfer energy through mutual inductance. An example of a coupled inductor is a transformer.

Multilayer Chip Inductor

Multilayer inductors are made up of thin ferrite plates with coil patterns printed on them. The layered coils and insulation between them create high inductance.

Shielded Variable Inductor

With these inductors, a wire wraps around a hollow cylinder bobbin and can change inductance according to the core material placed inside. Ferrite cores increase inductance while brass cores decrease inductance.

Molded Inductor

Inductors with molded plastic or ceramic insulation are often found in circuit boards. They’re shaped as either bars or cylinders.

Ceramic Core Inductor

Ceramic cores are dielectric and cannot store much energy, but they do provide low distortion and heat loss.

Inductor Applications

The following are popular applications for each inductor.

Air Core Conductor

• RF tuning coils
• Filter circuits
• Snubber circuits
• TV and radio receivers

Iron Core Conductor

• Transformers
• High-frequency applications

Toroidal Inductor

• Medical devices
• Industrial controllers
• Switching regulators
• AC circuits
• Output filters

Laminated Core Inductor

• Electric vehicle onboard chargers
• Noise and line filters
• CH/CL filter chokes for signals
• Transformers

Powdered Iron Core Inductor

• Transformers
• DC inductors

Axial Inductor

• Line filters
• Boost converters

Shielded Surface Mount Inductor

• Mobile and desktop devices
• Servers
• POL converters
• Power supplies
• Battery-powered gadgets
• DC/DC converters in distributed power systems and field-programmable gate arrays

Coupled Inductor

• Cuk, flyback, and single-ended primary-inductor converters
• Transformers

Multilayer Chip Inductor

• Bluetooth
• Wireless LANs
• Motherboards
• Wearables
• SBCs

Shielded Variable Inductor

• Automotive applications that comply with AEC-Q200 regulations

Molded Inductor

• Circuit boards

Ceramic Core Inductor

• High-frequency applications
• Small-signal filtering
• LC filter circuits

Custom Inductors from Custom Coils

Inductors are a type of device that transmits and measures current in relation to voltage. Inductors can be used in many types of applications, such as energy storage, filtering, and circuits. 

Contact us to let us know how we can provide you with custom inductors or other coiled products. If you’d like to begin your project with us, request a quote today.