Hello there! This is really more of a mechanical question.
I am making a cryogenic Heat switch. This is like an electrical switch, but for heat flow instead of current.
It involves a superconducting solenoid, and a superconducting junction to act as the switch.
My concern lies in the design of the former, the brass part you see here that the magnet wire winds around.
There are 4 layers of 100micron wire. There are 200 turns per layer. The wound section is 2cm long, which gives us a turn density of roughly 40,000 turns/meter.
1 Amp will be flowing through this superconducting wire when the coil is energized.
The wire comes in and immediately undergoes a sharp bend via a slot. Then, the wire is wound, and after the 4th layer, the wire is back at the side the winding started. it leaves the windings through a similar slot.
How can I design this such that there are no sharp bends in the wire that may cause it to kink, or damage the insulation of the wire? I have tried filing and scraping at the corners, but they still have quite a small radius of curvature.
If you have any design considerations, i would love to hear them!
thank you for reading.
![](https://scontent-sea1-1.xx.fbcdn.net/v/t1.0-9/20479694_10154839778836732_141967941804942206_n.jpg?oh=0f80bf586d6be3c51a29790ab3b03531&oe=59F54141)
you can see here that the wire is fed in, goes into a sharp bend, then gets wound.
![](https://scontent-sea1-1.xx.fbcdn.net/v/t34.0-12/20428319_10154827009821732_927944354_n.jpg?oh=bfa46db219a51c9ef4047e193f509628&oe=5981E345)
for those interested.
![](https://scontent-sea1-1.xx.fbcdn.net/v/t1.0-9/20228697_10154808114961732_4319930758044199299_n.jpg?oh=1565ade60d110c5428fd137953bf071f&oe=5A31C030)
![](https://scontent-sea1-1.xx.fbcdn.net/v/t1.0-9/20229353_10154808129226732_4410151069610998647_n.jpg?oh=7a2436d77f5fab690264502b8e1a2e1b&oe=59FEEAE7)
![](https://scontent-sea1-1.xx.fbcdn.net/v/t1.0-9/20245415_10154808344091732_1943775413956216139_n.jpg?oh=1dc52025adbc52f1dd5fa76258c6dc7a&oe=59F8DB05)