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ADVANTAGES OF USING BONDABLE WIRE
The use of bondable wire offer a number of advantages over vacuum or trickle impregnation and dip and pack varnish securing methods:Manufacturing Cost Savings
Oven methods can take up to several hours to complete. The oven must be preheated, the varnish applied and then the varnish must be allowed to cure before final testing can begin.
With the use of resistance bonding, manufacturers are able to accomplish the testing and bonding processes anywhere from 5 and 30 seconds. The testing and the bonding applications are combined, which increases the overall workflow, reduces the in-process inventory and significantly increases output.
The necessity to order, store, handle and maintain the varnish, varnish solvents, and any additives associated with the varnishing process is eliminated . As a result, raw material waste and overall waste disposal is reduced, creating just in time ordering practices and leaner manufacturing goals.
The fumes from the solvents must be viewed as a possible air pollutant and therefore controlled. Depending on the type of varnish being replaced the potential to reduce emissions exist. The use of ovens will be eliminated, therefore, there will be no open dip tanks, no mixing tanks, no drums of varnish or solvents being stored; eliminating the risk of spillage and human exposure. The amount of time spent on clean up will be significantly reduced.
EPA constraints, safety and environmental issues and concerns are reduced.
The bonded coat is more consistent and predictable compared to varnish coatings. Most products manufactured with bondable wire have a greater bond consistency throughout. In addition, the finished unit is solidly bonded and may not require any external retaining device, forms, ties or braces.
When you initially look at the cost of the bondable wire compared to the same class of non-bondable wire the cost is greater. However, bonding the heat activated adhesive coating is done in less than five seconds; dramatically reducing power consumption per part. With trickle impregnation, enormous amounts energy is used to keep the radiant heaters on, even when not in use. Minutes, not seconds, are required to create a valid bond. It has been shown over and over again that the significant savings in energy more than offsets the extra cost of using bondable wire.
On the average, bonding machinery costs about 1/2 as much as trickle impregnation machinery. On the lowest production end, the return on investment should be even greater, as less maintenance is required and the machinery should have a longer life, as it is simpler.
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