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PRONEC CO., LTD.
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Achieving Uniform Fusion and Improved Production Efficiency: Case Studies of Double Heater Winding
2026-05-05
Challenges
In bobbinless coil manufacturing, the hot-air winding method using self-bonding wire is generally employed. However, when a client outsourced production to another winding manufacturer, they encountered an issue where the coils swelled during reliability testing (under high-temperature and high-pressure conditions). Investigations revealed the following issues:
- The bonding layer of the self-bonding wire was not fully fused, with unfused sections remaining.
- The degree of fusion did not meet our internal standards, leading to concerns regarding reliability.
While post-process annealing was considered as a potential solution, the significant increase in man-hours proved to be a major obstacle.
Solution
We implemented a modified double-heater system to enhance the fusion effect of the hot-air heaters and improve the uniformity of the bonding process. This ensures that the bonding layer of the self-bonding wire is melted evenly, significantly increasing the overall degree of fusion throughout the coil. By eliminating the need for post-process annealing, we also successfully reduced labor man-hours and streamlined the production flow.
Key Results
The implementation of the double-heater winding system achieved the following outcomes:
- Enhanced Coil Quality
By combining the double-heater system with optimized winding parameters, we achieved uniform fusion of the bonding layer, ensuring consistently high-quality coils.
By combining the double-heater system with optimized winding parameters, we achieved uniform fusion of the bonding layer, ensuring consistently high-quality coils.
- Superior Performance
Coil reliability was significantly improved; the coils now maintain their structural integrity without swelling during high-temperature and high-pressure testing, successfully passing all reliability benchmarks.
Coil reliability was significantly improved; the coils now maintain their structural integrity without swelling during high-temperature and high-pressure testing, successfully passing all reliability benchmarks.
- Reduced Man-Hours
Eliminating the need for post-process annealing shortened production time and significantly boosted overall manufacturing efficiency.
Eliminating the need for post-process annealing shortened production time and significantly boosted overall manufacturing efficiency.
Conclusion
The adoption of the double-heater winding system has ensured uniform fusion, significantly enhancing both the quality and reliability of our coils. We remain dedicated to continuously refining our manufacturing techniques to meet the evolving demands of our clients.
If you are looking to boost production efficiency without compromising on quality, we invite you to reach out to us via our inquiry form for a professional consultation.
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Medical equipment / Electrical component for transportation equipment / Electronic parts
Main 3 Products
Air core coil, Bobbin coil, Coil Assembly, Solenoid coil, Wireless power transfer coil, WPC, RFID, Winding machine, OEM / Plastic molded products, overmolded products
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PRONEC is a specialized manufacturer in Thailand with over 30 years of experience in air-core coils, precision coils, and electronic component assemblies. With integrated in-house capabilities from pr ...
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