RF welding is the greatest approach for producing airtight seams since it warms from the inside out. This approach is only useful up to a certain thickness. One of the advantages of Radio Frequency welding is the ability to seal unique items with intricate patterns or motifs. It is capable of producing both tiny and big things. It is capable of joining numerous layers of comparable or different polar-molecular materials and seams with high tearing resistance.
What is RF Welding?
RF Welding stands for Radio Frequency. It is also called High-frequency welding or Dielectric welding. It is the method of joining materials by providing radio-frequency energy to the region to be joined. In Radio frequency welding, the heating happens inside the body.
As a kind of EMF protection, a gadget like the Trifield Meter is used to measure the frequency of the radio waves in your house; as previously said, welding requires a high frequency. It is often used for plastic welding comprising of thin polar polymers like polyvinylchloride (PVC). Non-polar plastic and PVC substitute materials, such as polyethylene (PE), may be welded together with RF heat welding.
RF Welding Process
Plastic molecules are heated in the RF welding process. The molecules begin to travel at an increasingly quicker rate, generating heat and fusing the plastic together. Dies stored on the top and bottom platen guides the fusing process. As the dies are drawn closer, pressure is placed onto the total area of the polymeric products being welded. Meanwhile, radio frequency waves of 27.12 MHz are transmitted through the dies. As the plastic cools, it becomes molten and welded together. The substance is fused in the form of the dies used once it has been entirely heating sealed.
It is a better option than stitching or gluing for creating strong, leak-proof seals. RF heat sealing is often used in medical device production for goods such as wound management devices, fluid bags/pouches, and patient heating products because of its operational efficiencies and constant high-quality welds. It is also used in military uses such as hydration bags, protective gear, and safety goods. To learn more about how does RF Welding work, you can watch this video.
Factors affecting RF Welding
The quality of RF welds is determined by a complex mix of mechanical properties (power output, frequency), temperature distribution, and gauge pressure, as well as material type and thickness. An experienced operator is usually the one who determines the best circumstances. Weld quality is often verified by conducting a pull experiment to establish the maximum stress of the weld or by inspecting the weld bead formed in between layers of welded joints.
When should you use Radio Frequency Welding?
The correct sealing method is based on your substance, the size and design of the product, and the volume of manufacturing necessary. Radio-frequency produces uniform, clean seams without the need for glue or solvents. If you make the same product on a regular basis and need a distinctively shaped weld, RF is the welding technique for you. Whereas other methods do not, RF welding technology enables you to strike the same part of the weld many times. Send us a sample of your product now, and we will advise you on how to weld each of your seams.
Benefits of RF Welding
- RF welding provides airtight and waterproof seams, as opposed to sewing and poking holes into the cloth.
- It welds the same spot more than once without causing fabric damage.
- For complicated welding, specialized dies are provided.
- Stronger seams than the substance itself in a variety of industrial jobs.
Which thermoplastic materials can be welded by RF Welding?
Because RF welding generates heat through the vibrations and alignment of charged molecules inside the polymer chain, it is limited to polymers containing polar molecules. The most frequent thermoplastics welded using the RF method are polyvinylchloride (PVC) and polyurethanes. Other polymers, such as nylon, PET, EVA, and certain ABS resins, may be RF welded, but particular conditions must be met. Nylon and PET, for example, may be welded if warmed welding bars are employed in addition to RF power. In general, RF welding is not recommended for polycarbonate, PTFE, polystyrene, polyethylene, or polypropylene. However, because of the looming limits on the usage of PVC, a specific type of polyolefin has been produced that can be RF welded.
What to use Ultrasonic or RF Welding?
The product determines whether ultrasonic welding or RF welding is used. Is it composed of soft or hard plastic? Are the joints dimensional or flat? Is it necessary to use tiny, precise welds or large, continuous seams? A few crucial points to remember are mentioned below:
1. Compatibility of materials: The most crucial factor to consider when deciding between ultrasonic welding and RF welding is material selection. Because tougher, more rigid polymers conduct acoustic signals better than softer materials, ultrasonic welding is often restricted to them. Materials with polar functional groups in their chemical composition are required for RF welding; non-polar substances are undetectable to radiofrequency radiation unless additional polar polymers are added to the welding process.
It is worth noting that both ultrasonic and RF welding function best with identical (or comparable) layers of material. Welding incompatible polymers are achievable with both techniques, but needs specialized equipment and/or process modifications.
2. Welding size: This is another crucial selection criterion. The horn size known as sonotrode which produces ultrasonic welding is a limitation. The wavelengths of the ultrasonic energy employed, in turn, determine horn size. As a consequence, unless the welder is modified or specialized methods like spot welding or rotational horns are employed, ultrasonic welds are seldom bigger than 3 inches. RF welding can create lengthy continuous welds as well as extremely tiny and accurate welds using custom-shaped dies.
If you feel your product is suited for radio frequency welding, read on to learn more about this service. If you want to learn more about welding, contact us right now. In contrast to radio frequency welding, we provide a variety of publications on other welding subjects. Learn more about Heliarc Welding.