High-frequency welding machines use the process of combining two materials through electromagnetic energy. The two electrodes of the high-frequency welder generate an oscillating electric field, which starts to move and move polar molecules within the material in order to orient itself according to the electromagnetic field. The movement of these molecules releases energy in the form of heat. When enough energy is applied, the molecules begin to melt and bond to each other. No external heat is applied. The welding is completed by applying pressure to the bonding area to ensure a successful seal.
A high frequency welder basically works as follows: in order to align themselves in conjunction with the electromagnetic field, two electrodes produce an oscillating electric field which starts to change and transfer polar molecules inside the materials. In the form of heat, the movement of these molecules releases strength. The molecules tend to melt and bind to one another when enough energy is added. There is no additional heat added. By adding pressure to the bonded area, the weld is finished, guaranteeing a good seal.
High-frequency mold welding helps the manufacture of molds that match into the kinds of positions where positive and negative electrodes are welded. In high-frequency electric fields, resins and films between pairs of electrodes emit heat. The entire field of the electrodes is essentially heated, even if the temperature of the electrodes is kept at room temperature, a temperature differential is caused. In the temperature distribution map on the left, temperature variations due to heat release are expressed, and particular areas that need to be melted can be selectively heated. This high-frequency welding mechanism helps to create beautiful finished products while avoiding surface and surrounding thermal effects.
There are some options, such as stitching, gluing, or using hot air, to using a high frequency welder. Why is it definitely the best choice for a high frequency welder? Firstly, unlike stitching, a high frequency welder offers a consistent air tight seal. The thread takes the strain and might crack as sewn seams are strained. High frequency welding similarly distributes stresses across the steel, creating a much better seam while avoiding the intrusion of any air, moisture or debris.
Gluing can have a solution that is airtight, but gluing takes much longer than high-frequency welders and also uses environmentally damaging, toxic solvents. Glued seams, after the glue has dried out, are often susceptible to loss. In order to melt it and create a bond, hot air is a process that adds heat to the outside of the material. This technique is powerful up to certain thicknesses only. In the centre, compounds that are so solid will not bind as the core will fail to melt, while the exterior layers are overheated or charred. From the inside out, high frequency welding heats and is the perfect tool for shaping air tight seams.
When plastic materials, film sheets or other electrical insulators are exposed to a powerful high frequency electrical field, a type of electric wave, collision, vibration and friction occur at the atomic level within the substance. In exchange, this induces self-heating, which binds the film and welds it. Certain materials are more difficult than others for RF welding and might also require a special process. Professional high frequency welders are ideal for welding all sorts of components, such as PET, PETG, PVC, Thermoplastic Polyurethanes (TPU), Open Celled Polyurethanes, LDPE/EVA, no matter the degree of difficulty.
In high frequency welders, several variables impact the intensity and seal efficiency. Any of the most critical variables in making a strong seal are tooling configuration, weld thickness, material thickness, and machine power. In the completeness of the weld, the appeal of high frequency welders is. Use this method to create a very strong airtight seal. Many welds undergo tensile testing, leak testing and optical testing to determine whether the correct conditions have been achieved.
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