RF Welding & RF Sealing Services
RF Sealing Services & RF Welding Services
RF Sealing Services & RF Welding Services
Vinyl Technology utilizes a technology called radiofrequency (RF) sealing or dielectric welding. This is a process utilizing radiofrequency waves to weld two films or fabrics together on a molecular level, creating a hermetic bond.
This is used by our RF welders in RF Sealing services to make custom products.
What is Dielectric Sealing, RF Sealing, or Heat Sealing?
This is a process that’s known by many names, and you might have heard one of the other terms for the process: dielectric sealing, RF sealing, RF welding, or heat sealing. They all describe the same high-tech method of joining thermoplastic films using Radio Frequency (RF) energy, and are used in our radiofrequency sealing techniques.
Those RF waves excite the molecules of the materials to be joined from the inside out, fusing the materials together. It doesn’t leak either air, moisture, water, or fuel, whichever is relevant to your application, making it an ideal process for our RF sealing services.
No Heat Required
Though you might hear “heat sealing” used to describe this process, it’s not entirely accurate. Our RF welding contractors do not use heat in the process of RF Welding. This is not a tabletop heat sealer you might use to close a bag of chips or preserve your leftovers–RF Welding is a molecular process, binding two materials with a seal much stronger than anything that any household appliance can do.
Using Dies for RF Welding & RF Sealing Services
An important component of any RF welding apparatus is the die that is used in heat sealing. The basic design of heat sealing dies consists of a solid, flat lower platen. The die consists of one or more bars made of brass that are shaped into the desired seal shape.
The radiofrequency heat sealing dies are placed over a sleeve or other material that needs to be sealed, and then, in the case of heat sealing, heated to a high temperature. The time and RF settings are set on the machine, and the process begins. After the material has been sealed, the product can be removed, and a new material can be placed onto the platen.
The dies used by our RF welders and radio frequency sealing services are of high quality. The die should be durable, able to resist wear and tear, and resistant to rust.
What is PVC Sealing?
PVC sealing is a high-frequency welding process that allows for the application of PVC (Polyvinyl Chloride) to a soft fabric or film. PVC has the advantage of being lightweight, durable, and abrasion-resistant, and is often used in waterproofing fabrics. PVC is considered to be an excellent material for radiofrequency welding because of its strong dipolar moment and other chemical properties.
PVC Welding refers to a similar process whereby PVC is the material of choice when welding fabrics, plastics, or other materials together.
What is HF Welding?
HF welding is another term used by professional RF welding contractors and is used interchangeably. Both terms are used to describe the process of using high-frequency radio waves to bind two thermoplastic materials together. Another term used to describe this process is RF heating, HF heating, or dielectric sealing.
Vinyl Technology specializes in creating custom RF-welded products.
How Our Radio Frequency Sealing Services & RF Welding Services Work
Radiofrequency energy is directed through electrodes custom-built to the required shape, usually through the use of a tool. This makes radio frequency sealing services the most versatile of the polymer film sealing methods.
RF sealing and heat sealing use a precise combination of time, pressure, and RF waves to form a stronger, more uniform weld than is possible using other methods.
Not all polymers can be dielectrically sealed. Acceptable materials include vinyl (PVC), ether and ester-based polyurethanes (PU), and chlorinated polyethylene (CPE). These materials are often coated or laminated onto substrates (fabrics like polyester, nylon, etc.) for additional strength and versatility.
Custom laminations may also be developed by our RF welders, unique to your required application.
Essentially, RF Welding works through a five-step process:
- Loading Parts: Joint members are placed into the welding machine to undergo RF heat sealing.
- Pressure Application: Pressure is applied to the joint member through electrodes. Pressure describes force applied to an area, and in this case, a fixed electrode at the bottom requires an actuator to drive the upper electrode downwards with the prescribed force.
- Electrical Field Application: At this point, an electrical field is applied for a designated amount of time while pressure is maintained throughout the process.
- Holding Pressure: As pressure is continually applied along with the electrical field by RF welders, the portions of the joint member directly in contact with the equipment will melt, and the liquid polymers will diffuse into each other at the respective points of contact.
- Unloading Parts/Cooling: This final step of the radio frequency sealing process engages through a chemical process of diffusion and solidification to “weld” the members together. At this point, after the joint cools down, the upper electrode is now brought back, and the parts are unloaded.
In other words, dielectric sealing is the process of joining thermoplastic films using radiofrequency (RF) energy to excite the molecules of the materials to be joined from the inside out, fusing the materials. The RF energy is directed through electrodes (dies) custom-built to the required shape of the seal or weld.
This makes radio frequency sealing the most versatile of the polymer film sealing methods.
It is different from your ordinary kitchen bag sealer in that it does not simply use heat and pressure to melt and join materials.
Choosing VTL For Top RF Sealing Services & RF Welding Services
On-Time Delivery
We have a 99.8% rate of delivering products on time. VTL is a reliable supply chain partner that understands the critical need to delivering quality products accurately, reliably, and on time.
Experience
Vinyl Technology LLC is the leading manufacturer for RF welded film and RF sealing services and has been around for 40 years. Our RF welders create products used for critical applications by hospitals and medical facilities, aerospace organizations such as NASA, and government and defense contractors.
If you are an industrial corporation looking for a high-performance solution with a reliable RF welding contractor and partner, then we may be a good fit for you.
High Quality, Best Value
With a top RF heat & RF-sealing service company like VTL, you’re getting only exactly what you pay for. Because we produce only what you designed, there isn’t a single weld out of spec or unexpected. That translates to a lower cost per unit than something you’d typically buy off the shelf. VTL is ISO 9100:2015, AS9100D Certified and Berry Compliant (when requested).
High Volume, Quick Production
Our experienced engineering team and RF welders can work with you on taking your blueprints from the conception stage to production. Our manufacturing facilities are designed for high-volume production runs to help you scale your costs.
If you are interested in starting a project, contact us today.
Certifications
Vinyl Technology, LLC complies with standards required by the US government and Department of Defense that include the National Institute of Standards and Technology (NIST), The International Traffic in Arms Regulations (ITAR), Defense Federal Acquisition Regulation Supplement (DFARS) to the Federal Acquisition Regulation (FAR), STANAG 4671, and MIL-STD-6396. VTL can also fabricate products that comply with the Berry Amendment when required.
VTL’s Quality System is currently certified AS9100D and ISO 9001:2015. Since 2014, VTL has implemented LEAN Manufacturing practices, Six Sigma, and Kaizen methodologies to improve operations. VTL is an FDA-registered manufacturer of medical products.
Radio Frequency Sealing Materials
VTL has been challenged with several different textiles for different applications. These are not the common garment fabrics, so expertise is critical. We work on a wide range of material types, including stiff coated materials, soft and stretchy, chemical-resistant, fire-resistant, laminated for weather resistance, and more.
Commonly used materials include:
- Mil-Spec Materials
- Polyurethane Coated Fabrics
- Vinyl Coated Fabrics
- Webbing
- Fabrics
- Netting
- Hook and Loop
Why Certain Materials are Better for RF Welding and RF Sealing
Polarity, or the separation of electric charges in a molecule, leads to electric dipole moments where there is a negative and a positive charge end. Because of how RF welding and PVC sealing work, materials with strong dipole moments – like PVC – are more suitable for the RF welding process.
Other contributing factors:
- High Dielectric Constant: Influences current resistance
- High Dielectric Loss: Influences heat generation by the electric field.
- High Dielectric Strength: Affects arcing through joint members during the sealing process.
Heat Seal Plastic Film
Vinyl Technology is a heat-seal plastic film manufacturer and RF welding contractor. Fluoropolymer films such as perfluoroalkoxy alkane (PFA) and polychlorotrifluoroethylene (PCTFE) are common examples of plastic films that can be heat-sealed to form bags and pouches. The radio frequency sealing and welding of plastic films is advantageous for their stain-resistance and barrier properties.
Heat Welding Vinyl Fabric
The most popular instances of a heat weld most commonly involve PVC or Vinyl fabric. The advantages of heat welding in general are that it allows for better control over thin materials, is a fast material heating process, and it helps maintain an enhanced seal in both strength and appearance. With vinyl fabric, the advantages offered include fire-retardant properties, oil and chemical resistance, and its high durability and strength.
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Our RF Sealing Service & Equipment
VTL currently has 40 radio frequency sealing machines or thermatron RF welders and continues to add more, uniquely positioning us to meet the capacity and capability requirements of our most demanding customers.
Models our RF welding contractors use include standard platen machines, bar welders, dual cycle machines, and proprietary equipment with up to 48″ x 96″ seal area. High-volume projects utilize shuttle and turntable configurations.
RF Welding machines range in output from 4 to 50 KW.
Different Types of RF Welding Machines:
- Kabar
- Hall Dielectric Machinery
- Faratron
- Proprietary VTL
- Thermatron
- Fara-Dyne
- COSMOS
