This section provides overview, applications, and principles of high frequency welders. Also, please take a look at the list of 3 high frequency welder manufacturers and their company rankings.
A high frequency welder is a device for welding thermoplastic resins in sheet form, such as polyvinyl chloride and nylon, by high-frequency dielectric heating.
Welding using a high frequency welder is called welding, and it is characterized by higher weld strength and a more beautiful finish than other welding methods using external heating.
It is similar to microwave heating such as in microwave ovens in that it heats by inducing molecular vibration of dielectric materials. However, unlike microwave heating that irradiates electromagnetic waves from all directions, high frequency welder can perform partial and deep heating because heating is performed by sandwiching the material between a pair of electrode plates.
High frequency welders are used to join sheet materials together.
Although the materials that can be used with the HF welder are limited due to its principle, it can be used for products that cannot be sewn to ensure airtightness, waterproofness, and durability, such as tents and life jackets, as well as business card cases, book covers, and bags, because the adhesive part is very beautifully finished without seams or seam allowance, and high strength and uniform quality can be achieved. This makes it ideal for products that cannot be sewn to ensure airtightness, waterproofing, and durability, such as tents and life jackets, as well as business card cases, book covers, bags, and other products that require aesthetic appearance.
In high frequency welders, dielectric heating causes molecular vibration of dielectric materials, and the friction of electrons generates heat.
Therefore, dielectric heating using high frequency welders are characterized by its ability to uniformly heat a material from the inside.
Therefore, dielectric heating using high frequency welders are limited to polar dielectrics such as vinyl chloride, nylon, and polyethylene.
The frequencies used for high frequency welders are in the short wave to centimeter wave equivalent frequency range of 3 MHz~30 GHz.
In the HF welder, the material to be welded is sandwiched between electrodes and high-frequency waves are applied, but heating is performed while applying a certain amount of pressure to prevent the unevenness of the material from affecting the weld.
At this time, the material reaches a temperature of 120 to 130 degrees Celsius in a few seconds and is in a semi-liquid phase.
When the heating is stopped and the material is cooled under pressure, the semi-liquid phase of the material mixes and reverts to the solid phase, which is the welding process.
With other external heating methods, the heated surface begins to dissolve before the bonding surface of the material, resulting in an unattractive finish.
The greatest feature of the high frequency welders process is that it does not apply heat externally, so appearance defects due to scorching or stringiness of the melted resin do not occur.
Another advantage is that the area to be welded is sandwiched between the anode and cathode molds, and dielectric heating by high frequency is applied locally, so there is no deformation or discoloration of the surrounding area.
Moreover, since no smoke is generated by heating during welding and fusing, no harmful components from PVC are emitted, making this a safe and environmentally friendly processing method.
The main materials used for processing with high frequency welders are as follows.
Used as a material for vinyl sheets, card cases, and artificial leather. It is the most commonly used material in high-frequency welding because of its softness and ease of thermal processing.
Widely used in applications that require elasticity, such as hoses, tubes, and cart tires. In soft cases for smartphones, the main body bumper and cover are welded together by high-frequency welding.
Polyethylene and polypropylene are members of the polyolefin family. It is formed into a bag shape by high-frequency welding and used for seasonings such as mayonnaise, toothpaste tube cases, etc.
Frequency selection must take into account the power applied and heat generation efficiency depending on the thickness and material of the object to be processed.
Generally, high-frequency magnetic fields in the range of 40 MHz to 200 MHz are used for plastic sheets such as vinyl and 10 MHz to 50 MHz for welding thermosetting plastics.
Additionally, 2.45 GHz, which is used in microwave oven magnetrons, is also used in high frequency welders and high-frequency transmitters for heating.
There is a wide range of high frequency welders, from handy types that can be used at home to large industrial welders that can be used to weld tent sheets.
The handy type used for workpieces at home or school ranges from 50,000 yen to 100,000 yen.
Equipment for industrial use, for manufacturing small products such as passcases or vinyl cases, costs around 3,000,000.
When it comes to equipment for large sheets such as blue sheets and tent sheets, the market price is around 5,000,000-10,000,000 yen.
*Including some distributors, etc.
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