Multi-layer co-extruded TPU calendered film: Innovation and performance breakthrough in high-frequency welding process

The Integration of Multi-layer Co-extruded TPU Calendered Films and High-Frequency Welding: Redefining Boundaries in Advanced Flexible Materials

Combining multi-layer co-extruded TPU calendered films with high-frequency welding technology, the industry is revolutionizing material processing through "molecular-level fusion" and "functional integration." This innovation not only overcomes the limitations of traditional bonding methods but also delivers more reliable and eco-friendly solutions for high-demand fields like healthcare, renewable energy, and consumer electronics via structural design and process optimization.

I. High-Frequency Welding: From "Surface Bonding" to "Molecular Symbiosis"

Traditional TPU film processing relies on hot plate welding or adhesives, which suffer from thermal deformation, weak sealing, and environmental concerns. High-frequency welding addresses these challenges by exciting the polarization movement of TPU molecular chains via electromagnetic fields. This generates uniform frictional heat at the microscopic level, enabling interpenetration and reconstruction of molecular chains.

• No external heat or chemical agents: The welded zone forms a continuous molecular structure with the base material, eliminating delamination risks caused by interfacial incompatibility.
• Synergy with multi-layer co-extrusion: TPU films can be engineered into "wear-resistant layer–reinforcement layer–sealing layer" composites. During welding, molecular chains from different functional layers form gradient transition zones under pressure, preserving layer-specific properties while enhancing overall weld strength through molecular entanglement.
  • Example: Welded areas of medical fluid bags maintain flexibility while achieving 30% higher puncture resistance, withstanding repeated squeezing without leakage.

II. Performance Breakthroughs: "Adaptive Evolution" Across Scenarios

High-frequency welding empowers TPU calendered films to excel in extreme environments:

1. Enhanced Weather Resistance

• Polyether TPU: Post-welding low-temperature embrittlement point is significantly reduced (e.g., remains flexible at -50°C), ideal for polar research equipment.
• Polyester TPU: Maintains dimensional stability at 120°C, suitable for high-temperature applications like desert energy storage systems.

2. Eco-Friendly Leap

• Zero emissions: No combustion or hazardous gases during welding.
• Closed-loop recycling: TPU materials are biodegradable or recyclable. For instance, welded dialysis bags pass rigorous sterilization tests and degrade rapidly in nature, reducing medical waste by 60%.

3. Expanded Design Freedom

• Supports complex shaping (e.g., curved surfaces, 3D structures) with multi-layer co-extruded films in transparent, matte, or colored finishes.

III. Deep Integration into High-End Applications

1. Medical Field

• Critical safety: High-frequency welding ensures leak-free seams in blood bags and nutrient solution bags even after high-pressure sterilization (121°C, 30 minutes).
• Transparent windows: Integrated welding allows real-time monitoring of fluid status without compromising structural integrity.

2. Renewable Energy Sector

• Hydrogen storage tanks: High-frequency welding optimizes molecular structures to reduce hydrogen permeation rates by 50% under high pressure. Welded zones match the film’s strength, extending tank lifespan and cutting hydrogen energy costs by 25%.

3. Consumer Electronics

• Flexible waterproof components: Used in foldable device hinges and outdoor wearables, achieving IP68 waterproofing with seamless welds.