From Molecular Fusion to Functional Integration: Analysis of High-frequency Welding Process for TPU Calendered Film

The Integration of TPU Calendered Films and High-Frequency Welding: Revolutionizing Advanced Flexible Manufacturing

By combining molecular-level fusion with functional stratified design, the synergy between TPU calendered films and high-frequency welding technology has transcended traditional material processing limitations, emerging as a core innovation in high-end flexible manufacturing. At its essence, this technology leverages electromagnetic induction-driven molecular chain reconstruction and gradient performance enhancement through co-extrusion, achieving simultaneous improvements in material functionality and production efficiency.

I. High-Frequency Welding: "Seamless Bonding" at the Molecular Level

Traditional hot-melt welding relies on external heat sources, often causing material deformation or interfacial delamination. In contrast, high-frequency welding excites the polarization of TPU molecular chains via electromagnetic fields, generating uniform frictional heat at contact surfaces under pressure. This triggers cross-penetration and reconstruction of molecular chains, eliminating adhesives or high-temperature tools.

• Key advantages:
  • Continuously fused molecular structure between welds and base materials, eradicating delamination risks.
  • Minimal heat-affected zones, enabling precision processing for complex geometries.

II. Co-Extrusion Structure: The "Material Code" of Functional Stratification

Multi-layer co-extrusion endows TPU films with stratified functionality, integrating wear-resistant, reinforcement, and sealing layers. Each layer’s properties are gradient-enhanced during high-frequency welding:

1. Wear-resistant layer (polyether-based TPU): Maintains flexibility in subzero environments.
2. Reinforcement layer (polyester-based TPU): High puncture resistance for durability.
3. Sealing layer: Molecular chain reconstruction creates flawless, airtight seams surpassing traditional methods.

During welding, molecular chains from different layers form gradient transition zones under pressure, preserving layer-specific traits while strengthening weld integrity through molecular entanglement.

III. Performance Breakthroughs: From Single to Composite Excellence

The integration of high-frequency welding and co-extrusion drives transformative advancements in weather resistance, functional integration, and design freedom:

1. Enhanced Weather Resistance:

• Withstands polar cold (-60°C) and desert heat (120°C) with superior anti-aging properties.

2. Functional Integration:

• Embeds self-healing coatings, conductive layers, or photochromic layers via co-extrusion, enabling unified "structure-function" outputs post-welding.

3. Customization Capabilities:

• Supports complex shapes (e.g., curved surfaces, 3D structures) with transparent or colored films, tailored for smart wearables, medical devices, and more.