Radio Frequency Tube Mandrel Sealing

mandrel tube sealing
The tooling dies creates an air and fluid tight seal around the insertion tube.

The most well known example of tube/mandrel RF sealing is medical intravenous bags (IV bags). The RF welding process welds a tube between two layers of sheet material. The result is an air/fluid tight seal around the perimeter of the flexible container as well as the tube weld within the perimeter.

RF welding one or more tubes into the seam of a flexible bag or bladder-like enclosure is a tooling based process. The thickness of the layers of flexible materials, most often some form of TPU, TPE or PVC and the wall thickness of the tube must all be pre-determined before manufacturing begins.

RF Welding is used to seal tubes in products

The basis of RF welding is to channel a specific frequency of electrical current (electromagnet energy) through RF welding-sensitive materials. The process can be further refined through the use of tooling, which positions (holds) the components to be welded in a specific configuration throughout the welding process. In the case of mandrel welding, the tubing is slid over the mandrel and is placed between two or more layers of materials which is subsequently placed between the upper and lower tooling die. The mandrel with the tubing on it is aligned with a 180° curve around the tubing/mandrel assembly. When energy and pressure is applied, all weldable materials temporarily soften and fuse together. The upper and lower layers of film are now fused in a 360° circular weld around the tubing. Visit our webpage for more information about how die cutting and tooling dies are used in the manufacture of products.

Why choose the RF tube welding process?

RF tube welding is ideal for many products in the medical industry, not just IV bags. The seals are strong and reliable, making them ideal for keeping substances contaminant free, as well as leak proof. These seals contain air, vapors or fluids and also control the flow of the contents, making them ideal for containment products such as inflatable bladders, and much more.

If you aren’t sure if your product should be made with tube mandrel sealing, contact SealWerks and Talk to an Expert today for more information about the product fabrication services we offer. We are happy to explain to you the different services we provide that are designed to meet your manufacturing needs.

The science of tube welding for tube insertion

A science in itself is the method of fusing a tube or valves in one or more positions on a flexible containment type item such as an IV bag, colostomy bag or foley. Tube welding is most successful when using an electromagnetic process such as radio frequency welding, high frequency welding or dielectric sealing to attain a strong, impenetrable seal at the insertion point.

A valve or tube attached to a bladder requires a tooling die to create a tight seal that will ensure proper tube installation. A tooling die is necessary for tube insertion in all products in order to produce a secure, unbreakable bond between the tube and the material being used for an inflatable or containment product requirement.

Heat sealed patient wrap
RF Welding can be used to weld tubes to a variety of thermoplastic and coated fabric materials.

Tooling is usually designed specifically for the product application. The type of tubing used must work in combination with the specific thickness of the materials forming the bladder or containment bag. Tooling dies, pressure and electromagnetic energy are the best methods for accomplishing consistent and effective tube seals that hold liquid, vapors and air pressure.

Using ports for tube sealing

Ports to connect tubes or valves to inflate and release air, vapors and liquids are another common RF and HF welding specific operation. Products like flotation devices, containment bladders and inflatable pillows are typically outfitted with valves or connection ports that facilitate functions essential to the performance of containment type products.

Whether you want a tube installed in a bag or a valve installed in a bladder, RF welding and heat sealing processes are the preferred method for the containment of inflatable or containment type products. Find more information about how or when to use Tooling Dies  Call us and talk to an expert, we’ll give you guidance on the proper way to insert inflation tubing or connection ports to your product.
reliable inflatable products
Inflatable products require the port to have a strong and tight, leak proof seal that is achieved with the radio frequency welding process.