Hot wedge welding is a continuous procedure most often coupled with a rotary function that bonds thermoplastic industrial fabrics, vinyl and films together with targeted heat, speed and compression values.
The Hot Wedge Welding Process
In a manner similar to a sewing machine, hot wedge rotary welding involves a pair of drive wheels that pull a heated metal wedge along a work surface. The procedure involves a heated wedge positioned in front of a set of rollers. One layer of weldable material is guided over the top of the heated wedge, while the other layer is guided under the wedge. The heat generated by this process is then transferred to the two pieces of material. Both materials pick up an extreme amount of heat from the wedge before converging between the compression rollers, which fuses the two materials together. This creates the pressure needed to permanently bond the materials together. The result is a leak-proof, tear-proof and hermetic seal. Because the materials are reinforced during the hot wedge welding process, they become much more durable than they were in their singular form.
Multiple Layers Can Be Welded Together
The hot wedge sealing process is ideally used to bond multiple layers of materials together, making this the preferred option when fusing more than two layers. The process, however, can only weld two pieces at one time. After the two joined materials have cooled, the process repeats itself, adding one layer at a time to the previously joined materials. The number of layers that can be bonded together is usually dependent on the type and the weight of the materials being use and the size of the metal wedges available. The type of material you use will determine the number of layers that the heated wedge can penetrate.
How It Works
Requiring a great deal of skill, the hot wedge must be positioned exactly at the welding point so it can heat the materials to the temperature needed to weld them together. Pulling the material across the hot wedge creates a permanent bond. To produce a flawless weld, all factors – temperature, speed, pressure, and rotary adjustments – must be in unison. The temperature, speed and pressure can be made individually, which is determined by the material being used. It is the result of that temperature, speed and pressure equation that is the objective for a good weld. Properly executed, hot wedge welding can bond materials quickly, precisely and consistently.