Joining of Textiles besides Sewing
May 2014 Techtextil Texprocess Atlanta
Karl Herzer / Product Manager PFAFF Welding Machines
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Joining of Textiles besides Sewing
Sewing...
a logical connection of
a woven or a knitted fabric
always continuous..
Joining Methods
or continuouseither press type and
tool depending
No Sew...
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Joining of Textiles besides Sewing
Hot Wedge Hot Air Ultrasonic Hot Air Taping
Welding-parameters:• Roller pressure• Speed
• Temperature
Welding-parameters:• Roller pressure
• Speed• Temperature
• Hot air flow
Welding-parameters:• Roller pressure
• Speed• Amplitude• (Style of wheel)
Welding-parameters:• Roller pressure
• Speed• Temperature• Hot air flow
Welding-parameters:• Roller pressure
• Speed• Laser energy
Laser
Welding Methods.. Continuous
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Joining of Textiles besides Sewing
History of Welding Machines
160 Years of Industrial Sewing – 70 Years of Welding
Basic patent of the First Welding Machine
Hot Wedge - 1942
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Joining of Textiles besides Sewing
Hot Wedge
Welding Methods
Hot wedge is mainly being used for welding PVC. Typical applications are production of smaller tents, tarps, pool liners, banners, inflatable structures, motorcycle seats etc.
Hot wedge creates a durable thermoplastic joint, together with low fume emission when welding PVC (compared to welding PVC by hot air).
Weldable fabrics: Thermoplastic foils and textiles, thickness from 0.2 – 2mm
Advantage compared to Hot Air: Concentrated heat, hardly any fumes, smooth seams
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Joining of Textiles besides Sewing
Milestones of Welding Machines
Hot Wedge Welding 1942 - Today
8300 8320
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Joining of Textiles besides Sewing
Applications of Welding Machines
Hot Wedge Welding / Stationary
8320
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Joining of Textiles besides Sewing
Milestones of Welding Machines
Hot Wedge Welding Mobile 1965 – Today
8309 8390
8360 8362
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Joining of Textiles besides Sewing
Applications of Welding Machines
Hot Wedge Welding Mobile
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Joining of Textiles besides Sewing
HotAir
Welding Methods
Direct welding by hot air depends a lot on the fabric. Typical application is welding of needle felt for filters (no perforation of the seam, no additional sealing of a sewn seam needed).
Weldable fabrics: Thermoplastic foils and textiles, thickness from 0.2 – 2mm
Advantage compared to Hot Wedge: Non wearing system, low maintenance, high speed
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Joining of Textiles besides Sewing
Milestones of Welding Machines
Hot Air Welding 1942 - Today
8300 8320
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Joining of Textiles besides Sewing
Applications of Welding Machines
Hot Air Welding
8320
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Joining of Textiles besides Sewing
Ultra-sonic
Welding with the ultrasonic method is probably the most diverse of the applications. It can be used for: disposable protective clothing, covers and cloths from the medical sector, filters, roller blinds, lingerie and outdoor garments. Specially knitted fabrics are very comfortable because there is no thread that limits the elastic stretch of the fabric.
Ultrasonic frequency should base on inaudible ´30-35 kHz - contrary to 20 kHz systems.
Not all fabrics can be welded by ultrasonic. Specially the fabric thickness is limited to a certain thickness: beyond a certain strength the outside is burned before the inside is liquefied.
Essential for precise seams: Rotative horn and inversely rotating anvil wheel
Weldable fabrics: Thermoplastic foils and textiles, thickness from 0.05 – 0.5mmGrammage up to 300g / sqm
Welding Methods
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Joining of Textiles besides Sewing
Milestones of Welding Machines
Ultrasonic Welding 1990 – Today
8304-082 8312
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Joining of Textiles besides Sewing
Applications of Welding Machines
Ultrasonic Welding
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Joining of Textiles besides Sewing
Hot AirTaping
Welding Methods
Regarding hot air it is important to distinguish between direct welding with hot air and seam sealing of a tape. The latter is the most common sealing method, used for creating a waterproof seam for membranes inside garments (used for outdoor applications). It is actually a hot melt gluing process by using a hot melt layer on the seam sealing tape. Other typical applications are waterproof shoes, work wear and chemical suits and sewn and foamed automotive interior equipment.
Sewing and taping is a normally a division of functions: The sewn seam will achieve the strength, the taping will create a liquid proof seam.
Taping doesn’t need thermoplastic fabrics. A hot melt glues can also stick on other fabrics.The type of glue has to match to basic fabric.
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Joining of Textiles besides Sewing
Milestones of Welding Machines
Hot Air Taping 1960 - Today
8306 + 8303 + 83308305
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Joining of Textiles besides Sewing
Applications of Welding Machines
Hot Air Taping
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Joining of Textiles besides Sewing
Laser
Welding with Laser technology is used for many years in various metal applications. Now the laser welding technology can be used for heating the tape on tape machines as well as for direct welding of technical textiles. With a laser of class 4. a special protection glasses need to be worn during the operating process.
There are 2 principal methods of introducing a laser beam to a textile seam: The hollow seam and the translucent seam.
The disadvantage of the current laser systems for joining textiles is the cost and the employment protection.
Welding Methods
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Joining of Textiles besides Sewing
Milestones of Welding Machines
Laser Welding 2005 – ?
8310 - Laser
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Joining of Textiles besides Sewing
Welding is always Testing..
Due to the Variations of Textiles
„The truth is always revealed on the soccer field“(Quotation of Otto Rehhagel, a famous German soccer coach)
Welding always means trial and error on the machine,
and success !
Please take advantage of the Experts on the Show...
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Joining of Textiles besides Sewing
Many Thanks!
Karl Herzer
Product Manager Welding Machines
www.pfaff-industrial.com
office +49 6301 3205 2329
mobile +49 1522 250 4256
PFAFF Industriesysteme und Maschinen AG
Hans Geiger Strasse 12
67661 Kaiserslautern
Germany
meet us at booth 4229 on Techtextil