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Heat Forming

Heat or Thermal Forming for PE

Polyethylene (PE) is a versatile thermoplastic material commonly used in various industries due to its flexibility, durability, and chemical resistance. Heat forming, also known as thermal forming, is a process that involves heating PE to a temperature where it becomes pliable and can be shaped into desired forms.

PE Heat Forming Process

1

Material Selection

Different grades of PE are selected depending on the application. High-density polyethylene (HDPE) is used for more rigid structures, while low-density polyethylene (LDPE) is better for flexible forms.

2

Heating

The PE sheet is heated to its softening point (typically around 120°C to 130°C for LDPE and slightly higher for HDPE). This can be done using ovens, heat guns, or specialized thermal-forming equipment.

3

Molding

Once heated, the material becomes soft and malleable. It is then placed over a mold or formed into a shape by applying pressure, vacuum, or compression, depending on the technique used.

4

Cooling

After shaping, the material is cooled in place, allowing it to retain its new form. Cooling can be done naturally or accelerated by fans or cooling systems.

5

Finishing

After cooling, the formed PE may undergo trimming or surface treatments to ensure smooth edges and a clean appearance.

PE Heat Forming Applications

Heat forming for PE is often used in packaging, automotive parts, medical devices, and protective covers.

Protective Covers

Packaging

Medical Devices

Automotive Parts

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Heat Sealing for Thinsulate Material

Thinsulate is a thermal insulation material widely used in outdoor clothing, footwear, and various products requiring lightweight insulation. It is made from fine microfibers that trap air and provide excellent insulation without the bulk. Heat sealing is a common method to bond layers of Thinsulate to other materials without using adhesives or sewing.

Thinsulate Process

1

Preperation

Layers of Thinsulate are placed between fabric or other material layers that need to be bonded. The material is pre-cut to the required dimensions.

2

Heat Application

A heat sealer, such as a bar or rotary heat sealer, applies heat to the material. The sealing temperature varies based on the Thinsulate variant, but it typically ranges from 110°C to 160°C.

3

Pressure Application

Simultaneously, pressure is applied to ensure the layers bond uniformly. The amount of pressure depends on the material thickness and bonding requirements.

4

Cooling & Bonding

As the material cools, the heat-melted fibers of Thinsulate bond with the fabric or other material. This forms a strong, durable seal that provides both insulation and structure.

Thinsulate Applications

Heat sealing for Thinsulate is commonly used in the manufacturing of insulation and Foamtec is specialized in the automotive application, where a lightweight but efficient thermal barrier is needed.

Automotive Insulation

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High-Quality Products

Both processes—thermal forming for PE and heat sealing for Thinsulate—are crucial for manufacturing products requiring durability, flexibility, and thermal management. By using these techniques, manufacturers can create custom products for various industries, from protective equipment to consumer goods.

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