Plastisol Curing with Induction

Ambrell has over 10,000 systems installed in over 50 countries and many of them are plastisol curing applications

curing plastisol with induction

Improve your plastisol curing process without ovens, hot plates or flame! Curing with induction heating focuses energy in your part only. You don't need a torch or a costly batch or furnace process. Cure your plastisol seal in a repeatable, precise flameless process.

We offer exceptional customer service before and after the sale. Your plastisol curing application will be analyzed and tested in the nearest Ambrell Applications Lab. There is no charge, and you will receive a system recommendation designed to deliver the best possible solution for your brazing requirements. Ambrell delivers the expertise, innovation and system quality to give your company a competitive edge.

Click to read one of our plastisol curing Application Notes (after a brief registration). Learn more about:

Overview

Curing involves any process where heat is used to catalyze or initiate chemical and molecular level structural changes in a polymeric materials such as epoxies, phenolics, polyesters and silicones. These materials are applied in many ways to various products for bonding, protective coating, sealing, insulation and other uses.

Gell coating is a partial-curing process whereby a liquid compound is heated (in this case plastisol) enough so it doesn’t run when it is flipped over.

Induction

applying plastisol to the canCuring plastisol oil filter seals with induction is a reliable, repeatable, non-contact and energy-efficient process, delivering quality results in a minimal amount of time. Improved temperature ramping cycles can be achieved with computer control of the solid state power supply.

Although induction heating is normally used with metals or other conductive materials, plastics and other non-conductive materials can often be heated very effectively by using a conductive metal susceptor to transfer the heat. Typical RF power supplies for curing applications range from 1 to 5 kW, depending on the parts and application requirements.

Advantages

Compared with costly oven, time-consuming batch or awkward hot-plate processes, induction curing has a great deal to offer

  • smallest footprint: systems require little floorspace, even for line processes
  • lowered material costs: lighter mix for gelling
  • significant energy savings: delivering energy into the susceptor plate only, minimal vented waste heat
  • improved work environment: workers are not exposed to elevated room temperatures, reduced air-conditioning needs
  • improved production rates: induction integrates into continuous line production
  • improved output and quality: precise control and monitoring enable repeatable high-quality results
  • improved safety: fire hazard eliminated with lowered overall process temperature
  • unparallelled support: our Applications Lab and Service departments ensure you get and keep the production you need
Assembly
typical setup for induction bonding

Filter assemblies are produced by curing a thermosetting material between a paper assembly and a steel or aluminum cover. As shown below, dual pancake induction coils are used in a static setup to provide heat to the top and the bottom plate. A dynamic setup utilizes long pancake coils for the heating. Localized temperatures of 150-175°C associated with such bonds avoid damage to the components and provide a high strength bond upon cooling. Heat cycle times are in the order of 5-10 seconds.

Processes
curing in oven process image

Induction is used to set the gel-set the sealant-flange-paper assembly, which enables inversion of the assembly for the final assembly and cure phase

full curing process image

This process takes full advantage of induction's benefits by first curing the flange assembly before flipping. Once inverted and assembled, the final induction cure takes place.

Testimonials
testimonial guy

"With induction heating we have accelerated the adhesive curing time (on a filter part) from 30 seconds to 6 seconds and have automated what was formerly a manual process. We have been able to cut production times and increase turn-around time. Beyond a doubt the reason we chose Ambrell was because of how responsive they were to our original request for technical assistance. Ameritherm spoke our language and gave us the high value assistance that we needed. There was no need to go anywhere else."

-Automotive filter manufacturer

testimonial guy

"By using induction heating instead of a convection oven we have decreased our production foot print from 86 ft long to 13 feet long. We've also reduced energy consumption and increased employee safety by reducing the fire hazard. But by far the biggest savings for us has been production uptime. Where previously we had a monthly oven downtime of 256 minutes per month we anticipate that the downtime will approach, if not equal, zero minutes."

-Automotive filter manufacturer

utm_medium material docid title blurb regn_link
curing steel curing_1 Curing Measuring Tape Paint The Ameritherm 20kW output solid state induction power supply along with a unique 30" long multi turn helical coil was found to produce the following results. apps_able.php
curing steel curing_2 Curing Adhesive on Steel Motor Shaft for Bonding A complex two coil system, shield and stud systems used to provide proper axial alignments of the shaft & coil while allowing the fixture to be open for removal of the shaft. apps_able.php
curing steel curing_3 Bonding Rear View Mirror Brackets to Windshield Glass A unique four-over-four double wound pancake coil is used for the bonding application. apps_able.php
curing steel curing_4 Curing the Inside Liner of Baby Food Bottle Tops A three turn oval pancake coil is used to cure the inside liner of a baby food bottle cap. The bottle cap travels through the coil at 25” per second to cure 500 caps per minute. apps_able.php
curing fabric curing_5 Curing Speaker Cone Epoxy Induction heating provides minimized coating defects, repeatable results and faster production times apps_able.php
curing ceramic curing_6 Curing Ceramic Fiber A special steel tube and coil combination is used to build an induction heating oven to cure the fiber on a continuous basis. The ceramic fiber travels in an alumina tube inside a hot steel tube apps_able.php
curing aluminum curing_7 Curing Alumium Car Molding Automotive manufacturers are constantly searching for cost-effective production technologies. apps_able.php
curing aluminum curing_8 Curing ink on aluminum bottle caps A double channel coil is used for the ink drying application. Fifteen bottle caps are placed inside the coil and power is applied for 3 seconds to dry the ink. apps_able.php
curing aluminum curing_9 Curing plastisol adhesive on an aluminum filter assembly A four turn helical coil is used to cure the plastisol adhesive. One filter end cap is filled with adhesive, attached to the filter and heated 90 seconds to cure the adhesive. apps_able.php
curing aluminum curing_10 Curing epoxy on aluminum copier roller assembly A four turn helical pancake coil is used to heat the end of the copier roller assembly. The assembly is heated 90 seconds to cure the adhesive. apps_able.php
curing aluminum curing_11 Curing a coating on both sides of an aluminum piston A three turn channel coil 19” (48.26cm) long is used to anneal 4 pistons running though the coil with a distance of 6” (15.24cm) between centers. apps_able.php
curing platisol curing_12 Curing plastisol adhesive on both ends of a filter assembly Induction heating provides improved distribution of heat, much faster cure time than heat plates previously used, much faster production rate and hands-free heating that involves no operator skill for manufacturing apps_able.php
curing steel/aluminum curing_16 Curing a coating by heating a steel tube and an aluminum block The client’s oven had a heating time of 20 minutes, so the time savings from a 90-second cycle are considerable. Additionally, induction is a repeatable process, unlike an oven and the induction system takes up less floor space than an oven. apps_able.php