Custom blackout window shades are one of the most effective means of blocking light, insulating a window, and maintaining a cool and private interior environment. For their contribution to safety and confidentiality, many people refer to blackout curtains as safety-first window shades. We’ll explore the benefits of blackout shades and how they enhance energy efficiency, boost worker productivity, and make an interior environment safer during an emergency.
Privacy and Security of Blackout Shades
Custom blackout window shades are a simple and immediate security and privacy upgrade for schools, government offices, medical buildings, and any other location that deals routinely with sensitive information. Along with providing physical obstruction to unwanted attention, blackout shades create a stronger sense of comfort and security for both employees and clients or visitors. They also dampen noise and contribute to a quieter environment, all while enhancing a room’s insulation.
Energy-Efficient Blackout Shades
Blackout window shades have the collateral benefit of lowering energy costs by blocking out significant amounts of solar heat and light, insulating the interior area during hot, summer months. This can improve HVAC system performance and reduce energy consumption, leading to lower utility costs and factory emissions.
Energy savings are also present during cold months when properly applied blackout shades can cut heat loss through windows by over 40%, which often results in a 10% reduction in heating costs. Thus, blackout window shades can contribute to the overall energy reduction needs of large structures, such as schools, medical facilities, government buildings, and various private businesses.
Creates a Comfortable and Productive Work Environment
Custom blackout window shades can improve workplace productivity and comfort in the following ways:
Blocking unwanted or excessive light
Preventing light seepage around the window edges
Reducing screen glare, which causes eye strain and fatigue
Making the work environment appear more pleasant and self-contained
Regulating a work environment’s temperature
Increasing energy savings while reducing HVAC system wear and tear
Creating privacy when needed
Additionally, blackout/safety-first window shades are easy to install for any window configuration. By choosing custom blackout window shades, you’ll ensure greater product effectiveness and light/heat-blocking capability.
Custom Blackout Shades from Carolina Covertech
For maximum effect, custom blackout window shades ensure the perfect fit around any window shape, resulting in more effective light- and heat-blocking functionality. At Carolina Covertech, we’ve ensured our blackout shades are easy to install and quick to deploy, so you can trust them in times of emergency.
We’ve been providing innovative covering and containment products using robust, yet flexible materials since 1858. That includes immense experience discovering which window shade materials and designs achieve the highest insulation and darkening effects. Because the correct size and fit are critical factors to ensuring full light blockage, we specialize in easy to install and quick to deploy custom blackout shades guaranteed to cover the length and width of the window.
Providing full coverage to the largest windows may require two or more tightly connected curtains made of heavy, thick material, creating solid overlap and minimizing any cracks or openings between the materials’ edges. To learn more about our safety-first window shades and how to achieve total window blackout, contact us, and tell Carolina Covertech’s covering and enclosure experts about your room darkening needs.
Many companies turn to contract manufacturers to handle their production needs and outsource manufacturing processes, providing a streamlined and efficient solution for their goods. The contract manufacturer may be involved in producing a variety of products for different clients. To ensure that the products are manufactured to the client’s specifications, the client provides detailed guidelines on the best way to build the product. These guidelines may include quality requirements, drawings, and other product specifications.
In addition to these instructions, the outsourcing company may give the contract manufacturer a prototype or sample of the product they want, along with a list of necessary components. This allows the subcontractor to ensure that the final product meets the client’s expectations and specifications.
How Does Contract Manufacturing Work?
The contract manufacturer and the outsourcing company discuss the company’s project requirements and needs. The contractor then follows this process:
Quotation: When a company considers outsourcing its manufacturing process, the contract manufacturer provides a comprehensive quote detailing the cost and the terms of the contract.
Design and development: Contract manufacturing involves collaborating with the contractor to design and develop the product, which includes testing and creating prototypes to ensure the product meets the required standards.
Component sourcing: Contract manufacturers are responsible for procuring the raw materials and other components essential for production.
Production: Contract manufacturers produce the product per the company’s requirements and specifications.
Quality Control: The manufacturers conduct various quality control checks on the products. This is to ensure they meet the desired specifications and standards before shipping.
Packaging and shipping: Contract manufacturers are responsible for packaging the products and arranging the shipment to the company or the customer.
Ongoing Support: Contract manufacturers offer continual assistance to ensure the proper functioning of the product throughout its lifespan, which includes providing repair and maintenance services whenever required.
What Are The Advantages Of Contract Manufacturing?
Many companies outsource all or some of their manufacturing processes to contract manufacturers for various reasons. To begin with, contract manufacturers offer a feasible solution for companies facing constraints in terms of resources or companies experiencing an overwhelming workload. They provide specialized technical expertise and manufacturing insights, which benefits companies lacking internal resources or looking to scale up rapidly.
Moreover, outsourcing to contract manufacturers can result in cost savings, which is an attractive option for companies seeking to optimize their budgets. Other companies outsource to free up their resources and focus on innovation and developing new products.
As such, when the project is a good fit, contract manufacturing can create numerous opportunities for companies with emerging technology.
Contract Manufacturing Examples
Below are three examples of contract manufacturing:
Manufacturing industry
In the HVAC industry, installing forced air systems requires ventilation systems made of sheet metal. While some companies may have the resources to build these systems in-house, most HVAC contractors outsource this to external sheet-metal fabrication companies. HVAC contractors provide the necessary specifications to the sheet-metal fabricator, who then constructs the ventilation components. Once completed, the contractors attach the ventilation components to the HVAC system, ensuring the efficient circulation of cool air.
Pharmaceutical industry
Within the pharmaceutical industry, drug makers have the option to work with contract manufacturers for various aspects of drug development and production. Due to the high costs associated with drug development, companies often outsource this stage. Once developed, drug manufacturers frequently contract out their manufacturing and commercial production.
As the pharmaceutical industry is strictly regulated, complying with the FDA regulatory requirements often involves extensive documentation. To address this, outsourcing the documentation of compliance is a common practice.
Automotive
In the automotive industry, approximately 50% of car manufacturing is performed by contract manufacturers. The manufacturers often outsource the production of basic components such as dashboard parts, tubing, and external electronics, including security systems, radios, and parking assistance devices.
Moreover, the manufacturing of gearboxes, suspension components, and electronics are also outsourced to contract manufacturers. Although car manufacturers have not yet outsourced the entire manufacturing process of a vehicle, many contract manufacturers create different cars under different labels and brands.
Optimize Your Manufacturing Processes with Carolina CoverTech
Contract manufacturing can offer numerous benefits to companies in terms of cost savings, technical expertise, and flexibility. Partnering with a contract manufacturer allows companies to focus on their core competencies while ensuring the quality and consistency of their products.
If you’re ready to optimize your manufacturing processes and take your business to the next level, work with Carolina CoverTech. We specialize in developing products that protect, cover, enclose and contain.
RF welding is manufacturing method that uses radio frequency (RF) to create a perfect seal between two layers of plastic material. Due to its safety, reliability, and other benefits, RF welding is used to create numerous products for the medical industry. This article will discuss how medical RF welding works, the benefits it brings, and common medical industry applications.
How Does Medical RF Welding Work?
RF welding, or RF sealing, is a process where pressure is conducted through two or more layers of dielectric plastic to merge the material’s molecules, fusing the plastic. The process works because polarized radio frequency molecules vibrate inside the polymer, causing friction that generates heat. Enough heat is generated to melt and seal the plastic layers together.
An RF welding sealer consists of a pneumatic press to open and close the energy applicator and a radio transmitter. These transmitters are also referred to as RF generators since they generate radio frequency energy. The RF welding process results in a permanent seal that features resistance equal to the material itself. These consistent, nearly transparent seals are uniform in size, super-strong, and airtight.
RF sealing technology is used to manufacture a wide variety of medical products, such as:
IV bags
Blood bags
Drink bags
Plasma bags
Oxygen bags
Medical dressings
Medical packaging pouches
What Are the Benefits of RF Welding?
RF welding delivers a high degree of consistency and reliability in the seals it creates. Additionally, while sewn seams are vulnerable to pressure and at risk of breaking, and glued seams rely on toxic chemicals and time-consuming dry times, RF welding features none of these drawbacks. It is a fast and environmentally friendly process that results in products with excellent longevity.
Another benefit of RF welding is that it is compatible with materials of all thicknesses, unlike hot air bonding. There is also no risk of the products burning and the finished seal is tighter than what can be achieved with any other bonding method.
Applications of Medical RF Welding
Both healthcare facilities and equipment developers rely on RF-welded products for patient care. Common applications include:
Bellows
Bladders with tubing
Containment and drainage bags
Emergency breathing system bags
Hospital bed deck and mattress barriers
NPWT systems
Hospital bed cushions
Kidney Dialysis Machines
Kidney dialysis machines must contain a patient’s blood for hours during treatment. RF welding techniques construct machinery durable enough to withstand these demands, including the dialysis machine’s intricate interior components as well as its exterior. Dialysis machine seals are crucial since this equipment will be operated for long hours on a regular basis.
IV Bag Machines
IV bags hold liquid that will directly enter a patient’s body, making sanitation an absolute necessity. While other sealing methods can produce toxins or introduce contaminants into IV devices, RF welding has none of these side effects. The sanitary seals are quick to produce and highly durable, preventing leaks and wasting resources.
Medical Disposables
Many types of single-use medical devices are used throughout the medical industry. For example, fluid management tools, enteral feeding devices, IV and blood transfusion equipment, and endo catch bags are just a few examples of high-use disposable products. Since these items play an integral role in routine medical operations, quality is essential for avoiding delays, interruptions, or dangerous product failure. It’s also important for these items to be sealed appropriately to prevent fluid loss and contamination.
Medically Designed Air Cushions
Medical air cushions use pressurized air to create a comfortable cushion for patients who are sitting or laying down. For these devices, a reliable seal is essential for product effectiveness. RF welding ensures no air will escape during inflation or use.
Medical RF Welding From Carolina Covertech
RF welding is an essential manufacturing process for the medical industry. It’s not only fast, contaminant-free, and reliable, but it’s also compatible with products of all sizes. Carolina Covertech specializes in RF welding for the medical industry and has over 162 years of experience in exceeding customer expectations.
We use the industry’s most technologically advanced equipment to create custom products from a range of plastic materials. You can learn more about our RF welding services here on our website. If you have any questions, contact us today.
Carolina CoverTech is a contract manufacturer of protective products, with services in product development, industrial sewing, heat sealing, and rigid to flexible conversions. These capabilities allow us to engineer high-quality protective, covering, enclosing, and containing materials. Our team applies creativity and technology to overcome obstacles in traditional storage products.
Learn more about the types of industrial cover materials, their applications, and our capabilities.
Types of Industrial Cover Materials
Many types of industrial, high-performance fabrics are available as equipment covers. Each fabric has different characteristics and benefits.
Cotton: Cotton is a natural fiber textile that becomes stronger when wet. Cotton duck is a common industrial fabric that’s strong, durable, and water-resistant.
Canvas: Canvas is a heavy-duty cotton duck fabric. Its tight weave protects equipment from harsh weather, sun, and wind. Waterproofing treatments for canvas make it suitable for marine equipment covers.
PVC: PVC is a synthetic vinyl fabric that is durable in all types of weather conditions. It’s easy to clean, flexible, flame-resistant, and water-resistant.
Polyethylene: Polyethylene fabric is an industrial plastic that is strong, durable, and abrasion-resistant. It can be customized for transparency for see-through machine covers.
Polypropylene: Polypropylene is a synthetic fabric resistant to chemicals, odors, moisture, and stains. It dries quickly, and the synthetic fibers are non-allergenic. The material also has a variety of indoor and outdoor uses because of its water-repellent properties.
Common Industrial Applications
One of the most popular applications of industrial fabrics is protecting non-waterproof portable storage containers from the elements. Polyethylene spill pallets capture any liquids spilled from storage containers, protecting the environment from contamination. Flexible, built-in bladder systems double their capacity. Both the storage container and spill pallet must be covered to prevent rain from getting inside.
Custom equipment covers are also suitable for industrial and commercial applications. At construction sites, they can prevent soil, stones, and sand from washing away in rain and windstorms. As boat, car, golf cart, and truck covers, the material can protect against damage from the sun. The covers also protect outdoor events from being interrupted by inclement weather.
Other industrial applications of custom covers include:
Aircraft covers
Industrial containment
Portable building enclosures
Insulation/climate barriers
Emergency medical response
Airport transportation and security
Recreational/offroad vehicle covers
Electronics protection
Carolina CoverTech Cover Solutions
Carolina CoverTech offers versatile, weather-resistant protection with a range of customization for different shapes and sizes. We design, develop, and manufacture high-quality, industrial fabric products that contain, protect, cover, and enclose. Our covers are reusable and allow for easy repairs to extend their life.
We specialize in waterproof cover systems that protect non-waterproof storage containers from rain. Using RF welding and heat sealing, industrial sewing techniques, and specialty fasteners, our covers offer long-lasting all-weather protection. The material also allows you to digitally print marketing content onto the covers, such as custom logos, names, websites, phone numbers, and slogans.
Download our brochure for more industrial fabric cover solutions.
Contact Our Experts for Premium Industrial Fabric Covers
Since 1858, over 250 companies have relied on our ability to produce weather-resistant, water-tight, and flexible manufacturing innovations. At Carolina CoverTech, we create protective products for golf carts and bags, inflatable bladders, and more. Contact us today to learn more about our custom cover solutions and other capabilities.
Two commonly utilized methods of plastic welding are RF welding and ultrasonic welding. While both processes utilize heat and pressure to create a strong bond, they achieve them in slightly different ways. These differences can make them suitable for distinct applications. That’s why it is important to understand them before you choose a plastic welding solution for your project.
Below, we provide an overview of RF welding and ultrasonic welding. It discusses what they are and highlights the key differences between them to help readers identify which process is right for their needs.
What Is RF Welding?
RF welding—i.e., radio frequency welding—uses high-frequency electromagnetic energy—i.e., radio waves—to create a bond between plastic components. The energy causes the molecules within the materials to vibrate at faster speeds, which generates heat. The heat melts the materials, enabling them to be fused when pressed together and allowed to cool.
What Is Ultrasonic Welding?
Ultrasonic welding uses high-frequency ultrasonic acoustic vibrations—i.e., mechanical vibrations that are above the audible range—to create a bond between plastic components. The vibrations are produced by a welding sonotrode and applied at the joint line of pieces held together under pressure. This process generates friction and, consequently, heat, which melts the materials, enabling them to fuse together as they cool.
Ultrasonic vs. RF Welding
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Initially, ultrasonic welding and RF welding seem highly similar. For example, the two processes produce strong and durable bonds between plastics quickly and cleanly. Additionally, both are energy efficient and eco-friendly. However, when you look at compatible materials and weld size ranges, it is clear they are different enough from each other that they may be used for different applications.
Compatible materials:Ultrasonic welding is typically used for hard and rigid plastics since these materials carry acoustic soundwaves better than soft and flexible ones. Examples include amorphous polymers and semi-crystalline polymers. RF welding is generally utilized for polar molecular plastics that are thin and flexible since non-polar materials are not affected by radio frequency energy.
Weld size ranges:Ultrasonic welding is relatively limited in the size of welds it can create due to equipment restrictions. Typically it produces welds that are 3 inches or smaller. RF welding can produce welds in a relatively broad range of sizes. It can create welds that are less than 1 inch in length or welds that are several feet in length.
While the above differences make ultrasonic welding and RF welding suitable for different applications, they are used within some of the same industries. Ultrasonic welding is commonly used in the following industries: appliances, automotive, electronics, medical, packaging, textiles, and toys. RF welding is frequently used in the following industries: automotive, aviation, construction, medical, military, packaging, recreation, and transportation.
RF Welding Solutions From Carolina CoverTech
Both RF welding and ultrasonic welding can be used to form strong bonds between plastics. However, they are appropriate for different materials and weld sizes. Understanding these differences can help you determine which one is right for your next project.
If you decide RF welding meets your needs and require a partner for your project, turn to Carolina CoverTech. As leaders within the RF welding industry, we have the knowledge, skills, and tools to deliver high-quality RF welded components and assemblies tailored to your requirements and restrictions. To learn more about our capabilities or discuss your project with one of our team members, contact us today.
