nsew wrote:I believe de-lamination occurs when exposed to high temperatures often inside sealed bags that are then exposed to direct sun. This can be avoided by not completely sealing a dry bag, roll top pannier etc in warmer climes and never leaving in direct sunlight. I always shade a bag carrying a mat when stationary.
I'm not sure this is correct, where did it come from? I used to work with the same manufacturing process, though heavier materials and in a different field, I'm not aware of the material or the weld being effected by heat. Pressure will be a factor, and leaving an inflated mat in the heat will increase that, as will overinflating in use.
If you look at anything else HF welded every seam under pressure ends in a T. This isn't possible on an internal baffle and once an end or edge of a seam lifts the rest can be peeled off like a sticking plaster. I've pulled apart lorry tarpaulins and onlookers have been shocked at how easily it's done once started, but of course this isn't a stress they'd normally be subjected to, trying to pull apart in any other direction and the seam is stronger than the material. It doesn't make mat failures inevitable, just more likely, if there's nothing to cause the end/edge of a seam to lift, the weld should last the lifetime of the material. The manufacturers must have known this from the start and have been re-designing to minimise it, shorter seams will help.
I have no idea how the button/cell designs are manufactured, I'd be interested to know. Sea to Summit say they've developed a liquid TPU bonding process, I have no idea what that is either! But they're offering a lifetime guarantee against delamination, which compared to what I've spent so far makes it look good value.