Ultrasonic Welding in Textile Industry

[box type="info" align="alignleft" class="" width=""]Ultrasonic welding has become a well-accepted method for joining high-volume, relatively small plastic parts. Ultrasonic welding is accomplished by converting high-frequency electrical energy into high-frequency mechanical motion. Ultrasonic welding technology has entered textile industry as an advanced technique for joining synthetic materials and blends to produce continuous impermeable seams or localized points of joining.[/box]

The basic parts of an ultrasonic welding device

The basic principle of ultrasonic welding

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• Step 1 - Parts in fixture
  The two textile parts to be assembled are placed together, one on top of the other, in a supportive nest called a fixture.
• Step 2 - Horn contact
  A titanium or aluminum component called a horn is brought into contact with the upper textile part.
• Step 3 - Pressure applied
  A controlled pressure is applied to the parts, clamping them together against the fixture.

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• Step 4 - Weld time
  The horn is vibrated vertically 20,000 (20 kHz) or 40,000 (40 kHz) times per second, at distances measured in microns, for a predetermined amount of time called weld time. Through careful part design, this vibratory mechanical energy is directed to limited points of contact between the two parts.The mechanical vibrations are transmitted through the textile materials to the joint interface to create frictional heat.
  When the temperature at the joint interface reaches the melting point, textile melts and flows, and the vibration is stopped. This allows the melted textile to begin cooling.
• Step 5 - Hold time
  The clamping force is maintained for a predetermined amount of time to allow the parts to fuse as the melted plastic cools and solidifies. This is known as hold time
• Step 6 - Horn retracts
  Once the melted textile has solidified, the clamping force is removed and the horn is retracted. The two plastic parts are now joined as if molded together and are removed from the fixture as one part.

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Ultrasonic Welding Components

An ultrasonic generator (power supply)

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[one_half_last]The ultrasonic generator converts the 110VAC or 220VAC electrical supply current into a high frequency, high voltage electrical signal.[/one_half_last]

An ultrasonic converter (transducer)

[one_half]The ultrasonic converter utilizes the high frequency electrical signal from the generator and converts it into linear, mechanical movement. This conversion ccurs through the use of piezo-electric ceramic disks that expand when a voltage is applied.[/one_half]

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An ultrasonic booster

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[one_half_last]The ultrasonic booster is a tuned component that mechanically adjusts the amount of linear vibratory movement from the converter to the required level for the specific application to produce optimal welding performance. The booster also provides a safe, non-vibrating location to clamp onto the welding tools.[/one_half_last]

An ultrasonic welding tool (horn/sonotrode)

[one_half]The ultrasonic welding horn is a custom made tool that is engineered to vibrate at a specific frequency. These tools are painstakingly designed using computer modelling technology for optimum performance and longevity.Ultrasonic tools must be tuned to match the frequency of the system. This tuning procedure requires consideration of the horn’s mass, length and geometry.[/one_half]

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The widely use of our ultrasonic welding in textile industry

Our innovative ultrasound technology ensures fast and reliable welding of a wide variety of materials including woven fabrics, Hook-and Loop fasteners, Velcro, clothing labels. Typical uses of ultrasonic welding are the application of motifs to garments, the curing and sealing to length of ribbons and straps, and the shaping of small garment parts that would otherwise be costly and time-consuming to sew.

Ultrasonic Textile Welding is suitable for professional medical products such as contamination-resistant gowns, masks and other non-woven fabric items used in hospital settings where pleats and seals must be perfectly executed to pass regulatory muster.

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The Advantages of our ultrasonic welding:

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• Adopting the hot melt effect, the product has increased water resistance, lighter weight and easier folding.
• Ultrasonic welding does not require flammable fuels and open flames, so compared to other welding methods, it's a safer process
• The ultrasonic welding technology sets itself apart with fast welding speeds, high welding strength and good sealing performance.
• Ultrasonic welding is aclean, efficient, and repeatable process that produces strong, integral bonds while consuming very little energy.
• The cooling time is very quick, and the pieces do not need to remain inside the tool for a long period of time to dry or cure the welding joint.
• Ultrasonic Welding Machinecan cut textiles while welding and realize automatic edge banding.
• This type of welding is not dangerous to humans, indeed the vibration are called ultrasonic because they are at frequencies higher than those that can be heard by the human ear.
• The welding process is clean because it doesn't use harmful solvents or glues while also not damaging the product.
• This welding technology is also easy to implement in a production process and has a low fault rate.continuous production without interruption

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Products recommened:

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