Disposable nonwovens are being used in a wide range of applications, whether packaged sterile surgical single-pack kits or personal protective equipment such as surgical caps and N95 masks, overalls and foot covers, disposable nonwovens provide an effective and inexpensive barrier against microorganisms and contamination. Its versatility extends to many other products, including hygienic and absorbent products, from shields and pads to diapers, undergarments, and disposable filters. All of these products mentioned above are made by seamless welding of nonwoven materials.
Ultrasonic seamless welding technology has played a vital role in promoting the rapid growth of the number of non-woven products and promoting its growth in this market area. Similar to the ultrasonic technology used for welding complex plastic parts, the ultrasonic welding technology transmits high-frequency mechanical vibration through the thermoplastic material to generate frictional heat to melt the seam surface of the non-woven fabric, thereby quickly bonding the non-woven fabric Together. Ultrasonic seamless welding machine technology has the following advantages:
Due to the speed, reliability, and energy efficiency of ultrasonic welding machines for slitting and stitching, manufacturers of non-woven products continue to convert older and energy-intensive cutting and stitching equipment (such as hot knives) to ultrasonic. The ultrasonic welder consumes power only when actually cutting or bonding. Because it generates heat immediately through high-frequency vibration, the hot knife can be preheated without additional energy consumption. There is no need to maintain it at a proper working temperature.
When ultrasonic welding is used to form seams or laminates, it is also swift, completing a single bond in a fraction of a second. It can also quickly continuous bond seams and is suitable for everything from disposable medical suits, surgical masks, and face masks to disposable hygiene products, diapers, nightgowns, filter media, etc. The fast, strong, and repeatable bond maintains the same strength as the parent material. Realize rapid production with minimal energy consumption, thereby reducing the cost of disposable absorbents and infection control products.
Good sewing effect
Compared with sewing, ultrasonic waves can form high-strength, high-integrity seams without stitches and do not need to create mechanical holes in the fabric containing and hide microorganisms or contaminants. It also eliminates the need for adhesives, including increased application workload, the increased time required for set-up and drying, and increased exposure to chemical pollutants. Ultrasonic seams can be used as soon as they are produced.
Although traditional sewing machines have been and will always be common in clothing factories worldwide, in many sportswear (including sportswear and outdoor clothing) areas, ultrasonic welding has proven to be a better choice. On a traditional sewing machine, the needle pierces the hole in the fabric, weakening the structure of the fabric, and the overlap of the material at the seam creates thick stitching, which is heavy, restricts movement, wastes, and increases The weight of the garment—many negative factors in the sportswear market. Ultrasonic sewing machines can create such small welds that they must be supported by seam sealing tapes. Ultrasonic stitching is also beneficial in the production of many products. Because of the formation of impermeable seams, clothing worn in contaminated environments (such as medical or scientific fields) can protect people from harm. This impermeable seam also facilitates the production of sails, parachutes, and any other textile materials that must withstand and withstand strong winds.
Ultrasonic seamless welding technology reduces waste in the production process. Because in the traditional sewing process, needle breakage often occurs, which causes a lot of garbage. And because there is no thread in ultrasonically welded clothing, the line will not deteriorate over time, and a large amount of material and waste can also be reduced. Simultaneously, this is very beneficial to the environment, making ultrasonic welding technology a “green” technology. When connecting non-woven fabrics, there is no need for any solvents or adhesives. The difference between ultrasonic sealing and thermal bonding is that due to ultrasonic energy to generate heat in the fiber, fiber degradation is minimized. In thermal bonding, heat energy is applied to the threads to melt them and avoid burrs.