Ultrasonic welding is a particularly gentle joining technique that is suitable for most thermoplastic materials. Depending on the size and geometry of the part, these parts can be welded with one or more ultrasonic welding heads. Ultrasonic joining technology has been established as the joining method for technical thermoplastic materials for a variety of applications throughout the plastics processing industry.
Table of Contents
- 1 Basic Composition
- 2 Ultrasonic welding machine working principle
- 3 Advantages of ultrasonic welding machine
- 4 Applications
- 5 How to choose a 15Khz ultrasonic welding machine
The power supply is the energy source for ultrasonic welding equipment, also known as the ultrasonic generator. This is because it takes standard electrical power (usually 115 V) at 60 Hz and converts it to an operating frequency of approximately 20 kHz or 20,000 cycles per second. Other commonly used output frequencies range from 15 to 70 kHz. The high frequency current can be converted into ultrasonic energy by an ultrasonic transducer.
Ultrasonic transducers are critical to any ultrasonic device. Ultrasonic transducers are available in different frequencies, and different frequencies are suitable for different devices. Ultrasonic welding equipment also has different frequencies such as 15Khz, 20khz, 35khz, etc. Different frequencies correspond to different welding applications.
Ultrasonic Variable Amplitude Rods
The conventional function of an ultrasonic amplitude rod is to hold the welding equipment in place or to increase or decrease the mechanical vibration transmitted by the ultrasonic transducer, thus enabling different production applications.
The tool head is generally in direct contact with the material being welded and can therefore be adjusted in size and shape to suit the application. The most common material used to make tool heads is generally titanium. Titanium metal is the material of choice for tool head construction because of its mechanical properties such as high fatigue strength and hardness. In addition, due to the price and application requirements there also exist economical tool heads made of aluminum and steel materials. You can choose a tool head made of different materials according to your needs!
Ultrasonic welding machine working principle
In ultrasonic plastic welding, the vibrational motion (amplitude) of the horn surface is transferred to the part. The vibrations move through the part and create friction at the interface between the parts. Heat is generated, which then melts. As it cools, a solid weld is formed.
Advantages of ultrasonic welding machine
Eliminate adhesives altogether
When you use ultrasonic welding equipment to directly bond nonwoven materials, you can avoid the use of all the expensive adhesive materials and complex adhesive delivery equipment.
Material cost savings
Ultrasonic welding technology saves production and processing costs by providing cheaper to purchase, lighter weight nonwoven and elastomeric materials. Avoid adhesive leakage or loss of elastic properties due to adhesives
Improved product comfort
The non-application of adhesives results in a softer, odor-free finished product and provides better breathability. It also allows for the use of lighter weight fabrics, so the final product is thinner and less visible when worn.
Ultrasonic bonding consumes less energy because it replaces the hot melt adhesive delivery and application system with efficient ultrasonic energy. In addition, there are fewer toxins in landfills after the product is used.
Reduce machine maintenance
Replace complexity and high wear and tear with a simple, reliable, clean ultrasonic cutting solution.
Hot melt plastics
Ultrasonic welding equipment is generally used to weld parts made of hot melt plastic, and it is difficult to weld plastic parts made of other materials.
Well known. Ultrasonic welding equipment can be used for welding of masks, both general masks and masks for medical use. Due to the cleanliness of ultrasonic welding, more and more masks are currently being welded using ultrasonic mask welding machines.
In addition, ultrasonic welding can also be applied to materials that require seamless welding, such as dust jackets and punching suits.
The 15Khz ultrasonic welding equipment can be used for welding of larger automotive parts. If you have a need in welding automotive parts, you can contact us for information.
How to choose a 15Khz ultrasonic welding machine
To determine which size ultrasonic welding machine you need, first consider the size of the part being welded. 15 kHz ultrasonic welding machines are designed for welding medium and large parts at higher amplitudes. Plastic assembly at 15 kHz allows welding of many softer plastics at greater far-field distances than conventional 20 kHz systems. A complete 15 kHz system is composed of a welder and a power supply suitable for the application in question.
HCSONIC specializes in the sales and service of thermoplastic or material joining products such as ultrasonic plastic welding, spot welding, ultrasonic mouthpiece welding and ultrasonic sewing machines. Please click here to contact us for assistance.