Ultrasonic welding technology quickly transforms clean non-woven materials into high-quality respiratory tools medical-grade surgical masks.
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How ultrasonic welding equipment works
First, the nonwoven is cut and sewn into narrow strips. Next, the narrow strips are stacked. An activated nonwoven filter layer is sandwiched between the inner and outer protective layers of the textile. After the individual layers have been placed, they are cut to a fixed size, pleated, and quickly “quilted” together by ultrasonic welding equipment. In addition, ultrasonic spot welding is also used to attach elastic or fabric lacing to the finished product.
Advantages of ultrasonic welding
Ultrasonic welding is exceptionally fast and produces strong and repeatable bonds of the same strength as the base material. Because this equipment is produced quickly with minimal energy consumption, the equipment provides the best quality at the lowest cost.
Compared to conventional sewing machines
Compared to conventional sewing machines, ultrasonic welding offers greater cleanliness because the seam is produced without mechanical holes in the thread and fabric that can contain and hide microorganisms or contaminants.
Ultrasonic welding machines provide the necessary level of hygiene needed to produce vital materials such as N95 masks. Because of the way ultrasonic welders work, they create a fabric connection that fits almost perfectly flat against the body and incorporates seam sealing tape that can be much stronger than traditional sewn seams.
While traditional sewn seams have always been a common location in garment manufacturing, ultrasonic welding has proven to be an excellent alternative for nonwoven applications.
On traditional sewing machines, needles pierce holes in the fabric, weakening its structure and providing “entry points” for moisture and potential disease to build up and pass through, while the overlap of the fabric at the seams creates thick seams that are bulky and can restrict movement, both wasting and adding weight to the garment.
With an ultrasonic sewing machine, it is possible to create a seam so small that it must be supported with seam sealant tape. The standard weld seam created by an ultrasonic sewing machine is only 0.5 mm. While traditional sewing stitches can wither and loosen, the bond created by ultrasonic welding remains as strong as the fabric/material to which it is bonded.
Compared to adhesives
Compared to adhesives, ultrasonic welding technologies offer additional benefits. They eliminate the additional cost of consumables, the extra work of application, the extra time required for setup and drying, and the risk of contamination by chemical contaminants.
Application of nonwoven fabrics
Ultrasonic technology is increasingly used in various areas of the nonwovens industry, including hygiene products, filtration. In general, ultrasonic bonding uses high-frequency sound to generate localized heat through vibration and to bond thermoplastic fibers together. In some applications, this technology can sometimes replace other bonding methods, such as adhesives and thermal techniques. The following are some of the applications of ultrasonic technology in the nonwovens industry.
Sanitary Products Market
The hygiene products market is one of the largest segments of the nonwoven fabric industry. The use of baby diapers and adult incontinence and feminine hygiene products is unique compared to products in other industries because of their extensive contact with the user’s skin. This requires materials that are soft and flexible and can wick and absorb liquids. In addition, the need to combine nonwoven materials with different properties to bring out the best in them when manufacturing such products poses no small challenge to the industry.
Ultrasonic welding, as a relatively clean and efficient welding method, enables the rapid embossing, laminating, and splicing of different nonwoven layers, to a certain extent enabling the rapid processing and manufacturing of products. The hygiene products produced by ultrasonic sewing machines create a fabric joint that is almost completely flat against the body and combined with seam sealing tapes that can be much stronger than conventional sewn seams.
Textile ultrasonic technology is used for specialty medical products such as anti-contamination gowns, masks, and other nonwoven items used in hospital environments where pleating and sealing must be perfectly executed to pass regulatory requirements. Ultrasonic welding equipment enables the joining together of drug-containing wipes with multiple layers that hold pharmaceutical chemicals for better wiping and higher purity properties.
In the mask production process, ultrasonic technology is used to weld masks, valves, nosepieces, warbands, etc. The 20Khz, 2000W welding equipment includes ultrasonic welding transducers, and ultrasonic welding generators are available for N95 and universal mask production. In addition, the ultrasonic spot welding machine can be applied to the welding of ultrasonic warbands.
HCSONIC is a professional manufacturer of ultrasonic welding technology, specializing in the production of ultrasonic welding equipment for medical masks. We can offer a wide range of ultrasonic generators and transducers with frequencies of 20 kHz, 30kHz, 35 kHz.
The main advantages of ultrasonic welding are the high level of precision and quality, as well as the increase in productivity and the elimination of consumables. These technologies ensure clean surfaces without the abrasion of textiles. For non-woven textiles (diapers, towels, masks, filters, etc.), HCSONIC offers solutions for cutting and intermittent or continuous high-speed welding. Ultrasonic welding technology can meet your requirements for precision, quality, and aesthetics.