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ultrasonic welding plastic materials

Vibrations are turned into heat and thus the plastic material melts, which results in a homogeneous joint. Ultrasonic welding works extremely well with a range of thermoplastics, but some are incompatible with each other or with the process, so choose with care. Ultrasonic welding of plastic materials creates a molecular bond within the weld seam. Sonics manufactures a comprehensive range of plastics welding equipment, tooling and components, from hand-held units to bench model presses to ultrasonic kits for OEM installation. Numerous patents confirm our position as market leader. This frictional heat is applied through high speed vibration generated in a sonotrode and delivered by a welding “horn.” Ultrasonic welding machines look similar to spot or resistance welders. Longitudinal vibrations in frequencies of 20 kHz, 30 kHz, and 35 kHz with tool amplitudes between 5 µm and 50 µm are introduced into the plastic materials under the action of force. The same applies for thermoset resins that are processed by curing and cannot be welded by means of ultrasonics. State-of-the-art ultrasonic welding machines and most recent measuring and testing equipment in our laboratories worldwide. The Ultrasonic Plastic Welding Machine market research report delivers a thorough analysis of this business sphere with expert insights on the past and present growth matrix. Ultrasonic welding of plastics is used widely in making electronics, medical devices and car parts. Financial independence provides a solid foundation. for applications that require high amplitude and a … So how does it work? Only together can we move forward and set new milestones. Find the latest press releases, videos and trade show updates, as well as up-to-date images and interesting graphics. PC, PMMA, and ABS can be welded to one another under certain conditions. Once you’ve selected material types for part design, ensure that your supply chain can manufacture (e.g. In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the … These vibrations are called ultrasound because they are at a frequency above than the hearing capacity of the human ear (greater than 16 kHz). Every ultrasonic bonding operation will vary based on the plastic materials being joined, the shape of the workpieces, and other factors. Click here for technical project management. Unsolicited applications are welcome. However, in some cases two different thermoplastics can be welded using ultrasonics, for example when the materials are chemically compatible and have similar melting points. Materials are joined by means of locally limited heat generation: Ultrasonic welding ensures maintained functionality of the components and provides continuous process monitoring unrivaled by other processes. Industrial ultrasonics is an acoustic principle. Moreover, all brochures, technical infos, and contact forms are provided for download. It is commonly used for plastics and metals, and especially for joining dissimilar materials. Ultrasound is a mechanical vibration similar to that produced by musical instruments. To ensure your production is running smoothly. For more help with plastics, view our ultrasonic welding diagrams or material selection guides, Units 1 & 5 Argyle Comm.Centre, Argyle St, Swindon, Wilts, SN2 8AR. Our technology is used in many different industries to permanently bond plastic materials and nonferrous metals. As a general rule: only identical thermoplastic materials can be welded homogeneously. Sheet sections of thermoplastics – the parts to be joined - are placed in a V-butt or T-butt position with a consumable plastic welding filler rod that must be the same or similar material at the joint area. Ultrasonic Welding (USW)is a welding technique that uses ultrasonic vibration of high frequency to weld the two pieces together. Medical devices, such as catheters, valves, filters and face masks are also assembled using ultrasonic welding. Once cooled down a solid homogeneous weld between the 2 parts is created. Herrmann Ultrasonics therefore offers a wide range of solutions for integration of ultrasonic systems and components. Leading the way in research and applied technology, Sonics is dedicated to providing the highest quality products … Since its inception in 1969, Sonics & Materials, Inc. has enjoyed over 5 decades of world leadership in the fields of liquid processing and ultrasonic welding, sealing and cutting technology. Factors such as driving forces, opportunities, and obstacles that will shape the industry dynamics are explained in detail. This is about working together based on our values and about our mission to apply these values in our daily work. It is accomplished by converting high-frequency electrical energy into high-frequency mechanical motion. All trade shows, 1261 Hardt Circle • 60103 Bartlett, IL • USA. Plastic welding is defined as molecular material bonding of thermoplastic materials. This machine series allows for complex ultrasonic joining of injection molded plastic parts and nonferrous metals. For example, without a means of alignment built into the joint it is impossible to predict where the parts will be positioned after welding. Ultrasonic plastic welding is the joining or reforming of thermoplastics through the use of heat generated from high-frequency mechanical motion. Up to 130 different process reference data are available and can be visualized: Sensors and electrical components are not only used in industrial manufacturing but also in automation engineering or in daily use. Ultrasonic Welding is the fastest and most cost effective method used today to join and assemble plastic parts and non-ferrous metals. Toll Free: (888) 634-1143. This is a big misunderstanding. High requirements for visual appearance, production speed, or geometry are met. t: 01793-641040  Reg. It offers many advantages, including process reliability and repeatability, lower energy usage than other joining techniques, material savings (because there is no need for consumables, such as glue or mechanical fasteners), and labor savings. Welding of plastics using ultrasonics. The process of ultrasonic welding of plastics is achieved by applying a vibrating metal tool … Ultrasonic energy has been used to join thermoplastics for over 70 years. Hot Gas (Air) Welding: Hot gas (or hot air) welding, is a technique that uses heat. Ultrasonic welding is whereby high-frequency ultrasonic acoustic vibrations are applied to two components being held together under pressure to create a solid-state weld. The absolutely clean ultrasonic technology for nonwovens makes this possible. More basic knowledge on ultrasonic welding of plastics and examples for joint designs are available here. Customer benefits are always our paramount goal. Kerry Ultrasonics was formed in 1954 and had been a prominent manufacturer of plastic welding and ultrasonic cleaning equipment. The … Ultrasonic welding has applications in many fields including the thermoplastics industry. Not all materials can be welded. Industry-specific ultrasonic solutions, Herrmann products and profound expertise of ultrasonic technology – all brochures and publications. The following factors have a negative impact on weldability: The following additives have a positive influence on weld work: These reinforcement materials predominantly improve the sound conductivity in semi-crystalline plastics. Metals are joined through molecular bonding caused by the vibration. For example, ultrasonic welding is used to make electrical connections on computer circuit boards, and assemble electronic components such as transformers, electric motors and capacitors. In the event that a material is adapted or changed, it’s good to reevaluate the process with the help of your ultrasonic supplier, since weld parameter changes or even equipment changes may be required. Benefit from our experience and get the best consulting; from basic applications, to process optimization and complex integration concepts. Did you know? Wang: Ultrasonic plastic welding uses the piezoelectric ceramic effect to convert electrons into machinery, allowing high-speed friction between the media with similar melting points to generate heat. Plastic assemblies specifically designed for ultrasonic welding incorporate geometries at the interface between the two-or-more components that help initiate plastic melt in the weld joint area. The demand of the production industry for complex and efficient automatic systems is constantly increasing. Ultrasonic welding is the method of joining two parts by converting the electrical energy into the heat energy, It is suitable for the plastics and the metals, It can use high-frequency ultrasonic acoustic vibrations to the materials that are being held together under … Ultrasonic welding is cost effective and a green technology. Welding of plastics using ultrasonics. Sonics & Materials (UK) Ltd. was formed in August 2004 after taking over the plastic welding business from Kerry Ultrasonic. Click here for sealing of packaging materials. The process of ultrasonic welding of plastics is achieved by applying a vibrating metal tool (horn) at 90° to the stationery plastic parts which then vibrate. Elastomers are plastics that are processed by means of cross-linking; they do not react to ultrasonics. Thanks to intelligent software and variant diversity, the ultrasonic welding machines can be specifically configured to your demands: Complete system with functional units for mechanical engineering, modular and easy to commission. The company is ISO 9001 certified and is consistently in the vanguard of industry innovators. Feedback from users. Herrmann Ultrasonics, E-module: promotes sound conduction and determines coupling, Melting point: determines the heat requirement, Viscosity of the melt: high viscous melts can be kept within the joining area more easily, the process sequence is more uniform, Ultrasonic components for special-type welding machines, Robust and reliable in continuous operation. Base materials used for the parts Material (base material) selection also plays an important role in the ultrasonic welding process. When combined with pressure, friction produces heat & melts the parts at the horn contact point. A large number of every-day products are welded using ultrasonics. Unmatched Support. We supply you with a full-service package, including short response times. Titanium horns can be coated with materials like Carbide, Nickel, or Teflon. Ultrasonic welding is well suited for a large number of automotive components, where high part counts and appropriate strength are required. However, the overall process is generally the same. In ultrasonic plastic welding, a vibratory motion at the horn face (amplitude) is transferred to the part. Misunderstanding of workpiece material: Ultrasonic plastic welding machine also has requirements for the material of the workpiece to be welded. In this process there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together. In addition to welding, ultrasonic energy is commonly used for processes such as inserting metal parts into plastic or reforming thermoplastic parts to mechanically fasten components made from dissimilar materials. Becaus… Let's talk business! Ultrasonic welding eliminates the need to use fasteners, glues and/or solvents. Ultrasonic Welding Basics. Some materials can be welded well, some are basically fused, and some are not fused. Welding dissimilar thermoplastic materials according to their polymer compatibility, such as PP, PVC, PE, PET, ABS, composites, tissues, fleece or films. Experienced ultrasonic engineers develop the perfect concept for your customized requirements and special integration tasks. Yan: Before you start explaining the relation of Lingke and the printing consumables, please explain what ultrasonic plastic welding is?. Ultrasonic welding of two parts made from the same plastic material will usually obtain the best result. Once the vibration is stopped, the tool maintains a holding pressure on the joint to create a bond. At Herrmann, optimization means to focus on continuous and long-term improvements: in manufacturing, for process sequences, in service, in education or with regard to partnerships. In general, rigid plastics exhibit excellent far-field welding properties because they readily transmit vibratory energy. Direct contact is important to us because we want to hear from you and offer our expertise. Find here the answers to most frequently asked questions. News from the company, press releases, images, and logos - compiled for you. Go to seminar overview, Trade shows are a platform for direct exchange – we show you our latest developments and state-of-the art technology. State-of-the-art measuring and control technology safely detects any process faults: Ultrasonic systems and modules for continuous joining of nonwovens and web material operate economically, with low wear, and without adhesives. Click here for laminating of nonwoven materials. Ultrasonic welding is used in almost all major industries like automotive, electronic and appliances, medical, packaging etc. While it is possible to ultrasonically weld plastic materials without specific joint design details, the weld process is greatly enhanced by adding proven features that aid in the process. How it started: from small business to medium-sized company in the high-tech sector. There are thermoplastic materials, elastomers, and thermoset resins: Thermoplastic materials are plastics that are processed by heat and are well suited for ultrasonic welding. We meet the industry's requirements for: As far as joining of thermoplastic materials and nonferrous metals is concerned, Herrmann Ultraschall is the first point of call. (joint area) so the plastic material will melt and form a molecular bond between the parts. It is frequently chosen when parts are too complex or expensive to be molded in one piece. Ultrasonic sealing technology has become an established and economic alternative of heat sealing: Laminating without the use of adhesives and embossing without the use of heat? UW is commonly used for plastics and especially for joining dissimilar materials. Every sonotrode is designed, calculated and carefully documented according to customer requirements: The ultrasonic modules are provided in a flexible modular system and allow for easy integration into packaging machines.

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