Ultrasonic technology

WHAT IS ULTRASONIC TECHNOLOGY

Ultrasonic technology is a sophisticated welding method that allows joining two different parts into a single object without the use of chemical reagents or glues.

Ultrasonic waves work at a molecular level with thermoplastic polymers. A small percentage of these plastics is necessary for ultrasonic technology to work.

The direct consequence of ultrasonic soldering technology lies in its application in a wide range of fields.

HOW DO ULTRASOUNDS WORK

In order to get two items welded correctly, some essential elements are required: first and foremost high-frequency and low-amplitude vibrations, these generate heat melts plastic components on its interface.

These frequencies, undetectable for the human hear, are called ultrasonics..

Placement of parts during the welding process can be either manual or automatic, depending of the application. One of them gets fixed in a static holder while the other part gets exposed to sinusoidal ultrasonic vibration that is perpendicular to the contact area.

Friction obtained from these ultrasonic vibrations causes heat, thus remixing the plastic polymers of both parts. Once they cool down, said polyers stabilize and create a weld.

New computer regulted systems have been devised to adjust welding times and amplitude and above all the amount of delivered energy on the two parts’ contact area and gurantee an optimal welding. 

TOOLS

Ultrasonic equipment usually comprises a generator, a converter, a booster and a sonotrode.

Ultrasonic generators are ccapable of reaching frequencies up to 20 kHz. These electrical frequencies are transformed into mechanical movement by a converter that contains piezoelectric ceramics.

Such mechanical movement is transferred to the booster afterwards, increasing its amplitude until reaching the sonotrode.

Then the sonotrode transfers the vibration into the two items subjected to the welding process.

NOISE

Just like every machine tool, depending on their application, even ultrasonic equipment can be a source of ambient noise.

All products made by Sonic Italia have been conceived to operate beyond threshold of human hearing (1700-1800 Hz)​. 

The extensive incursion of thermoplastics in major technological fields such as automotive, white goods, electrical parts, medical and military gear, has permitted to create a wide range of applications.

It is necessary to prepare and apply different measures of protection when using blare-generating machines.

  • Earmuffs (individual protection, local noise)
  • Welding tool guards against localized sonance 
  • Soundproofed cabins for collective protection and block high level of noise

Components built and marketed by Sonic Italia do not generate any kind of radiation.

Any potential sound nuisance that might be caused by machinery is due to a mechano-acoustical effect of air resonances that generates sound waves. As in concordance with Italian Law (L. 89/392 att. 1 step 1.5 parag. F).

In any case, according to the statistics, only 15-20% of our applications cause an high-level noises.

Sonic Italia offers its technical expertise for consultancies for soundproofing studies with the assitance of its network of suppliers and qualified technicians.

MATERIALS AND WELDABILITY

Riveting and and welding are two different ways to assemble industrial components.

 

Riveting consists in merging a mass of materials and shaping it like the head of a rivet with the purpose of combining two different elements such as plastics and metal.

 

The benefit of this method is that the sonotrode can be traced back once the materials are cold, keeping the pieces rigidly anchored.

 

Ultrasonic welding with energy directors on the other hand, it is necessary to consider many factors: the type of raw materials, shape, injection or thermoforming deformations during molding, the soldering variety (mechanical, liquid-tight, pressure-sensitive), sonotrode distance into the surface area, etc.

 

FOR MORE INFORMATION
To have some constructive recommendations and technical data about ultrasonic technology, you can get several useful documents at the download section. Our staff will gladly find a solution that suits your business needs.

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