Ultrasonic plastic welding
How Does Ultrasonic Plastic Welding Work?
The ultrasonic plastic welding process uses high frequency mechanical sound waves (ultrasonics) to create molecular heat between thermoplastic materials. These high frequency acoustic vibrations are transmitted through thermoplastic material by a sonotrode. Typically two parts are located and supported in a fixture beneath the sonotrode. The sonotrode extends and applies a clamping force (pneumatic) to the parts. Localized frictional heat is generated at the joint area (energy directors) creating a molecular bond between the two parts. Typical operating frequencies are: 20 kHz, 30 kHz and 35 kHz.
Advantages And Benefits Of The Plastic Welding Process
Using ultrasonic plastic welding, no adhesives, screws, connective bolts or soldering materials are necessary. The possibilities for ultrasonic applications are broad. The process is very fast (less than one second) and can be automated very easily. The machines can be installed anywhere since no exhaust or heat has to be removed and therefore no ventilation system is required. The applied heat occures only in the joining area, avoiding any temperature changes or surface damage to the plastic parts. The joints are repeatable, clean and precise.
What are the common joint designs for ultrasonic plastic welding?
The so-called "energy director" approach is used for many joints. This requires a triangular projection be used on one of the pieces being joined and placed where the melting initiates. For leak-tight joints and some semi-crystalline parts, a shear joint is recommended. A shear joint requires some interference between the parts to be welded. As the parts are ultrasonically heated and compressed, one part "shears" softened plastic from the other.
Possibilities For Ultrasonic Plastic Applications
The use of ultrasonics for welding is applicable to small and large plastic parts. For example, products in the electronics & communications, household appliances & toys, medical and laboratory devices and automotive components industries can benefit from the utilization of ultrasonics in a production and laboratory environment.
In our modern application laboratories we can evaluate your products and demonstrate our capabilities. Please provide us with your requirements so that we can discuss it with you in greater details.
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