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Ultrasonic welding process

Ultrasonic welding process
Ultrasonic welding is a quick, clean, efficient assembly process used to assemble the processing thermoplastics fittings, and some synthetic member. Schomburg Polystyrene is the use of the bond between the bond between the new moon rubber products and metal parts for bonding and other non-Shuo plastic material! It replaces the solvent cement mechanical ruggedness and the bonding process is a state-of-the-art assembly technology! Ultrasonic welding is not only connected to the assembly function and with a moisture-proof, waterproof sealing effect.

Ultrasonic advantages:

1, energy
2, no cooling equipment Smoke ventilation
3, low cost, high efficiency,
4, easy to automate production!

Ultrasonic welding machine works!

Ultrasonic welding device through a transistor function device current 50/60Hz frequency into 20KHz or 40KHz power high-frequency energy supplied to the converter. Converter to convert electrical energy into mechanical vibrations for ultrasonic energy, mechanical energy from the ultrasonic welding machine welding head after the shift of the pressure regulating device is responsible for transmission. The welding head is the mechanical vibration can be transmitted directly to the need laminated products, an acoustic device.

Vibration welding work pieces pass through the adhesive surface vibration friction generated heat can melt the plastic,
Vibration in the molten material to reach its interface stops short to keep the pressure can melt the glue curing produces a strong molecular bonds,
The entire cycle is usually less than one second to complete, but the welding strength is close to a piece of material attached!!

Welding:

Refers to a generalized two thermoplastic welding process. When the ultra-sound to stop the vibration,
The solid material is melted, the completion of welding. The engagement the point strength even close to a block of raw materials,
As long as the products have to match the design of the joint,
Completely sealed is absolutely no problem,

Dish together:

Melting mechanical lock is formed of a different material plastic bolts.

Embed:

A metal parts embedded in the plastic products aside hole.
With high intensity, short molding cycle install the advantages of fast! !
Similar to the insert in the mold design!

Bending / generated

The sonic the part of the accessories melting to form a plastic protruding parts or plastic tube or other extruded parts. The advantage of this approach is to overcome the fast processing, the smaller the inner pressure, good appearance and material nature.

Point defended

Spot welding is not set aside, or energy control two local welding of thermoplastic components. Spot welding can also be generated in a strong bonding structure, particularly suitable for large accessories, there is a protrusion of the plastic sheet or cast thermoplastics, and the complex structure, difficult to enter the engaging surface of the item.

Shear

Cutting and sealing order and disorder thermoplastic material ultrasound technology. The edge of the seal in this way does not crack, and there is no flash, curling phenomenon.

Textile / film sealing textile products and some of the film can also be used to seal the ultrasound. Film implement pressed together, but also textiles clean local shear seal. Suture at the same time also played a decorative role.
Factors affecting ultrasonic welding

Speaking of thermoplastic welding force, can not fail when it comes to ultrasonically welding the requirements of the various resins. Its most important factors include the polymer structure, the melting temperature, flexibility (hardness), the chemical structure.

Polymer structure

Ordering disorder non-crystalline polymer molecules, the material softens gradually melting until the flow temperature (Tg glass transition temperature). Such resins are usually effective transmission supersonic vibration and good welding a wide range of pressure / amplitude range.

Semi-crystalline polymer molecules arranged in an orderly manner, there is a sharp melting point (Tm melting temperature) and re-freezing point. The solid crystalline polymer is elastic, can absorb a part of high-frequency mechanical vibrations. Therefore, this type of polymer is not easy to ultrasonic vibration energy transmitted to the lamination, help request higher amplitudes. Requires a high energy (high melting temperature) in order to interrupt the semi-crystalline structure so that the material from a crystalline state into a viscous flow state, which also determines the melting point of the material such obvious once the melted material leaving the heat source, temperature decrease would lead to the rapid solidification of the material. It is necessary to consider the particularity of such materials (for example: high-amplitude, the junction point of a well-designed, effective contact with the ultra-sound fixture, and excellent work equipment) in order to achieve the success of the ultrasonic welding.

Polymers: thermoplastic and thermosetting

Monomers combined process is called "polymerization". The basic polymer can be divided into two categories: thermoplastic and thermosetting. After the molding of thermoplastic material is heated can be re-re-softening and molding, the group experienced only state changes only - This feature makes the decision to the adaptability of ultrasonically welding of thermoplastic materials. The thermosetting material is generated by the non-antagonistic chemical reaction was again heated or pressurized not make the molded thermoset product soften the thermosetting material is not suitable for the use of ultrasound, it has traditionally been considered.

Melting temperature

The higher the melting point of the polymer, the more ultrasonic energy required for welding.

Hardness (Modulus of elasticity)

The hardness of the material to its ability to effectively transfer supersonic vibration is very influential. In general, the harder the material its conduction stronger force.

Ultrasonic welding:

Ultrasonic frequency vibrations of the welding head, in a predetermined period of time and under pressure, the friction heat, the plastic junction fused with each other, both solid and convenient

Ultrasound buried inserted:

Metal and plastic ultrasonic welding head to the vibration friction heat to melt the plastic contact surface, the metal Chun squeeze into the plastic hole.

Ultrasonic riveting, molding covering:

Plastic tip member, through the holes of the metal member, the vibration tip end of the welding head to a high amplitude, so that the melting along the contact surface of the weld head into a rivet shape, a metal plate is riveted live


Ultrasonic spot welding

Two layers of plastic plate welding, welding head the central guide pin super wave vibration to save wear layer plastic plate, due to vibration can produce segregation, plastic junction indirectly create friction heat, so that the two layers of plastic plate welding.

Ultrasonic plastic welding compatibility and adaptability:

Thermoplastics, due to the different nature of the various models, resulting in some easily ultrasonic welding, some not easily soldered. Chart black box, which means that the good compatibility of the two plastic, easy to carry out the ultrasonic welding, the circle which means that in certain circumstances compatible welding performance is acceptable, spaces, said two plastic compatibility is poor, difficult to welding.
Ultrasonic welding of the weld design:

Two thermoplastic parts by ultrasonic welding requires the ultrasonic vibration to the upper halves of the assembly is passed through the welding head, and finally transmitted to the two halves of the junction or interface In this case, the vibration energy is converted into heat for melting the plastic. When After the vibration is stopped, the plastic is cured under pressure, in combination with the surface of the weld.

The combination of the two surface design, it is very important for optimum welding results. Various connection design, each of which has the features and advantages of the use of various design, depending on many factors, for example, plastic Type Part geometry requirements of welding (i.e., viscosity, strength, sealing, etc.).

Clamp means:

Plastic ultrasonic welding, an important factor is the clamp means the jig main purpose of the apparatus is fixed to parts, so that it aligned with the welding head, while the assembly to provide appropriate support material being welded, replacement parts geometry, wall thickness, and Parts the symmetry can affect the transfer of energy to the interface design fixture must be considered.

Some uses, such as riveting and intercalation, in the welding head contact area following the hard supporting device. The aluminum fixtures provide the necessary stiffness, chrome parts to prevent scarring and improve the wear resistance is required.

In some applications, the jig must have a certain degree of flexibility to ensure that the different phase state in the connecting zone different phase state in the worst combination of ships, this range is to be welded; However, due to certain parts material and geometric shape, combined with the two halves may be synthesized as a whole, up and down vibration, if this condition occurs, the order of the grooves change from a rigid material to an elastic material, or durometer to be changed by the soft material with another material, is often sufficient links the area to re-establish a different phase state.

The simple experiment jig availability timber, an epoxy resin or plaster construction of more sophisticated, longer life of the fixture to be aluminum, steel, brass, cast urethane, or other elastomeric material. Wide range of fixture design, simple metal plate fixture from the rapid dismantling of both the requirements of the application and productivity usually determines fixture design.Ultrasonic welding process


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