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Ultrasonic plastic welding technology in the automotive industry

In modern vehicles, whether it is decorative pieces (such as bumpers, fenders, wheel covers, baffle, etc.), interior trim (such as instrument panels, door inner panels, deputy dashboard, debris cover, seat chair, the rearguard, etc.), or the function and structure (fuel tank, radiator water chamber, air filter cover, fan blades, etc.), everywhere you can see the shadow of the plastic parts. Currently, Hyundai Motor 100kg plastic material to replace the traditional metal materials originally scheduled 200 to 300kg, the weight loss effect is very prominent, which is of great significance to save energy and reduce greenhouse gas emissions. Such as automotive plastic intake manifold instead of metal to reduce the quality of 40% to 60%, and the surface light clear flow resistance, improve engine performance and improve combustion efficiency and reduce fuel consumption, noise and vibration reduction have played a role. According to statistics, automotive plastic varieties has reached dozens of species, average per vehicle use of plastics account for 5% to 10% of the vehicle weight, with the technology to expand the application of the requirements for the development of the automobile lightweight and automotive plastic, automotive plastic bicycle usage in the future will increase further.

Automotive plastics divided into two types: one is a thermosetting plastic, they can withstand the normal baking finish operation; a thermoplastic, with easy processing, fast advantages. In automotive plastics, among the top seven varieties of plastic material, with the proportion of roughly: Polypropylene 21%, 19.6% polyurethane, polyvinyl chloride 12.2%, thermoset composites 10.4%, ABS %, 7.8% of nylon, polyethylene, 6%.

Connection of the plastic is a key part of their wider application. Plastics can be connected by mechanical fastening, bonding or welding. Fastening connection is fast, applicable to all plastic, but the cost is high, concentration of stress will be generated, can not form the sealing joints, or to obtain proper performance. Bonding can obtain excellent performance and high-quality connectors, but the operation is difficult, and requires careful joints and surface preparation, and the speed is very slow, and is not suitable for mass production. Welding economy, simple, fast, reliable, able to form static strength is close to the connector of the base metal, and thus suitable for mass production, is becoming more widely used in the automotive industry. The level of plastic welding technology has become one of the hallmarks of measure automobile production technical level and the development of new materials level.

Automotive plastic welding method

Plastic welding is limited to the welding of thermoplastic, because only the thermoplastic can be melted when heated or softened, heating the thermosetting plastics can not be softened and remelting.

Hot air welding oxyacetylene gas welding metal-like open fires the former, but the latter is heated with hot air. Hot gas welding process, the hot gas flow from the torch (typical temperature of 200 ° C to 300 ° C, a flow rate of 15 ~ 60L / min) at the same time heating the filler rod and the weldment continuous filler rod, when the softening of the surface of the material to achieve a sticky state, pressure into the weld. The filler rod material is exactly the same ingredients as the base material, is generally circular (diameter of about 3mm), the bead when welding thick plate welding. One disadvantage of the circular filler rod is easy in the the bead process of hollow bubble trapped in the weld, resulting in reduced strength, this problem can be solved through the use of triangular cross-section rods. Available hot air welding Typical materials include polyvinyl chloride, polyethylene, polypropylene, plexiglass, polycarbonate, polyoxymethylene, polystyrene, nylon, ABS, and so on. The main advantage is that the hot gas welding adaptability (flexibility), a simple portable equipment for processing large, complex parts. Hot air welding applicable to the irregular structure, but it is slow, the welding quality is largely dependent on the skill of the operator, it is rarely used in mass production, but it applies to the repair operations.


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