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design of the ultrasonic weld line

design of the ultrasonic weld line
Ultrasonic welding technology experience parsing
Strength can not achieve the desire standard.
Of course, we must be aware of the strength of the ultrasonic welding jobs may never reach the strength of one piece only say close to forming one's strength and weld strength requirements of the standard must rely on a number of co-ordination, these complexes What is it?
※ strong plastic material: ABS with ABS mutually fused definitely better than ABS and PC are fused to the strength, because of the two different materials whose melting point is also not the same, of course, the strength of the weld can not be the same, although we explored ABS and PC material possibility of mutual welding? Our answer is absolutely welding, but whether post-weld strength is that we want to? It is not necessarily a! The other hand thought if ABS and nylon, PP, PE melting the situation how? If the ultrasound the HORN instantly issued 150 degrees of heat, ABS material has been melted, nylon, PVC, PP, PE just to soften it. We continue to heat to more than 270 degrees, nylon, PVC, PP, PE has been up to in the ultrasonic welding temperature ABS material has been resolved to the addition of molecular structure! Three conclusions can be summarized by the above discussion:
Same melting point plastic weld strength stronger.
The greater the gap between the melting point of the plastic material, the smaller the weld strength.
Higher density of plastic (rigid) than the density the lower (toughness), high weld strength.

2 product surface scars or cracks.
Ultrasonic welding jobs, product surface scars, the junction breaks or cracks is common. High heat because ultrasound job will have two situations: 1. Direct contact with the surface of the plastic products 2. Vibration conduction. Ultrasound fat cheer for plastic products, the product surface prone to burns, 1m / m within flesh thin plastic columns or holes, are also vulnerable to rupture phenomena, this is the ultrasound jobs precedent phenomenon is no avoided. On the other hand, a long time to weld due to the lack of energy of ultrasound output (extension stations and HORN upper mold), the vibration friction energy is converted to heat is required, in order to accumulate heat energy to compensate for the output power of the deficiencies. The way of such welding, not instantly reach the vibration friction heat, and have to rely on the welding time to accumulate the heat, the melting point of the plastic products reach the welding results, so will cause heat to stay too long in the surface of the product, while the cumulative temperature pressure will cause product of burns, Zhenduan or rupture. In power output (number of segments) must consider, welding time, dynamic pressure with the factors to overcome such work shortcoming.
Solution:
1. Reduce pressure.
2 to reduce the delay time (early oscillation)).
3. Reduce welding time.
4 media coverage (such as PE bags).
5 die fixture surface treatment (hardening or chrome).
6. Machine reduced the number of segments or expand than to reduce the upper die.
7. Easy shattered or broken products, buffer fixture should be made of soft resin covering the cork (this does not affect the weld strength).
8 easy to break the product angle Right Angle plus R.


3. Products produce distortion.
Happen deformed our regulatory satisfied three reasons:
Body and desire frit or Gein angle or the radian can not agree with each other.
2. Meat thickness (2m / m or less) and a length in excess of more than 60m / m.
3 Injection molding pressure and other conditions leading to deformation distortions.
So when our products are deformed by ultrasound job, from the surface it seems like ultrasonic welding reasons However, this is just a result, any factors not welded plastic products after welding, forming what results. If not for the main cause, it would cost a lot of time to explore the treatment does not suit the remedy to the problem, and in the ultrasound indirect conduction welding job straight (non-melting), pressure 6kg following is unable to change the plastic braking system inertia. So do not try to use strong pressure to change before welding deformation (maximum pressure welding machine 6kg), including forced extrusion with die fixture. Perhaps we may be mired in a blind spot, that is, from the surface to explore the deformation reasons, that is not welded before the naked eye can not see, but after the completion of the ultrasonic welding deformation was observed, it is obvious. The reason is the welding will be due to the presence of the guide fuses, and more difficult to find the cumulative error of the product itself, a variety of angles, in radians with more than expected, ultrasonic welding is completed, but it appeared as the naked eye can see deformation.
Solution:
A lower pressure (the pressure is preferably less than 2kg).
2. Reduce the ultrasonic welding time (to reduce the intensity of the standard).
3 increase the hardening time (for at least 0.8 seconds or more).
4. Analysis of ultrasound upper and lower die whether partial adjustment (when necessary).
Analysis products deformation major reason for improvement.

4 products internal parts damage
※ ultrasonic welding products undermine the following reasons:
Ultrasonic welding machine power output too.
Ultrasound energy amplifier energy output is too strong.
The bottom mold Fixture force points left vacant by the ultrasound conduction vibration and destruction.
Plastic products, fine into the bottom of the right angle, but have not set up a buffer to ease energy R angle.
5. Incorrect the ultrasound processing conditions.
Pillar of plastic products or the more vulnerable parts of the open placed in a plastic mold parting line.
So when our products are deformed by ultrasound job, from the surface it seems like ultrasonic welding reasons However, this is just a result, any factors not welded plastic products after welding, forming what results. If not for the main cause, it would cost a lot of time to explore the treatment does not suit the remedy to the problem, and in the ultrasound indirect conduction welding job straight (non-melting), pressure 6kg following is unable to change the plastic braking system inertia. So do not try to use strong pressure to change before welding deformation (maximum pressure welding machine 6kg), including forced extrusion with die fixture. Perhaps we may be mired in a blind spot, that is, from the surface to explore the deformation reasons, that is not welded before the naked eye can not see, but after the completion of the ultrasonic welding deformation was observed, it is obvious. The reason is the welding will be due to the presence of the guide fuses, and more difficult to find the cumulative error of the product itself, a variety of angles, in radians with more than expected, ultrasonic welding is completed, but it appeared as the naked eye can see deformation.
Solution:
Early ultrasound oscillation time (to avoid contact with the oscillation).
2. Reduce stress and reduce the ultrasonic welding time (lower intensity standard).
3 to reduce the number of machine power segment or small power machine.
Lower ultrasonic mold expansion ratio.
5 the bottom die at the force pad cushion rubber.
6 bottom mold Products to avoid vacant or gap.
7.HORN (upper die) dig hole after re-measured frequency.
8 on mode dig holes and paste the flexible material.

5 products produce excess material or burrs
※ ultrasonic welding after the product excess material or burrs following reasons:
Ultrasound power is too strong.
Ultrasonic welding time is too long.
3. Too much air pressure (dynamic).
4 upper die under pressure (static) too.
5 upper die (HORN) the energy expansion ratio is too large.
6 plastic products guide fuses too lateral or too high or thick.
Above six caused flash burr occurs ultrasonic welding job, however, one of the most critical in the sixth ultrasound guided fuse opened, generally in the ultrasonic welding operation, the air pressure at about 2 ~ 4kg range, according to the Experience of ultrasound guided fuses in the bottom of the 0.4 ~ 0.6m / m × height 0.3 ~ 0.4m / m: this type Δ cusp was about 60 ° beyond this value guide to the ultrasonic welding time, pressure, the machine or the upper mold power increases, so to form the cause of burrs and the burr reason in the above 1 to 6.
Solution:
1. Reduce the pressure to reduce the time of ultrasonic welding (lower strength standard).
2 to reduce the number of machine power segment or small power machine.
Lower ultrasonic mold expansion ratio.
4. Use the ultrasound machine to fine-tune the positioning and fixing.
5. Modify ultrasound guided fuses.
6 After welding the size can not control the tolerances
※ In ultrasonic welding job, the product can not control the tolerance range for the following reasons:
Machine stability (energy conversion, no additional safety factor).
2 the amount of deformation of plastic products beyond the range of Ultrasound natural fusion.
3 fixture positioning, or endurance unstable.
Ultrasound on-mode energy to expand output does not match.
5 weld machining conditions no additional safety factor.
Solution:
1. Increase the the welding safety factor (sequentially by welding time, pressure, power).
2 enable tuning screws (should be controlled to 0.02M / m).
Check ultrasound adequacy mode output energy (the insufficient increase the number of segments).
Check fixture positioning whether stability together with product endurance.
5. Modify ultrasound guided fuses.
Ultrasonic plastic welding water, airtight lead fuse (soldering) design

We desire to reach the water, airtight functionality, positioning and ultrasound guided fuse is key for the success or failure of, so to consider in the design of the product, such as: positioning, material, flesh, with the ultrasonic guided fuses corresponding proportion absolute relationship. In general water, hermetically requirements, guide Fusible height should be in the 0.5 ~ 0.8m / m range (depending on the product flesh may be), such as less than 0.5m / m or less, to achieve the airtight function of the water, unless positioning set to be very standard, and thick flesh more than 5 m / m, or ineffective. The general requirements for water airtight product positioning and ultrasound guided fuses as follows:


Miter: Good the watertightness and large products welding, the contact surface contacting angle = 45 °, x = w / 2, D = 0.3 ~~ 0.8mm better.


Stepped tip type for: watertightness and prevent the convex or cracking of the method, the contact surface of the angle = 45 °, x = w / 2, d = 0.3 to 0.8 mm preferably.


The peak and valley tip for: watertight and high strength splice, d = 0.3 to 0.6mm inside the height h of the contact surface depends on the size and shape changes, but h is about 1 ~ 2mm.

The ※ above three water airtight ultrasonic guided fuses design method.

Product implementation ultrasonic job could not reach the water, airtight fixture positioning, in addition to ultrasonic guide fuses, the product itself is positioning factors, the the ultrasonic set of conditions is also a main cause. Deeper we explore another reason cited Xiangshui airtight (welding conditions), seeking efficiency and fast is the most basic goal of ultrasonic welding job, but often overlooked essentials for efficiency, the normal There are two phenomena:
First, the rate of decline, the buffer is too fast: a form of speed, so the dynamic pressure coupled with the acceleration due to gravity flattening ultrasonic guided fuses will not be able to play the role of guide melting, forming the illusion welding guide fuses.
Long welding time: the plastic products due to receive over a long period of heat, not only of the plastic material melted plastic tissue and cause coking phenomenon produce sand holes, water or gas, this sand hole penetration out. This is the most difficult to find at the general production technology.


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