What is the application of ultrasonic welding principle in process to non-metal material?
Ultrasonic welding principle is applied over than joining, the most application as below:
Energy ultrasonic welding: two plastic parts overlay together under pressure between which there is energy director (called welding rib) designed to melt as replacement to form joining.
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Energy ultrasonic welding: two plastic parts overlay together under pressure between which there is energy director (called welding rib) designed to melt as replacement to form joining.
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What is the advantage of ultrasonic welding?
What contents in ultrasonic system?
What is critical to ultrasonic welding?
F: Clamp Force; A: Amplitude; f: Ultrasonic Frequency
E=P*F*A*f*T
Integral form:
E = \int \mu P v \, dt, which indicates that the energy is the integral over time of the product of the friction coefficient, pressure, and velocity.
Energy density:
E = K_1 P^{n_1}, where the energy density (E) is related to the welding pressure (P) by a power function.
Energy distribution:
E_0 = E_t + E_w, where the total energy equals the sum of frictional heat generation (E_t) and heat generated by plastic deformation (E_w).
Moreover, it is very important that have suitable construction designed for ultrasonic welding according to parts material, geometric shape and welding result standard.
The types of ultrasonic welding machine
How to control the work of ultrasonic?
When stop ultrasonic output?
Depth mode:
there are two types: a. ultrasonic stops work when machine head descends to the position in height preset; b. ultrasonic stops work when machine heads descends in a moving distance preset in system.
What kind of thermoplastic material can be welded by ultrasonic?
Different material different welding result by ultrasonic, the welding compacity between two similar or two dissimilar material is different.
| Ultrasonic Welding Performance Analysis for Thermoplastic Materials | ||||
| Material Combination | Welding Compatibility | Welding Difficulty | Weld Strength (vs. Base Material) | Welding Appearance |
| ABS + ABS | Excellent | Very Low | 85% – 95% | Smooth, No Flash |
| PC + PC | Excellent | Very Low | 90% – 100% | Transparent, Glossy |
| PS + PS | Excellent | Very Low | 80% – 90% | Smooth, Minimal Flash |
| PMMA + PMMA | Good | Low | 75% – 85% | Transparent, No Cracks |
| PVC + PVC | Good | Low | 70% – 80% | Smooth, Chemical Resistance Retained |
| PP + PP | Good | Medium | 65% – 75% | Slightly Rough, Visible Weld Line |
| PE + PE | Good | Medium | 60% – 70% | Slightly Rough, High Toughness |
| PA66 + PA66 | Good | Medium-High | 60% – 70% | Rough, Visible Weld Seam |
| PET + PET | Fair | High | 50% – 60% | Brittle, Easy to Crack |
| ABS + PC | Excellent | Low | 80% – 90% | Smooth, Good Adhesion |
| ABS + PS | Good | Low | 75% – 85% | Smooth, Minimal Flash |
| PC + PMMA | Good | Medium | 70% – 80% | Transparent, Good Clarity |
| ABS + PVC | Fair | Medium | 60% – 70% | Smooth, Moderate Adhesion |
| ABS + PP | Poor | High | 30% – 40% | Uneven, Easy to Delaminate |
| PC + PP | Poor | High | 25% – 35% | Brittle, Easy to Crack |
| PS + PP | Poor | High | 20% – 30% | Uneven, Low Strength |
| PA66 + PP | Very Poor | Very High | <20% | No Effective Weld |
| PET + PE | Very Poor | Very High | <15% | No Effective Weld |
Welding depth mode control, ultrasonic frequency 15KH & 20 KHz , power output 3000W, 3200W, 4200W & 6000W.
ZB-E1542 is an ultrasonic welder in economical series in high power output. Machine applies IGBT ultrasonic system in 15KHz 4200W with positive resonance design. Machine applies pneumatic cylinder to force ultrasonic welding action. Machine welding control mode including time mode, energy mode and external trigger mode. During welding, it can control welding process in two steps with set amplitude for each steps.
ZB-E Series ultrasonic welding machine applies pneumatic cycler to force welding. Machine applies IGBT ultrasonic system to control welding. Welding parameter is set on HMI. Ultrasonic amplitude is adjustable in 10~100% by 1%. Machine ultrasonic output can be controlled by time mode and energy mode.
Ultrasonic Welder with PVC film rolling system to feed-in before welding and wind after welding aiming protect parts surface during ultrasonic welding
Portable ultrasonic welding machines, also called handheld ultrasonic welder, normally is in 28KHz, 30KHz, 35KHz, 40KHz in power of 800~1200W. Because of its benefit of light weight & small size, easy operation and economical investigation, etc, handheld ultrasonic welder is welcomed by different production industries, such as automotive industry, electronics industry, garment industry, etc.
Ultrasonic welding machine with dynamic force trigger, ultrasonic frequency 15KH, 20 KHz , 35KHz, power output 1200W, 3000W, 3200W, 4200W & 6000W.
Ultrasonic welding machine applies rotary table index for different operation station for semi-automatic operation. Machine rotation indexing system applies servo motor system & splicer for accuracy and high motion speed. Ultrasonic system specification is customized according requirement.
ZB-101542-P is a ultrasonic plastic welding machine designed with soundproof Shell to insulate ultrasonic noise. Machine applies 15KHz 4200W ultrasonic system made by MP Sonic to realize ultrasonic welding in high power output.
This machine is applied to bond the lining material to injection molded parts at edge by ultrasonic welding method to position material avoid loose after laminating
Ultrasonic welding tooling, designed according to customer requirement, with FE Analize to ultrasonic welding horn. Material can be aluminum, steel or titanium; base fixture can be desiged with auxiliary function such as clamps, sliders, vacuum system, turning system in case in need.
Ultrasonic cutting tooling in 20K, normally applied to cut food such as bread, cake, pizza, etc, or rubber material product such as tire, etc. Comparing to 40KHz ones, 20K ultrasonic system can realize the cutting in much bigger size.
