Ultrasonic welding grows in popularity due to the increasing development of soldering applications in the thermoplastics industry. These advantages have been made possible thanks to an ever more accurate research of the employed materials, machinery design and the necessary tools. It could be said that what makes ultrasonic welding so successful is the preliminary project of the soldering gear and a deep understanding of the ultrasonic phenomena related to it.
Do you want a free consultation from our team of experts? Fill in the form above.
The ultrasonic technology contributes to the creation of common plastic items designed to be permanently assembled, this includes the conscious decision of excluding the possibility of getting disassembled and repaired. It is particularly popular for manufacturing disposable products for hygienic purposes, such as medical instruments.
How does Ultrasonic Welding Works?
Ultrasonic vibrations resonate at frequencies ranging from 20 to 40 kHz, emitted by a generator that is powered by a regular 50 Hz current.
A converter then transforms these high frequency vibrations from the generator into mechanical movement. This is comparable to an ultra fast micro hammering action.
The ongoing amplitude produced by the converter becomes thermal energy (latent fusion heat) through friction generated by the contact of two surfaces and the absorption of ultrasonic waves: materials melt into the parts that are meant for welding. This creates a nearly homogeneous joint after it cools down.
Thermoplastics, and hence the resulting force of their connection, can be positively influenced by adjusting the amplitude or the force applied to it.
There are several welding systems in the market that work using this same principle: from portable units to standard machinery and completely custom made solutions for mass production, devised according to modern standards. Such method is fast, efficient, and environmentally friendly because it does not require additive substances.
Ultrasonic Welding Advantages
Some of the benefits that allowed ultrasonic welding to be so widespread can be enumerated as follows:
- It is a clean, reliable welding technique that may be applied to several manufacturing processes;
- It does not employ additional materials for joining pieces, plus it is safe for both workers and the environment;
- Usually it is characterized by cycle time that can reach below the second one, which makes it a widespread technique in industrial assembly lines;
- It guarantees uniform higher quality that lasts longer;
- Because of the way it functions, it requires very low energy;
- The welding machine’s setup is very simple and once set it is reliable for a long period of time. This type of welding produces very little wear and tear of mechanical parts and no residues whatsoever;
- Heat-sensitive items can be assembled free of risk of getting damaged since ultrasonic welding produces minimal heating confined to the soldering point.
Visit our dedicated page and ask for free advice by filling out the form.
Different Uses of Ultrasonic Technologies
In addition to its application in thermoplastics, ultrasonic welding is particularly useful for seaming, weaving, spot welding, or inserting metal rivets inside plastics. Other common procedures for ultrasounds are cutting and sealing edges of films or synthetic fabrics, as well as for making wastless portioning in the food industry.
Visit our YouTube channel to see Sonic Italia’s multiple operations.
A few examples of this:
- Automotive: dashboards, door locks, interior and exterior lining, headlights and interior lights, fuel and air filters, fuel tank floats, brake fluid containment boxes, valves and sensors;
- White goods: refrigerators, dishwashers, washing machines;
- Electronics: switches, relays, buttons, cables, piezoelectric disk joints, connectors, PCB production, audio and video accessories;
- Telecommunications: landline and mobile phones, screens;
- Small appliances: blenders, vaporizers, vacuum cleaners;
- Office supplies: folders and binders, printer cartridges;
- Medical provisions: dust-proof masks, surgery garments, diapers, blood filters, syringes, arterial filters;
- Textiles: fabric flaps incision, velcro bindings.
More Info about Ultrasonic Welding
Sonic Italia counts with over thirty years of experience in designing and building ultrasonics technology. It offers its technical staff and laboratories for direct sample tests and functional analysis.
Its highly qualified personnel develops customized ultrasonic techno-applicative solutions, from standard welding options to semi or fully automated systems.
Do not hesitate in contacting us book an appointment for a visit by one of our representatives or at our headquarters in Rho (MI).
Do you want a free consultation from our team of experts? Fill in the contact form