Ultrasonic Welding Design For Plastics

Designandoperation ofan ultrasonicweldingunit 4 3. When designing plastic parts to be assembled by ultrasonic welding engineers have several options.

Ultrasonic Plastic Welding Machine For Welding Joining Thermoplastic Parts Plastic Welding Welding Machine Ultrasonic

Plastic assemblies specifically designed for ultrasonic welding incorporate geometries at the interface between the two-or-more components that help initiate plastic melt in the weld joint area.

Ultrasonic welding design for plastics. Which to choose depends on many factors including the materials. The size and rigidity of the parts. The main element of the welding machine is a transducer which converts the HF.

And performance requirements such as joint strength cosmetics and leak-tightness. Welding of plastics using ultrasonics. The ultrasonic horn is vibrated vertically 20000 20 kHz or 40000 40 kHz times per second at distances measured in thousandths of an inch microns for a predetermined amount of time called weld time.

The choice of design depends on the following factors. Welding of Plastics. When cooled a weld is formed.

Longitudinal vibrations in frequencies of 20 kHz 30 kHz and 35 kHz with tool amplitudes between 5 µm and 50 µm are introduced into the plastic materials under the action of force. For ultrasonic welding of plastics the welding machine has the same features as the one for metals. The vibrations move through the part and creates friction at the interface between the parts.

One of the key factors to successful ultrasonic welding is good component design in particular the shape of the surfaces to be joined ie the joint design. Frequency 35Khz 40KHz Generator 1500W1000W 800W1200W Welding model Time model energy model power model depth model Distance micro-adjustment 20-100mm Precision001 mm The height of the frame in max 180mm Input Voltage 220V110V Function 1Frequency auto. 18 rows The process of ultrasonic welding of plastics is achieved by applying a vibrating metal tool.

Because ultrasonics allow for the welding of dissimilar plastics adding ports and fittings to film bags or pouches is made possible. The ultrasonic welding process converts electrical energy into mechanical vibrations. Ultrasonic welding of plastics is used widely in making electronics medical devices and car parts.

Ultrasonic welding can be used to create water and air tight seals in films to create custom plastic bags create seamless fabric joints for medical devices etc. Grated design elements that are molded into the parts such as snap-fit or press-fit joints. The ultrasonic welding technology for plastics is considered part of the melt welding processes.

There are a variety of joint designs possible each with specific features and advantages. Another is that the pieces must be assembled around another part or parts. Medical devices such as catheters valves filters and face masks are also assembled using ultrasonic welding.

Fundamentals and New Developments. Ultrasonic welding of plastic materials creates a molecular bond within the weld seam. When and Why to Use Ultrasonic Welding.

Think motor housings or enclosures Ultrasonic welding can simplify part design. UltrasonicweldingofHoechst engineeringplastics 5 31 Requirementsfor optimum ultrasonic welds 5 32 Factors affecting weldingproperties 6 321 Effect ofthe mouldingcompound 7 3211 Effect ofmeltviscosity 7 3212 Effect ofpigments 7 3213 Effect ofreinforcing materials andelastomeradditions 8 322 Effect. A butt joint a step joint a tongue-and-groove joint and a shear joint.

The process is based on a conversion of friction and vibration energy into heat. It is frequently chosen when parts are too complex or expensive to be molded in one piece. 35Khz plastic welder with free ultrasonic welding joint design service Parameter.

Ultrasonic Plastic Joining Technical Information PW-3 Part Design for Ultrasonic Welding Ultrasonic energy has been used to join thermo - plastics for over 35 years. For example ultrasonic welding is used to make electrical connections on computer circuit boards and assemble electronic components such as transformers electric motors and capacitors. In ultrasonic plastic welding a vibratory motion at the horn face amplitude is transferred to the part.

The vibrations move through the part and creates friction at the interface between the parts. Creating heat then melting. Section 4 ultrasonic welding section 5 laserIR welding section 6 RF welding section 7 and hot gasextrusion weld-.

One common reason is because its not feasible to mold the pieces as one unitary part. Through careful part design this vibratory mechanical energy is directed to limited points of contact between the two parts. Consider ultrasonic welding whenever the design calls for joining separate plastic pieces.

EXAMPLE A typical assembly consisting of a knob of impact styrene and a steel insert as shown. In adhesive bonding a consumable. Ultrasonic exposure time is usually less than one second but during this brief contact the plastic reforms itself around knurls flutes undercuts or threads to encapsulate the insert.

Ultrasonic welding of thermoplastic materials is by far the most common form of ultrasonic assembly and is used extensively in all major industries including. In ultrasonic plastic welding a vibratory motion at the horn face amplitude is transferred to the part. Ultrasonic energy has been used to join thermoplastics for over 70 years.

Using a welding tool called a sonotrode the high-frequency vibrations generated by the ultrasonic system in combination with pressure are transferred to the parts to be joined which leads to relative vibrations in the jointing zone. Energy supplied by ultrasonic oscillator into vibrations.

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