Ultrasonic Welding
Technology
Ultrasonic Welding is a plastics welding process, in which two work pieces are bonded as aresult of a pressure exerted to the welded parts combined with application of high frequency acoustic vibration (ultrasonic).
Ultrasonic vibration transmitted by a metal tool (horn, sonotrode) causes oscillating flexing of the material and friction between the parts, which results in a closer contact between the two surfaces with simultaneous local heating of the contact area. The plastic melts in the contact area, the polymer molecules are cross-linked, forming a strong joint.
Ultrasonic Welding cycle takes about 1 sec. The frequency of
acoustic vibrations is in the range20 to 70 kHz (commonly 20-40
kHz). The ampltude of the acoustic vibrations is about 0.002"
(0.05 mm).
Thickness of the welded parts is limited by the power of the
ultrasonic generator
Ultrasonic Welding is used mainly for processing amorphous polymers (Polysterene(PS), Acrylonitrile-Butadiene-Styrene (ABS))
- Medical equipment (filters, face mask, valves, cardiometry reservoir)
- Automotive components (glove boxes doors, filters, valves, airflow sensors)
- Appliance (vacuum cleaner, steam iron, dishwasher components)
- Electrical equipment (switches, terminal blocks,connectors)
- Electronic and computer components
- Toys
- Short welding cycle
- Easily automated and controllable
- Small amount of flash forms
- Low energy consumption
- Only small and thin parts may be welded
- Tool design is required
