ultrasonic welding plastic materials
Sheet sections of thermoplastics – the parts to be joined - are placed in a V-butt or T-butt position with a consumable plastic welding filler rod that must be the same or similar material at the joint area. (joint area) so the plastic material will melt and form a molecular bond between the parts. Herrmann Ultrasonics therefore offers a wide range of solutions for integration of ultrasonic systems and components. injection mold) tight-tolerance parts consistently. Find here the answers to most frequently asked questions. How it started: from small business to medium-sized company in the high-tech sector. Moreover, all brochures, technical infos, and contact forms are provided for download. Ultrasonic Welding is the fastest and most cost effective method used today to join and assemble plastic parts and non-ferrous metals. Toll Free: (888) 634-1143. Elastomers are plastics that are processed by means of cross-linking; they do not react to ultrasonics. Once cooled down a solid homogeneous weld between the 2 parts is created. Only together can we move forward and set new milestones. We supply you with a full-service package, including short response times. But it is always the people who are most important. The process of ultrasonic welding of plastics is achieved by applying a vibrating metal tool … The map shows you how to reach us quickly. 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. In ultrasonic plastic welding, a vibratory motion at the horn face (amplitude) is transferred to the part. Wang: Ultrasonic plastic welding uses the piezoelectric ceramic effect to convert electrons into machinery, allowing high-speed friction between the media with similar melting points to generate heat. In general, rigid plastics exhibit excellent far-field welding properties because they readily transmit vibratory energy. In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the … More basic knowledge on ultrasonic welding of plastics and examples for joint designs are available here. The following drawings illustrate the basic principle of ultrasonic welding. Ultrasonic welding of plastic materials creates a molecular bond within the weld seam. More basic knowledge on ultrasonic laminating of nonwoven materials and web materials and examples for applications. Our workshops range from basics seminars to in-depth expert knowledge, and always provide practical orientation. Sonics & Materials (UK) Ltd. was formed in August 2004 after taking over the plastic welding business from Kerry Ultrasonic. Yan: Before you start explaining the relation of Lingke and the printing consumables, please explain what ultrasonic plastic welding is?. Click here for laminating of nonwoven materials. 01661446 VAT GB 348675511 Privacy Policy. Ultrasonic welding is a widely recognized and accepted process for joining thermoplastic materials. Ultrasonic plastic welders, spin welders, vibration welders, hot plate and staking / inserting machines are available, as well as custom tooling and fixtures. PC, PMMA, and ABS can be welded to one another under certain conditions. Titanium is the preferred choice of material for making ultrasonic horns because of its good fatigue strength, excellent acoustic properties, and good surface hardness. Click here for sealing of packaging materials. Kerry Ultrasonics was formed in 1954 and had been a prominent manufacturer of plastic welding and ultrasonic cleaning equipment. Ultrasonic welding works extremely well with a range of thermoplastics, but some are incompatible with each other or with the process, so choose with care. It is always the people who make the difference in a company. In this process there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together. Worldwide. +1 (630) 626-1626info@herrmannultrasonics.com, Secure your spot now! The absolutely clean ultrasonic technology for nonwovens makes this possible. The … However, the overall process is generally the same. Ultrasonic plastic welding is suitable for virtually all thermoplastics. for applications that require high amplitude and a … So how does it work? Our experts develop the acoustic weld tools by means of innovative calculation methods and state-of-the-art measuring technology. To ensure your production is running smoothly. © Reach Us. PLASTIC MATERIAL REFERENCE GUIDE FOR ULTRASONIC WELDING. Financial independence provides a solid foundation. Ultrasonic welding is particularly suitable for their production and complies with product requirements, such as: Nowadays, the requirements of battery products have become increasingly diverse and complex: In addition to precision, strength, and minimum particle formation, process validation and traceability are equally important quality criteria. State-of-the-art measuring and control technology safely detects any process faults: Ultrasonic systems and modules for continuous joining of nonwovens and web material operate economically, with low wear, and without adhesives. We are looking forward to your application. The Ultrasonic Plastic Welding Machine market research report delivers a thorough analysis of this business sphere with expert insights on the past and present growth matrix. Factors such as driving forces, opportunities, and obstacles that will shape the industry dynamics are explained in detail. We explain, the physical mechanism of the ultrasonic technology, which components are required, and which variables are most influential. Ultrasonic energy has been used to join thermoplastics for over 70 years. Titanium horns can be coated with materials like Carbide, Nickel, or Teflon. Ultrasonic welding of plastics is used widely in making electronics, medical devices and car parts. ABS, Acrylic, Polycarbonate and PVC are amorphous polymers - with little or no crystalline structure, they are ideal for ultrasonic welding. All trade shows, 1261 Hardt Circle • 60103 Bartlett, IL • USA. This frictional heat is applied through high speed vibration generated in a sonotrode and delivered by a welding “horn.” Ultrasonic welding machines look similar to spot or resistance welders. Polyethelene, Polypropylene, Polyester and Nylon are semi-crystalline - much more difficult to weld with ultrasonics. To weld different materials, they need similar molecular structures - crystalline ones are only weldable to themselves. By means of staking, embedding, and swaging it is also possible to bond other types of materials to thermoplastic materials. What were the determining factors for ultrasonics? Phone: (714) 630-9530. Welding dissimilar thermoplastic materials according to their polymer compatibility, such as PP, PVC, PE, PET, ABS, composites, tissues, fleece or films. This machine series allows for complex ultrasonic joining of injection molded plastic parts and nonferrous metals. We provide comprehensive solutions for your welding and joining tasks - made in Germany. Benefit from our experience and get the best consulting; from basic applications, to process optimization and complex integration concepts. To give you help with ultrasonic welding of plastics for your application, this ultrasonic welding guide lists the most common unfilled grades of plastic available & their suitability for each style of ultrasonic welding As a rule, stiffer materials are easier to weld & those with higher melt temperatures need more energy. Fax: (714) 630-9531. sales@amtecinc.com Direct contact is important to us because we want to hear from you and offer our expertise. In addition to welding, ultrasonic energy is commonly used for processes such as inserting metal parts into plastic or reforming thermoplastic parts to mechanically fasten components made from dissimilar materials. It is frequently chosen when parts are too complex or expensive to be molded in one piece. Since its inception in 1969, Sonics & Materials, Inc. has enjoyed over 5 decades of world leadership in the fields of liquid processing and ultrasonic welding, sealing and cutting technology. Find the latest press releases, videos and trade show updates, as well as up-to-date images and interesting graphics. When combined with pressure, friction produces heat & melts the parts at the horn contact point. Ultrasonic welding has applications in many fields including the thermoplastics industry. The company is ISO 9001 certified and is consistently in the vanguard of industry innovators. Ultrasonic welding of plastic materials creates a molecular bond within the weld seam. Some materials can be welded well, some are basically fused, and some are not fused. 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. It’s about our WHY and an endless journey. Ultrasonic welding is cost effective and a green technology. Ultrasonic welding uses high-frequency vibration to melt and weld plastic. It is accomplished by converting high-frequency electrical energy into high-frequency mechanical motion. Ultrasonic welding is well suited for a large number of automotive components, where high part counts and appropriate strength are required. 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. The following factors have a negative impact on weldability: The following additives have a positive influence on weld work: These reinforcement materials predominantly improve the sound conductivity in semi-crystalline plastics. Not all materials can be welded. A horn pushes against the parts being joined, applying pressure … Misunderstanding of workpiece material: Ultrasonic plastic welding machine also has requirements for the material of the workpiece to be welded. Once you’ve selected material types for part design, ensure that your supply chain can manufacture (e.g. A tool vibrates at ultrasonic frequencies and causes concentrated molecular vibration in the weld joint. Ultrasonic plastic welding is the joining or reforming of thermoplastics through the use of heat generated from high-frequency mechanical motion. More basic knowledge on ultrasonic sealing of packaging and examples for applications. Our good contacts with universities and associations yield valuable impulses. Ultrasonic welding is whereby high-frequency ultrasonic acoustic vibrations are applied to two components being held together under pressure to create a solid-state weld. Every sonotrode is designed, calculated and carefully documented according to customer requirements: The ultrasonic modules are provided in a flexible modular system and allow for easy integration into packaging machines. UW is commonly used for plastics and especially for joining dissimilar materials. The parts being sonically welded are fitted together and sandwiched between a metal “nest”, which holds them in place, and a metal sonotrode, or horn. Ultrasound is a mechanical vibration similar to that produced by musical instruments. Thanks to intelligent software and variant diversity, the ultrasonic welding machines can be specifically configured to your demands: Complete system with functional units for mechanical engineering, modular and easy to commission. As a general rule: only identical thermoplastic materials can be welded homogeneously. Metals are joined through molecular bonding caused by the vibration. Herrmann Ultrasonics, E-module: promotes sound conduction and determines coupling, Melting point: determines the heat requirement, Viscosity of the melt: high viscous melts can be kept within the joining area more easily, the process sequence is more uniform, Ultrasonic components for special-type welding machines, Robust and reliable in continuous operation. The demand of the production industry for complex and efficient automatic systems is constantly increasing. Welding of plastics using ultrasonics. 2021 Medical devices, such as catheters, valves, filters and face masks are also assembled using ultrasonic welding. These vibrations are called ultrasound because they are at a frequency above than the hearing capacity of the human ear (greater than 16 kHz). It offers many advantages, including process reliability and repeatability, lower energy usage than other joining techniques, material savings (because there is no need for consumables, such as glue or mechanical fasteners), and labor savings. Ultrasonic welding eliminates the need to use fasteners, glues and/or solvents. Customer benefits are always our paramount goal. Ultrasonic welding qualifies as the best suitable joining technology: Using ultrasonics, consumer components can be produced and joined in a cost-effective way; at the same time, the process provides great flexibility in terms of design. This is a big misunderstanding. In the event that a material is adapted or changed, it’s good to reevaluate the process with the help of your ultrasonic supplier, since weld parameter changes or even equipment changes may be required. The process of ultrasonic welding of plastics is achieved by applying a vibrating metal tool (horn) at 90° to the stationery plastic parts which then vibrate. Trade shows are a platform for direct exchange – we show you our latest developments and state-of-the art technology. State-of-the-art ultrasonic welding machines and most recent measuring and testing equipment in our laboratories worldwide. Ultrasonic Welding (USW)is a welding technique that uses ultrasonic vibration of high frequency to weld the two pieces together. Did you know? Elastomers are plastics that are processed by means of cross-linking; they do not react to ultrasonics. Our technology is used in many different industries to permanently bond plastic materials and nonferrous metals. Crucial advantages over conventional thermal processes: With state-of-the-art ultrasonic welding technology, non-ferrous metals, mainly aluminum and copper, can be permanently joined by molecular bonding induced through physical vibrations. Some people understand that any material can be welded. Once the vibration is stopped, the tool maintains a holding pressure on the joint to create a bond. Hot Gas (Air) Welding: Hot gas (or hot air) welding, is a technique that uses heat. Unsolicited applications are welcome. Ultrasonic welding is the method of joining two parts by converting the electrical energy into the heat energy, It is suitable for the plastics and the metals, It can use high-frequency ultrasonic acoustic vibrations to the materials that are being held together under … At Herrmann, optimization means to focus on continuous and long-term improvements: in manufacturing, for process sequences, in service, in education or with regard to partnerships. Worldwide. A large number of every-day products are welded using ultrasonics. For example, without a means of alignment built into the joint it is impossible to predict where the parts will be positioned after welding. Go to seminar overview, Trade shows are a platform for direct exchange – we show you our latest developments and state-of-the art technology. While it is possible to ultrasonically weld plastic materials without specific joint design details, the weld process is greatly enhanced by adding proven features that aid in the process. Plastic welding is defined as molecular material bonding of thermoplastic materials. Up to 130 different process reference data are available and can be visualized: Sensors and electrical components are not only used in industrial manufacturing but also in automation engineering or in daily use. Numerous patents confirm our position as market leader. Unmatched Support. This is about working together based on our values and about our mission to apply these values in our daily work. Feedback from users. 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. It is commonly used for plastics and metals, and especially for joining dissimilar materials. Ultrasonic welding uses friction to heat plastics to a temperature high enough that they’ll bond together. The same applies for thermoset resins that are processed by curing and cannot be welded by means of ultrasonics. The friction between the molecules heats and melts the plastic. Every ultrasonic bonding operation will vary based on the plastic materials being joined, the shape of the workpieces, and other factors. Materials are joined by means of locally limited heat generation: Ultrasonic welding ensures maintained functionality of the components and provides continuous process monitoring unrivaled by other processes. Industrial ultrasonics is an acoustic principle. Base materials used for the parts Material (base material) selection also plays an important role in the ultrasonic welding process. Plastics assembly is a fast, clean, efficient, and repeatable process that consumes very little energy. Industry-specific ultrasonic solutions, Herrmann products and profound expertise of ultrasonic technology – all brochures and publications. Welding of plastics using ultrasonics. Ultrasonic Welding Basics. Benefit from our local machine and service portfolios. These include many parts made of thermoplastic materials for interior and exterior applications, and engine compartments, but also of nonferrous metals for cable harnesses and lithium-ion batteries: Food is better protected by good packaging and kept fresh longer which is more sustainable. Let us explain the principles in detail and show you the large number of fascinating application options. For more help with plastics, view our ultrasonic welding diagrams or material selection guides, Units 1 & 5 Argyle Comm.Centre, Argyle St, Swindon, Wilts, SN2 8AR. Ultrasonic welding is used in almost all major industries like automotive, electronic and appliances, medical, packaging etc. Ultrasonic welding is an industrial process whereby high-frequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solid-state weld. t: 01793-641040 Reg. Metal with a thin section can also be welded with USW. Ultrasonic welding of two parts made from the same plastic material will usually obtain the best result. There are thermoplastic materials, elastomers, and thermoset resins: Thermoplastic materials are plastics that are processed by heat and are well suited for ultrasonic welding. Becaus… News from the company, press releases, images, and logos - compiled for you. It is most commonly used to weld thermoplastic materials and dissimilar materials. Click here for technical project management. We meet the industry's requirements for: As far as joining of thermoplastic materials and nonferrous metals is concerned, Herrmann Ultraschall is the first point of call. High requirements for visual appearance, production speed, or geometry are met. Sonics manufactures a comprehensive range of plastics welding equipment, tooling and components, from hand-held units to bench model presses to ultrasonic kits for OEM installation. Let's talk business! There are thermoplastic materials, elastomers, and thermoset resins: Thermoplastic materials are plastics that are processed by heat and are well suited for ultrasonic welding. Vibrations are turned into heat and thus the plastic material melts, which results in a homogeneous joint. Our experts develop the perfect concept for your welding and ultrasonic cleaning.... Full-Service package, including short response times metal with a thin section can also be welded and thus plastic. 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Shows you how to reach us quickly we move forward and set new milestones of cross-linking ; they do react! Electronics, medical devices and car parts the need to use fasteners, glues and/or solvents mechanical vibration to... Against the parts being joined, applying pressure … ultrasonic plastic welding, a vibratory motion at the horn point... And especially for joining thermoplastic materials Lingke and the printing consumables, please explain what ultrasonic welding... To in-depth expert knowledge, and obstacles that will shape the industry dynamics are explained in detail and show the! Joining dissimilar materials will melt and form a molecular bond within the weld seam show you latest! The weld joint please explain what ultrasonic plastic welding machine also has requirements for the of! How it started: from small business to medium-sized company in the weld seam,!
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