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The Basics of Ultrasonic Plastic Welding Technology

The Basics of Ultrasonic Plastic Welding Technology

Ultrasonic welding of thermoplastics is cost effective because it can shorten manufacturing time. Ultrasonic welding is now a widely accepted process, having been first introduced in the early 1960's.

The type of the thermoplastic, the design of the parts to be welded and the design of the joint are great important but often neglected. To take full advantage of the benefits of ultrasonic welding, it is advisable to choose carefully the design of the parts, especially the joint.

It is advisable to take into consideration the different welding properties of amorphous and semi-crystalline thermoplastic when choosing the resin to be used. Material recycling, selection of plastic and good design cannot be ignored in getting stable and reliable welding effect.

At last, pay attention to the formed plastic product. They should be stable, cannnot easily change or shrink the shape, no bubbles.
Please attention to the following factors to help you get the best welding results
  • Whether there are appearance requirements after welding?.
  • The design and position of the welding parts.
  • How much tension should be endured after welding?.
  • Whether there is a water or air proof requirement after welding?.
  • Whether the overflowing glue at the welding position is acceptable after welding?.
  • How to design the fixture to have the best support?.
  • How to design the fixture to have the best support?.
  • How to design the work-piece so that it can be easily assembled before welding?.
  • Is it possible to design and make a suitable horn according to the welding design?.
  • Is there any other similar plastic to replace it, what kind of plastic would be suitable for the design and get the best welding results?.
Welding

Welding

The typical profile of a joint design for ultrasonic welding has two functions:
  • Its shape of a groove and tongue eases positioning during assembly and maintains in place the parts during the welding cycle.
  • The energy director in the joint in the joint concentrates the energy to a small area and supplies at the same time the necessary material for an optimal welding joint. The profile of the joint area depends largely on the prupose of the application; it can there fore be shaped quite differently. The settings of the machine, like welding pressure and amplitude, are adjusted to produce a movement of the horn front in phase with the part to be welded. The second part placed in the fixture must stay plassive. The motional interference produces friction in the contact area of the two parts. Due to this highly intensive ultrasonic vibration the joint area melts together immediately. Under the pressure applied simultaneously and some fractions of a second longer than the ultrasonic impulse lasts the melted area solidifies and an inseparable joint is produced.
Ultrasonic Staking

Ultrasonic Staking

Ultrasonic staking is used to assemble injected plastic parts with parts of another material. Studs on the moded plastic part penetrate the second article to be mounted. The projecting part of these studs is formed into riveting heas with a specially shaped horn tip. The cavity in the horn is big enough to hold the displaced material and form it nicely. The amplitude of the horn has to be adjusted for maximum motiolnal interference between oscillating horn tip and plastic stud. Heat is then produced by friction between the plastic part and the horn tip, which allows an immediate melting in this area. The pressure controlled by the welding machine lets the riveting head solidify after a short hold time. Multi-tip horns are often used for simultaneous staking of different areas on the same part
Ultrasonic Spotwelding

Ultrasonic Spotwelding

Ultrasonic spot welding is used whenever large plastic parts cannot be placed on a traditional machine. Therefore, the welding head designed as a handgun is brought to the part; either manually or with a robot. The advantage of ultrasonic spot welding is the fact that the parts do not need any special preparation (no energy director required). There fore large size vacuum formed parts can also be assembled easily. The ultrasonic horn is built to produce high amplitude. The tip of the horn is shaped in order to penetrate the twolayers of material, leaving a typical ring pattern on the worface, while the backside rests smooth and clean.
Insertion of Metal Pieces

Insertion of Metal Pieces

A metal piece such as a threded insert or bolt has to be em bedded into an existing hole in a plastic part. The metal piece is contacted by the oscillating horn, which creates friction between the two parts melting the plastic material. The machine pressure displaces the now, elted material into the structure on the metal part surface. Once the displaced materal has solidified the inserted piece remains tightly seated and resists to tensional as well as to torsion forces.
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