ultrasonic welding plastic materials

Our good contacts with universities and associations yield valuable impulses. The same applies for thermoset resins that are processed by curing and cannot be welded by means of ultrasonics. Welding of plastics using ultrasonics. Titanium is the preferred choice of material for making ultrasonic horns because of its good fatigue strength, excellent acoustic properties, and good surface hardness. This is about working together based on our values and about our mission to apply these values in our daily work. Experienced ultrasonic engineers develop the perfect concept for your customized requirements and special integration tasks. 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. Becaus… UW is commonly used for plastics and especially for joining dissimilar materials. The … 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. As a general rule: only identical thermoplastic materials can be welded homogeneously. The company is ISO 9001 certified and is consistently in the vanguard of industry innovators. Did you know? Ultrasonic plastic welding is the joining or reforming of thermoplastics through the use of heat generated from high-frequency mechanical motion. The friction between the molecules heats and melts the plastic. Feedback from users. 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. There are thermoplastic materials, elastomers, and thermoset resins: Thermoplastic materials are plastics that are processed by heat and are well suited for ultrasonic welding. To weld different materials, they need similar molecular structures - crystalline ones are only weldable to themselves. Once the vibration is stopped, the tool maintains a holding pressure on the joint to create a bond. 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. (joint area) so the plastic material will melt and form a molecular bond between the parts. Our technology is used in many different industries to permanently bond plastic materials and nonferrous metals. Herrmann Ultrasonics therefore offers a wide range of solutions for integration of ultrasonic systems and components. Go to seminar overview, Trade shows are a platform for direct exchange – we show you our latest developments and state-of-the art technology. Ultrasonic welding is cost effective and a green technology. 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. for applications that require high amplitude and a … Only together can we move forward and set new milestones. Moreover, all brochures, technical infos, and contact forms are provided for download. Ultrasonic welding is used in almost all major industries like automotive, electronic and appliances, medical, packaging etc. Let's talk business! For example, without a means of alignment built into the joint it is impossible to predict where the parts will be positioned after welding. 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. 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. Ultrasonic Welding (USW)is a welding technique that uses ultrasonic vibration of high frequency to weld the two pieces together. It is frequently chosen when parts are too complex or expensive to be molded in one piece. The absolutely clean ultrasonic technology for nonwovens makes this possible. Ultrasonic welding of plastic materials creates a molecular bond within the weld seam. Industrial ultrasonics is an acoustic principle. It is most commonly used to weld thermoplastic materials and dissimilar materials. Numerous patents confirm our position as market leader. Click here for laminating of nonwoven materials. Medical devices, such as catheters, valves, filters and face masks are also assembled using ultrasonic welding. Ultrasonic welding of plastic materials creates a molecular bond within the weld seam. 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. It is always the people who make the difference in a company. What were the determining factors for ultrasonics? 01661446  VAT GB 348675511 Privacy Policy. +1 (630) 626-1626info@herrmannultrasonics.com, Secure your spot now! Metals are joined through molecular bonding caused by the vibration. Titanium horns can be coated with materials like Carbide, Nickel, or Teflon. Plastics assembly is a fast, clean, efficient, and repeatable process that consumes very little energy. But it is always the people who are most important. We explain, the physical mechanism of the ultrasonic technology, which components are required, and which variables are most influential. Ultrasound is a mechanical vibration similar to that produced by musical instruments. Metal with a thin section can also be welded with USW. Let us explain the principles in detail and show you the large number of fascinating application options. 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. 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. 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. How it started: from small business to medium-sized company in the high-tech sector. Kerry Ultrasonics was formed in 1954 and had been a prominent manufacturer of plastic welding and ultrasonic cleaning equipment. However, the overall process is generally the same. Fax: (714) 630-9531. sales@amtecinc.com 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. Trade shows are a platform for direct exchange – we show you our latest developments and state-of-the art technology. t: 01793-641040  Reg. The following drawings illustrate the basic principle of ultrasonic welding. 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. Vibrations are turned into heat and thus the plastic material melts, which results in a homogeneous joint. This machine series allows for complex ultrasonic joining of injection molded plastic parts and nonferrous metals. 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. Our experts develop the acoustic weld tools by means of innovative calculation methods and state-of-the-art measuring technology. Ultrasonic sealing technology has become an established and economic alternative of heat sealing: Laminating without the use of adhesives and embossing without the use of heat? Some people understand that any material can be welded. 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. Ultrasonic welding eliminates the need to use fasteners, glues and/or solvents. Find the latest press releases, videos and trade show updates, as well as up-to-date images and interesting graphics. Ultrasonic welding is well suited for a large number of automotive components, where high part counts and appropriate strength are required. 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. Click here for technical project management. Base materials used for the parts Material (base material) selection also plays an important role in the ultrasonic welding process. There are thermoplastic materials, elastomers, and thermoset resins: Thermoplastic materials are plastics that are processed by heat and are well suited for ultrasonic welding. Worldwide. So how does it work? 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. More basic knowledge on ultrasonic laminating of nonwoven materials and web materials and examples for applications. Plastic welding is defined as molecular material bonding of thermoplastic materials. In ultrasonic plastic welding, a vibratory motion at the horn face (amplitude) is transferred to the part. To ensure your production is running smoothly. A horn pushes against the parts being joined, applying pressure … 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. Every ultrasonic bonding operation will vary based on the plastic materials being joined, the shape of the workpieces, and other factors. Ultrasonic welding uses high-frequency vibration to melt and weld plastic. 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. 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. Ultrasonic welding uses friction to heat plastics to a temperature high enough that they’ll bond together. 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. Welding of plastics using ultrasonics. Factors such as driving forces, opportunities, and obstacles that will shape the industry dynamics are explained in detail. Benefit from our experience and get the best consulting; from basic applications, to process optimization and complex integration concepts. Not all materials can be welded. Ultrasonic welding is a widely recognized and accepted process for joining thermoplastic materials. Ultrasonic plastic welding is suitable for virtually all thermoplastics. 2021 Reach Us. We provide comprehensive solutions for your welding and joining tasks - made in Germany. Find here the answers to most frequently asked questions. Worldwide. Ultrasonic Welding Basics. Elastomers are plastics that are processed by means of cross-linking; they do not react to ultrasonics. Ultrasonic plastic welders, spin welders, vibration welders, hot plate and staking / inserting machines are available, as well as custom tooling and fixtures. More basic knowledge on ultrasonic welding of plastics and examples for joint designs are available here. By means of staking, embedding, and swaging it is also possible to bond other types of materials to thermoplastic materials. Sonics & Materials (UK) Ltd. was formed in August 2004 after taking over the plastic welding business from Kerry Ultrasonic. However, in some cases two different thermoplastics can be welded using ultrasonics, for example when the materials are chemically compatible and have similar melting points. In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the … Some materials can be welded well, some are basically fused, and some are not fused. Hot Gas (Air) Welding: Hot gas (or hot air) welding, is a technique that uses heat. High requirements for visual appearance, production speed, or geometry are met. Toll Free: (888) 634-1143. In this process there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together. All trade shows, 1261 Hardt Circle • 60103 Bartlett, IL • USA. The demand of the production industry for complex and efficient automatic systems is constantly increasing. It is commonly used for plastics and metals, and especially for joining dissimilar materials. 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. Misunderstanding of workpiece material: Ultrasonic plastic welding machine also has requirements for the material of the workpiece to be welded. This is a big misunderstanding. 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. Ultrasonic welding of plastics is used widely in making electronics, medical devices and car parts. 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. Our workshops range from basics seminars to in-depth expert knowledge, and always provide practical orientation. 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. Ultrasonic welding has applications in many fields including the thermoplastics industry. 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. 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. Financial independence provides a solid foundation. Leading the way in research and applied technology, Sonics is dedicated to providing the highest quality products … It is accomplished by converting high-frequency electrical energy into high-frequency mechanical motion. News from the company, press releases, images, and logos - compiled for you. Once cooled down a solid homogeneous weld between the 2 parts is created. More basic knowledge on ultrasonic sealing of packaging and examples for applications. 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. The map shows you how to reach us quickly. When combined with pressure, friction produces heat & melts the parts at the horn contact point. 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. Once you’ve selected material types for part design, ensure that your supply chain can manufacture (e.g. 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. © In general, rigid plastics exhibit excellent far-field welding properties because they readily transmit vibratory energy. injection mold) tight-tolerance parts consistently. 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 … Polyethelene, Polypropylene, Polyester and Nylon are semi-crystalline - much more difficult to weld with ultrasonics. ABS, Acrylic, Polycarbonate and PVC are amorphous polymers - with little or no crystalline structure, they are ideal for ultrasonic welding. Ultrasonic Welding is the fastest and most cost effective method used today to join and assemble plastic parts and non-ferrous metals. 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. We are looking forward to your application. Industry-specific ultrasonic solutions, Herrmann products and profound expertise of ultrasonic technology – all brochures and publications. 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. Ultrasonic welding of two parts made from the same plastic material will usually obtain the best result. It’s about our WHY and an endless journey. A tool vibrates at ultrasonic frequencies and causes concentrated molecular vibration in the weld joint. Click here for sealing of packaging 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. All thermoplastic materials (except PTFE) can be welded. Customer benefits are always our paramount goal. 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. Phone: (714) 630-9530. State-of-the-art ultrasonic welding machines and most recent measuring and testing equipment in our laboratories worldwide. PC, PMMA, and ABS can be welded to one another under certain conditions. Welding dissimilar thermoplastic materials according to their polymer compatibility, such as PP, PVC, PE, PET, ABS, composites, tissues, fleece or films. Unsolicited applications are welcome. These vibrations are called ultrasound because they are at a frequency above than the hearing capacity of the human ear (greater than 16 kHz). The process of ultrasonic welding of plastics is achieved by applying a vibrating metal tool … Unmatched Support. Yan: Before you start explaining the relation of Lingke and the printing consumables, please explain what ultrasonic plastic welding is?. Elastomers are plastics that are processed by means of cross-linking; they do not react to ultrasonics. Ultrasonic energy has been used to join thermoplastics for over 70 years. 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