What are the ultrasonic welding methods?

The welding technology of ultrasonic welding machine is a high technology, which can be applied to all hot-melt plastic products without adding solvents, adhesives or other auxiliary products, thus improving productivity, reducing costs, improving product quality and production safety. Ultrasonic welding, the commercial power is converted into high-frequency and high-voltage signals through the power box, and then the signals are converted into high-frequency mechanical vibration through the transducer system, which is added to the plastic products, so that high-speed friction occurs between the two parts of the plastic products and the temperature rises. When the temperature reaches the melting point of the product, the interface of the product melts rapidly, and it is cooled and shaped under a certain pressure to achieve perfect welding. Ultrasonic welding is divided into the following categories:

Tools/raw materials

ultrasonic welding machine

ultrasonic transducer

Methods/steps

First, ultrasonic spot welding.

Two flat plastic parts, without tenons and rivets, the welding head is designed as a pistol, and one end is welded through and melted into the other plane. The advantage is that the welding surface does not need any special design, and the amplitude of the welding head is higher for larger planar workpieces, so the design of the welding head surface should be based on the final requirements.

Second, ultrasonic welding.

The design of a typical ultrasonic welding surface must have the following two functions:

1. The tenon and tenon design ensure convenient alignment in the welding cycle;

2. The design of welding wire is slim, but there must be enough fusible material to fuse the welding surface. The specific design method depends on what kind of workpiece equipment is used for welding. Parameters such as welding pressure and amplitude can be adjusted to ensure that the welding head can contact the welding surface and apply pressure. The lower workpiece is a pressure receiving part and is placed in the bottom die. The welding head generates ultrasonic high frequency, which makes the upper workpiece vibrate and heat, thus fusing with the lower workpiece. After the welding head stops vibrating, the pressure is maintained, and the melted part is cooled and formed. The whole welding time is mostly one second. This method is widely used in industry, such as automobile parts, medical care, toy stationery and so on.

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Thirdly, ultrasonic embedding.

Refers to the embedding of metals and screws in plastic parts. When the welding head contacts the metal nail, heat is generated due to vibration, so that the nail is embedded in the plastic part.

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Fourthly, ultrasonic riveting.

This method is used for two plastic parts with different materials, one of which is that a plastic rivet penetrates the other material, and the welding surface of the welding head is designed to be covered by rivets. High-frequency vibration generates heat, which melts plastic nails and forms and covers another material.