The ultrasonic welding of plastics uses high-frequency sound waves to create frictional heat between thermoplastic materials.
Ultrasonic welding has numerous advantages including speed, weld quality, weld strength, consistency, and efficiency.
It is environmentally safe as there are no chemicals to be used in process, less energy requirement, and is computer-controlled.
Process requires less manpower and time.
S.P. Engineers' ultrasonic welding machines can be integrated into custom-designed assembly systems to meet the specific needs of customers and their applications. The design of S.P. Engineers products encourages innovation so that any configuration is possible, from standalone, single-station systems to fully integrated automation.
Ultrasonic plastic welding is the joining or reforming of thermoplastics through the use of heat generated from high-frequency mechanical motion. Ultrasonic welding means joining without adhesives, screws, or heat from an outside source. During this process, plastics are strategically melted using ultrasonic vibrations so that a cohesive or form-fit joint is produced. As an economic production method with short cycle times, ultrasonic welding ensures a large degree of process control and repeatable quality results. Ultrasonic welding of plastic materials creates a molecular bond within the weld seam. Ultrasonic vibrations are focused on using a special design of the components or tools. This specific geometry within a component is referred to as energy director. The contact points in the joining area are actively molded using energy input to achieve elastic deformation. Friction occurring between the contact surfaces and within the molecule chains generates heat that causes the material to melt.
ADVANTAGES OF ULTRASONIC WELDING SPM
Additional material: Ultrasonic welding does not require any additional material such as fasteners, inserts, adhesives, or solvents. It also offers the benefit of low energy consumption. Lower production costs translate to lower costs for your business.
Ease of assembly: Process requires only the alignment of the two parts in the fixture, thus well suited for automated assembly.
It saves time: It is much faster than traditional welding methods, as virtually no time is needed for drying or curing. It is a highly automated process, which also saves on manpower and helps you get the parts you need faster.
Hermetic Seals: Ultrasonic welding is capable of creating hermetic seals. It is a type of sealing that makes a given object airtight (excludes the passage of air, oxygen, or other gases).
Energy efficiency: There is no excess heat, which must be removed from the workplace when other processes are used. This saves on cooling costs required to maintain the plant’s internal temperature.
High Production Rate: Higher production rates can be achieved as the actual welding time is very less. That means more production can be done in lesser time.
Clean Atmosphere: Unlike adhesive & solvent joining systems, on ventilation equipment is necessary for the removal of toxic fumes.
Immediately Handling: Welding parts can proceed to other operations at once without waiting for parts to cool. This makes an advantage for automated assembly line applications.
