Ultrasonic welding machines: the ultimate in plastics welding

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Ultrasonic welding machines: the ultimate in plastics welding

by: KurtFugal | Total views: 3 | Word Count: 553 | View PDF | Print View
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Ultrasonic welding's innovative, efficient style of using vibrations instead of heat to melt plastic makes it the perfect, clean solution to plastic-welding needs.

Ultrasonic welding, perhaps the most rapidly developing field in the industry, uses high-frequency vibrations - not heat - to weld plastic pieces together. Ultrasonic welding machines are used to join small- and medium-sized pieces of plastic by creating frictional heat that melts the plastic together. Once the vibrations stop, the plastic immediately cools and solidifies.

Among the benefits of ultrasonic welding are that it's quick, repeatable and does not use any "consumables," or additional materials. There are no screws, nails, bolts, soldering materials, glues or other adhesives necessary. The finished pieces come out strong and clean - in fact, ultrasonic welding machines can also create hermetic seals. Plus, because no heating is involved, no ventilation system is required.

Through pressure and high-frequency mechanical vibrations (15 kHz to 40 kHz), the plastic is quickly melted into a solid-state weld. Many ultrasonic welders run at 15 kHz, 20 kHz, 30 kHz and 40 kHz frequencies.

The ultrasonic process begins with two thermoplastic pieces that have similar melting points. They are placed together, one atop the other, in the ultrasonic welding machine. Then, high-frequency vibrations are applied directly to the joint being welded. With the vibration application concentrated in the joint itself, the process melts the joint but not the base materials. When the plastic melts, the vibration is stopped and pressure is applied - and the plastics are melded. Because the process is as fast and efficient as it is, weld times are sometimes less than a second.

The ultrasonic welding process has become invaluable to many industries. They include the automotive, cosmetic, computer, appliance, toy, medical, electronics, textile, packaging and food industries. Ultrasonic welding is usually preferred in the medical-supply industry, because the no parts are contaminated by outside materials. Products processed with ultrasonic welding machines can even be used for "clean rooms" in hospitals. One of the most typical uses of ultrasonic welding is in the packaging and food industries, which also count on the contaminant-free, clean, quick process.

The roots of the ultrasonic welding industry go back to the late 1940s, when ultrasonic waves were first used, mostly for cleaning. Then in the 1950s, ultrasonic welding was first introduced for plastics and metals. It was in 1965 that ultrasonic welding was patented by two men, Robert Soloff and Seymour Linsley. The toy industry was the first to embrace the innovative welding process; and now, there are a growing number of uses every year.

Today, ultrasonic welding is considered the leading assembly method for rigid thermoplastics. Models of ultrasonic welding machines include: ultrasonic hand guns; bench-top integrated ultrasonic welders; automation ultrasonic actuator heads and modular power supplies; and closed-loop process controls, like energy welding, distance welding, time welding, force welding, automatic frequency tuning and variable-amplitude output control. There are microprocessor and standard-time models available, as well as tools of the trade, like ultrasonic horns, fixtures, converters and boosters for all makes, models and brands of ultrasonic welders.

Many companies provide plastic assembly solutions, but the best of those companies offer top-notch service and technical support and meet the individual needs of each customer. For superior ultrasonic welding machines, check out Plastic Assembly Systems at www.heatstaking.com.
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