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ADVANTAGES PLASTIC WELDING BY ULTRASONICS: MORE PRECISE, ENERGY-SAVING, EFFICIENT, ENVIRONMENTALLY FRIENDLY, ...

In contrast to many different ways of joining plastics together, there are several advantages to using ultrasonic technology: faster, safer, cleaner, more efficient, more environmentally friendly, more precise, more transparent, and many more.

On this basis, it quickly becomes clear that ultrasonic joining technology is an asset for any industry – even in demanding sectors such as medical technology, food & packaging or hygiene products.

PLASTIC WELDING SIMPLY EXPLAINED

The high weld and seal quality, even for demanding products, proves to be a very good solution for joining plastics together. Characteristics such as tightness, freedom from particles and high reproducibility are indispensable here, especially for the above-mentioned industries. The prerequisite is always optimally designed joining parts by the customer.
Longitudinal vibrations with frequencies of 20-35 kHz with tool amplitudes of 5-50 μm are introduced into the plastic parts under the effect of force. This creates a material bond in the weld seam.
Very good results can be achieved through the optimal design of the components. The energy direction sensor, which must be integrated in the component, plays an important role. This specifically deforms the contact points in the joining area by causing the material to generate focused heat through the introduction of ultrasound, causing the molecular chains to change.
The joined parts can then be immediately processed further for the coming process steps.

Read more details about the medical technology sector here..

PROCESS TYPES

Longitudinal process

The welding system is set up vertically, which means that the vibrations are also introduced vertically into the joined part. This creates a targeted welding pressure.

Torsional process

Here, too, the welding system is vertically structured, as in the longitudinal process. Due to the high-frequency friction welding and the tangential introduction of the vibrations, the process differs from the above. The sonotrode takes the upper joining partner with it and moves it horizontally to the lower joining part.
The advantage is the low load due to the tangential movement. The process is therefore optimal for components such as sensitive joining parts, foils, thin injection molded parts.

THE ADVANTAGES OF PLASTIC WELDING

+ Very short process times
+ Little to no thermal damage to the component due to cold welding tools
+ Low energy requirement for welding and thus high efficiency
+ No solvents and additives necessary (pure recycling)
+ Constant, reproducible welding results are possible via a wide range of welding parameters
+ Different thermoplastic materials can be welded together
+ The welding tools do not heat up, so there are no warm-up or cool-down times and the tools can be changed quickly
+ No risk of injury from hot machine parts
+ Very good integrability into existing systems
+ Possibility of intelligent networking and self-control – Industry 4.0