Plastic Welding : How Ultrasonic works

Physician found in early 1933 that, when ultrasonic is applied on plastic parts, the phenomenon of resonance in between plastic parts can generate friction heat. As the heat goes up to certain level ( melting point of resin), two parts were join together. Thus formed a Weld.
Ultrasonic welding is one of the most extensive method used on fastening plastic industry. But not all kinds of plastic resin can be welded by ultrasonic. It depends on the resin’s nature ( physical properties). Generally speaking, crystalline resin (like PP, PE) is difficult to be welded by ultrasonic, but require special treatment and higher technologies.

Followings are some of Welding technologies used with Ultrasonic :
When ultrasonic is applied on to the stud (rim) of part generated friction heat and as a result, melt and form the Welding head ( mushroom)….etc

Ultrasonic Embedding : When ultrasonic energy applied on Metal part through horn, heat generated between metal and plastic, as plastic begin to melt, pressure from Horn will push metal part on to desire position.

Ultrasonic Spot welding : With a special welding tip of horn, as Ultrasonic were applied onto two plastic sheets, The horn tip with energy will melt down the sheets and join two sheets in a second. Multi-spots can be welded in a time on special systems.

Ultrasonic Cutting : A high vibration speed of horn may remove the burrs or gate-way from parts and keep the Cutout in smooth and clean.

Ultrasonic Forming: Similar to Ultrasonic staking, Heat generated between horn tip and plastic part, plastic heats and melt in localized area. Horn press in continue way and allow plastic to cool down and solidified. A special shape is formed.

 

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