Ultrasonic welding: the quintessential plastic welder
Thanks to their quick, clean, efficient heat-free process, innovative ultrasonic welding machines are the perfect answer to all plastic-welding needs.
One of the most rapidly developing fields in the welding industry is ultrasonic welding, a process that uses high-frequency vibrations instead of applied heat to melt plastic. Small- and medium-sized pieces of plastic are welded together with ultrasonic welding machines because the machines create frictional heat that melts the plastic together. After the plastics are melted and the vibrations stop, the plastic quickly cools and solidifies.
In addition to being quick and repeatable, ultrasonic welding machines do not use any additional materials, known as “consumables.” So, no screws, nails, bolts, soldering materials, glues or other adhesives are required. And because finished pieces come out strong and clean, ultrasonic welding machines are also used to create hermetic seals. Another benefit is they require no ventilation system, because no heating is involved.
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.
To begin the process, two thermoplastic pieces with similar melting points are placed in the ultrasonic welding machine. Next, high-frequency vibrations are applied directly to the joint that is being welded. Because the vibrations are limited to the joint, only the joint - not the base material - is melted. Once the plastic is melted, the vibration is stopped, pressure is applied, and the pieces are melded together. The entire process is so fast and efficient, weld times can be less than a second long.
More and more industries are coming to rely on ultrasonic welding machines. They include the automotive, cosmetic, computer, appliance, toy, medical, electronics, textile, packaging and food industries. Ultrasonic welding is often used in the medical field because the process can ensure that no parts are contaminated by outside substances, which is why products welded with ultrasonic welding machines are able to be used for “clean rooms” in hospitals. The food and packaging industries also favor ultrasonic welding, again because the process is clean and contaminant free.
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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