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.
There are many benefits of electronic welding, including that the process is quick and repeatable. Further, the process does not "consume" any additional materials, which means it does not require screws, nails, bolts, soldering materials, glues or other adhesives. Ultrasonic welding machines may even be used to create hermetic seals, because the finished pieces are so strong and clean. An added benefit is that no ventilation system is required because no heating is involved.
It is through pressure and high-frequency mechanical vibrations (15 kHz to 40 kHz) that plastic is melted into a solid-state weld. Most preferred 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.
Now one of the most progressive industrial techniques, ultrasonic welding has come a long way. Ultrasonic waves were first used in the late 1940s, mostly for cleaning. It was in the 1950s that ultrasonic welding was introduced as a way to weld plastics and metals. In 1965, two men - Robert Soloff and Seymour Linsley - were granted a patent for ultrasonic welding. The innovative welding process first started to take hold in the toy industry, and has spread to a growing number of applications 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.
In today's competitive ultrasonic-welding-machine market, it is important to find a plastic assembly solutions provider with top-notch service and technical support, and a company that meets each customer's individual needs. For superior solutions, check out Plastic Assembly Systems at www.heatstaking.com.
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.
There are many benefits of electronic welding, including that the process is quick and repeatable. Further, the process does not "consume" any additional materials, which means it does not require screws, nails, bolts, soldering materials, glues or other adhesives. Ultrasonic welding machines may even be used to create hermetic seals, because the finished pieces are so strong and clean. An added benefit is that no ventilation system is required because no heating is involved.
It is through pressure and high-frequency mechanical vibrations (15 kHz to 40 kHz) that plastic is melted into a solid-state weld. Most preferred 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.
Now one of the most progressive industrial techniques, ultrasonic welding has come a long way. Ultrasonic waves were first used in the late 1940s, mostly for cleaning. It was in the 1950s that ultrasonic welding was introduced as a way to weld plastics and metals. In 1965, two men - Robert Soloff and Seymour Linsley - were granted a patent for ultrasonic welding. The innovative welding process first started to take hold in the toy industry, and has spread to a growing number of applications 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.
In today's competitive ultrasonic-welding-machine market, it is important to find a plastic assembly solutions provider with top-notch service and technical support, and a company that meets each customer's individual needs. For superior solutions, check out Plastic Assembly Systems at www.heatstaking.com.
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