Ultrasonic Plastic Welding System
Altrasonic is the market and innovation leader for ultrasonic plastic welding.
Ultrasonic welding is a future-oriented process that joins plastic together using ultrasonic. In welding process, the materials are placed on top of one another and moved against one another under low pressure and high-frequency mechanical vibrations. In just a fraction of a second, a permanent joint with outstanding physical properties is created without thermally stressing the components. All this yields a high-quality and economically superior alternative which doesn't require filler materials.
Types of ultrasonic assembly:
Ultrasonic vibratory energy is used in several distinct assembly and finishing techniques such as:
Welding : The process of generating melt at the mating surfaces of two thermoplastic parts. When ultrasonic vibrations stop, the molten material solidifies and a weld is achieved. The resultant joint strength approaches that of the parent material; with proper part and joint design, hermetic seals are possible. Ultrasonic welding allows fast, clean assembly without the use of consumables.
Staking : The process of melting and reforming a thermoplastic stud to mechanically lock a dissimilar material in place. Short cycle times, tight assemblies, good appearance of final assembly, and elimination of consumables are possible with this technique.
Spot Welding : An assembly technique for joining two thermoplastic components at localised points without the necessity for preformed holes or an energy director. Spot welding produces a strong structural weld and is particularly suitable for large parts, sheets of extruded or cast thermoplastic, and parts with complicated geometry and hard-to-reach joining surfaces.
Ultrasonic assembly is the method of choice for many applications in the automotive, appliance, medical, textile, packaging, toy and electronics markets, among others. The basic advantages of ultrasonic assembly - fast, strong, clean and reliable welds - are common to all markets.
1. Appliance: In this high-volume market, hermeticity, strength and also cosmetic appearance are important. Applications include: steam iron, pump housing, vacuum cleaner wand, and dishwasher spray arm.
2. Automotive: Hermetic seals in applications such as lenses, filters and valves. Other applications include: glove box door, instrument cluster, air diverter and mass airflow sensor.
3. Consumer: Precision welding, staking and forming operations are used in the manufacture of the Swatch®.
4. Electrical: Multiple staking and inserting applications are often automated for high-volume production requirements with consistent reliability. Applications include: terminal blocks, connectors, switches (e.g. toggle, dip, rotary quick and diaphragm), and bobbin assemblies.
5. Medical: Non-contamination and the ability to be operated in a clean room are as important as the strength of the weld. Reliable, repeatable assemblies for critical life-support devices are produced with new capabilities in process control. Applications include: arterial filter, cardiometry reservoir, blood/gas filter, face mask and IV spike/filter.
6. Packaging: From aseptic packages to toothpaste tubes, the ability of ultrasonic assembly to seal through product contamination in the joint area is a major advantage. In addition to good cosmetic appearance, ultrasonic assembly provides tamper-evident seals for blister packs. Applications include: condiment dispenser, blister package, juice pouch, juice carton and plastic coated paper cups.
7. Toys: In this highly competitive industry, the elimination of adhesives, screws and solvents, or other consumables is a bonus added to strong, safe, flash-free assemblies.