Welcome to Telsonic - Ultrasonic Technology

Ultrasonic Plastic Assembly, This general heading covers a number of different joining techniques for thermoplastics in which mechanical vibration is used to generate homogeneous connections by generating frictional heat. They include ultrasonic plastic welding, forming (riveting, swaging, spot welding, embedding), sealing, cut’n’seal processes and torsional welding.

What all of these processes have in common is the fact that the entire procedure takes place in a matter of seconds or even milliseconds. No consumable materials are required, and no voltage is applied at the sonotrode. The product itself remains cold hence the components can be worked on immediately after the welding operation.

The key areas in which ultrasonic joining techniques for plastics are used include:

– Automotive industry
– Electrical engineering/electronics
– Packaging industry
– Medical/pharmaceutical industry
– Household goods/domestic equipment industry
– Textile industry

Nonwovens, fabrics and interlaced yarns made of synthetic fibre materials can be cut to shape or trimmed quickly and cleanly with the aid of the ultrasonic process, and the cut ends are sealed in the same operation. This cutting and sealing method, referred to by TELSONIC simply as cut’n’seal, delivers non-fibrous, soft edges even with two or multi layers of material. The cutting contour is always defined by the anvil, while the sonotrode has a flat surface.

The cut’n’seal technology developed by TELSONIC is the preferred choice in the manufacturing of all types of filters, hygiene and personal care products, as well as articles for medical technology, health and safety in the workplace and environmental protection.

Recognised for many years as a pioneer within the industrial ultrasonic’s industry, Telsonic continues to develop new technologies and processes that open up new opportunities and applications for ultrasonics across many different industries. The packaging industry is the latest to benefit from a series of new and in certain cases unique, product and concept developments, targeted at sealing applications on flexible and rigid packaging.

Ultrasonic plastic welding is associated with the welding of acrylics and polycarbonates, this is usedin many different products like Blister Packs, dashboards, small consumer Goods, Cartons and much more... Ferrous and non ferrous metals can also be welded. For Ultrasonic Metal Welding the molecular connection between the two products is created under high pressing pressure once the surfaces of the materials have been cleaned of oxides and other contaminants with the aid of ultrasonic vibration.

Depending on the type of contact made and the layout of the welding equipment, a distinction is made here between linear welding, wire splicing and Torsional welding, as well as continuous seam welding. The fact that highly reproducible results can be achieved and that the individual steps are easy to automate has made ultrasonic plastic welding and metal welding particularly important in the following applications: Contacts of all types, Automotive wiring harnesses, Batteries, Cans and containers, Solar panels

Cleaning methods based on ultrasonic's exploit the cavitation principle: billions of tiny imploding gas bubbles in the cleaning fluid generate shock waves which loosen the dirt particles and force them free. The cleaning effect can be optimised even further by carefully adding cleaning agents, heating the cleaning tank and by adding mechanical agitation to the process.

With the aid of ultrasonic's, all kinds of contaminations, for example grinding paste residue, oil, grease, flux and other types of foreign bodies can be completely removed. Applications range from the cleaning of clockwork mechanisms to overhauls of jet engines.

Ultrasonic cleaning has become absolutely essential in the following fields of industry: Metal-working industry, Precision mechanics, Optics and glass, Automotive industry, Electronics industry, Galvanic industry, Chemical industry, Power stations

Historically, heat sealing has been the technology used on many HFFS (Horizontal Form Fill Seal) and VFFS (Vertical Form Fill Seal) packaging machines. Although this has become the established process for many applications, it can have its drawbacks. Common issues include, leakages attributed to product contamination within the seal area, coarse particles such as sugar or coffee causing puncturing, odours from trapped product and unsightly burnt edges.

In addition, applications with short cycle times, especially where complex laminate materials are used, also pose a risk that the seal does not have sufficient time to bond and cool causing packages or cartons to re-open with resultant leaks and spillages. Packaged product can also be heat sensitive and products such as chocolate for example can cause downtime problems with machine stoppages when melting occurs.

The Ultrasonic process does not suffer these drawbacks and also offers additional benefits, not possible when using radiant heat processes.

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