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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
Cut n’Seal
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.
Ultrasonic Packaging
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.
Taking the Heat Out of the Process
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.
Ultrasonic Plastic Welding
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
Ultrasonic Cleaning
Cleaning methods based on ultrasonics 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 ultrasonics, 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 |
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