ultrasonic mask welding machine

Ultrasonic welding is a process used to join two plastic parts together to form a strong, finished assembly. The process relies on high-frequency (ultrasonic) vibrations being generated and applied to the parts via a horn. Welding occurs as the vibrations are absorbed in the interface between the two parts, generating friction and causing the plastic to melt. The ultrasonic vibrations are generated by a series of components, including the power supply, converter, booster and horn, which ultimately delivers the mechanical vibration to the parts.

The role of the power supply is to convert the incoming line voltage (at 50 or 60Hz) into a new frequency. This electrical energy then is sent to the converter, which as the name implies, converts the electrical energy into mechanical vibrations. The converter consists of piezoelectric ceramic discs, which expand and contract at the rate of the supplied electrical energy. The magnitude of the vibrations is referred to as amplitude, a term that becomes very important when specifying an ultrasonic system for a given application. The vibrations then are transmitted through the booster, which typically increases the amplitude by a predetermined multiple, also known as gain. Finally, the booster’s output amplitude is transmitted through the horn, where it then can be delivered to the plastic parts.

Ultrasonic spot welding machine compositon An ultrasonic generator (power supply)

The ultrasonic generator converts the 110VAC or 220VAC electrical supply current into a high frequency, high voltage electrical signal.

An ultrasonic converter (transducer)

The ultrasonic converter utilizes the high frequency electrical signal from the generator and converts it into linear, mechanical movement. This conversion ccurs through the use of piezo-electric ceramic disks that expand when a voltage is applied. 

An ultrasonic booster

The ultrasonic booster is a tuned component that mechanically adjusts the amount of linear vibratory movement from the converter to the required level for the specific application to produce optimal welding performance. The booster also provides a safe, non-vibrating location to clamp onto the welding tools.

An ultrasonic welding tool (horn/sonotrode)

The ultrasonic welding horn is a custom made tool that is engineered to vibrate at a specific frequency. These tools are painstakingly designed using computer modelling technology for optimum performance and longevity.Ultrasonic tools must be tuned to match the frequency of the system. This tuning procedure requires consideration of the horn’s mass, length and geometry.Common tool head sizes are 150 * 40mm and 110 * 20mm.

Sectional view of ultrasonic welding machine WW2020L

Advantages of ultrasonic welding

Ultrasonic welding has many advantages when compared to traditional welding technologies. Many industries use ultrasonic welding due to these specific combinations of merits.

Ultrasonic welding is an eco-friendly process that takes seconds, consumes very little energy and reduces costs while maintaining a high degree of quality. The equipment fuses contact points on cell phones and other consumer electronics that are generally inaccessible with other welding methods. These techniques can be adapted to a wide range of commercial and industrial applications. In the food industry, the ultrasonic welding process is used to create a hermetic seal. It can fasten blister packs and facilitate the manufacturing of a variety of products, including toys, disposable lighters , pipettes and intravenous catheters.

Ultrasonic welding is commonly used in the plastics, aerospace and automotive industries to join similar materials. It is particularly useful in the production of medical products. Since the process does not introduce exhaust or other contaminants and the welds do not degrade, the manufacturing equipment can be used in a clean-room environment.

Ultrasonic welding is very effective at sealing or welding plastics. However, you cannot weld all types of plastics.ike metals, plastics also have different types. And it is very important to ensure that the plastics to be welded are chemically compatible.If you try welding polyethylene and polypropylene, it may melt together, but there will be no chemical bond. A chemical bond is important for creating strong weld joints.Another factor to keep in mind while welding any material through ultrasonic welding is maintaining a uniform contact area.

Attributes

Parameter

Attributes

Parameter

Brand

HCSONIC

Item Model

HC-W20

Maximum Power output

2200W

Frequency

20KHZ

Maximum Amplitude

10µm

Working model

Continuous, intermittent

Weldable materials

Thermoplastic materials

Welding Head Material

Al,Steel

Welding Head Size

110*20 or 150*40mm

 Driven Type

Electric

Technical Support

Video, mail, phone

Warranty

One year, except horn

Full Set Weight

11KG

Place of Origin

China

Production time: within 15 days or according to customer requirements.Shipping method: DHL, FedEx, UPS, TNT, sea or air.