WIN Utrasonic
 
 
 
Technical Introduction of the Utrasonic Welder
Utrasonic
 
The sound vibrations in the air and more than 20,000 Hz, which is the upper limit
of the audible frequency range of 16 to 20,000 Hz can hear people in general definitions,
with the highest sound vibration → “Utrasonic”
Now In other words, the ultrasonic sound waves used for purposes other than to listen to
the frequencies used in industrial applications → “Utrasonic”
The recent ultrasonic on the the thermal expertise of the physical, chemical, electrical,
mechanical, metal, medicine, biology, and is spreading. The actual use of a wide range
sounding, washing, cleaning, welding, processing, distributed, sewage disposal,
dust collection, and diagnostics.
   
Principles and features of the ultrasonic welder
 
  The ultrasonic welder AC 110 ~ 220V, 60Hz (50Hz) of the power oscillator is converted to
mechanical vibration energy, the electrical energy input to the oscillator.
This is the way in which horn for complex joint surface causing strong friction moment,
the bonding surface of the workpiece melt adhesive is strong molecular bonds.
   
   
Oscillator BLT (Bolt Clamping Langevin type Transducer) oscillator assembled into a PZT element that is currently being used electro-mechanical conversion rate is the most widely used to apply a large power ultrasonic transducer. Applying electrical energy to match the frequency of the oscillator and oscillator.The resonance occurs and the best kinds of mechanical vibration energy to convert to.
- High mechanical sensitivity
- It can be used at high temperatures.
- robust.
- Metal parts, machined bolts, easy to splice the horn
Main Horn The difference between the amplitude and the amplitude generated by the oscillator and plastic welding occurs. To compensate for this, coupled with the bolt in the middle of the main horn horn transducer and the tool to adjust the amplitude.
Tool Horn Amplitude welding tools, depending on the product, the shape of the horn varies according to the product used. Complex bonding surface for causing strong friction moment, bond products.
   
Characteristics of ultrasonic welding
 
  Internal heating of the weld area, and there is no need for the cleaning process,
is a continuous sealing.
  Exothermic welding and fusing heterogeneous materials, welding, and,
optionally, at the same time.
  Transfer efficiency and attractive effect. The welding speed is fast.
  Was not fever, except for the area of welding, the weld surface is clean.
  Firm adhesion.
  Quality, stable operation, simple, and cost-saving.
  Automated molding and tooling cost savings.
  The working environment is improved.
   
Types and advantages of the ultrasonic welding
 
Staking
  Strong intensity
  You can create the desired shape
  Wide coverage
  Can be applied to other materials
Sport
Welding
  Joint design and hole processing is unnecessary and welding is simple.
  welding time is short. Strong intensity
  Multiple spot welding can be at once
  Bolt and Screw parts do not need
  The exterior is clean
Swaging
  crystallized Time is short
  Strong intensity
  The exterior is clean
  High reproducibility and easy to control.
  Bolt and Screw parts do not need
Welding
  The exterior is clean
  welding time is short. Strong intensity
  Wide coverage
  The most commonly used welding
Inserting
  Insert time is short.
  Takes place at a time with multiple inserts.
  Metal inserts around the resin less stress (residual stress)
  The molding cycle is fast
Gate
Cutting
  Short gate Cutting time
  Multi-Gate Cutting takes place at a time
  Because the gate does not remain on the molded product is clean.
   
Use of ultrasonic welder
  High-frequency mechanical vibration íŠ Plastic passíŠ Areas of friction welding, melting óí Welding operations
 
Welding of thermoplastic resin products
Resin metal insert

Assembly and processing of various
plastic products

Electronics, automotive parts, toys, stationery,
medical devices, packaging, household goods, etc.
⇒ widely used in various plastic products.
   
Plastic material properties that affect the ultrasonic
 
1) Resin
 
Thermo-plastic Resin
Change state only formed after re-melting and reheating
repressurization If this attribute does not change appearance.
Materials suitable for ultrasonic welding
 
Thermoset Resin
Once the formation, re-pressurized and re-melting furnace
does not happen.
Non-conformity to the ultrasonic welding.
   
2) Plastic Frame
 
Amorphous resins
"The glass transition temperature band does not harden quickly"
in a wide range of irregular molecular arrangement and gradually
soften and melt flow.
Less loss of pressure and the amplitude of ultrasonic energy
delivered well in a wide range of welding work done
 
Semi-crystalline resins
Regular molecular arrangement and sensitive melting temperature
and fast curing characteristics.
Link to hardened the molecular structure, similar to a spring.
íŠ Some high-frequency mechanical vibration absorption
The ultrasonic energy is being delivered to the weld area
fringed difficulties
íŠ Requires a high-amplitude
   
3)

The melting temperature

 
Higher melting temperature, ultrasonic energy required for welding is higher.
   
4)

Rigidity (modulus of elasticity)

 
The rigidity of the plastic affects the ultrasonic energy delivered to the weld area.
If the material is hard, the ultrasonic is delivered well.
   
5)

Welding of the dissimilar materials

 
Welding plastic melt temperature should be similar, and the temperature difference
is 22 ° C and should not be welding.
The molecular structure of the material is similar to the welding of the dissimilar materials..
→Generally similar to the molecular structure of amorphous resin, heterogeneous crystalline
    resin material should melt.
   
6) Other factors that affect the weld (moisture)
 
Materials that
absorb moisture
Nylon, polycarbonate, polyester, polysulfone, etc.
(Absorb moisture, will adversely affect the welding characteristics.)
 
The welding of the material to absorb moisture
Heated at 100 ° C, the water in the organization occurs pores in the plastic.
Degradation to the area of plastic welding characteristics.
Confidentiality is not maintained.
Did not beautiful appearance, the weld strength decreases
 
Troubleshooting
Immediately after the injection, welding

Kept in plastic bags polyethylene welding.

Moisture absorbing plastic products : Light / after drying by heat welding.