DUKANE // Ultrasonic Welding and Cutting // Packaging

 

Processing Techniques

Ultrasonic Bonding

Ultrasonic bonding assembles two or more layers of materials by passing them between a vibrating horn and a rotary drum (often referred to as ananvil). The rotary drum is usually made from hardened steel and has a pattern of raised areas machined into it.  The high frequency mechanical motion of the vibrating horn and the compressive force between the horn and the rotary drum create frictional heat at the point where the horn contacts the material(s). The frictional heat bonds the material together only at the horn/material contact points. This gives the bonded material a high degree of softness, breathability and absorption. These are the exact same properties which are critical for hospital gowns, sterile garments, diapers and other applications used in the medical industry and clean room environments.

Ultrasonic bonding requires far less energy than thermal bonding which uses heated rotary drums to bond materials together. As a result, ultrasonic bonding is economical and requires no consumables, adhesives or mechanical fasteners.

Ultrasonic Slitting

When a thermoplastic material is slit ultrasonically, its edges are also sealed. Sealing the edges of a woven fabric is beneficial because the yarns are prevented from unraveling and the smooth, beveled edges prevent buildup of the roll material. When two or more layers are ultrasonically slit together, the layers will become joined. The strength of the bond is determined by the material and anvil geometry.

Many factors influence the speed at which fabric can be ultrasonically slit. Some of the parameters are the geometry of the cutting wheel (anvil), the material composition, material weight and thickness.

Ultrasonic Plunge

In the plunge method, the material remains in a fixed location and is periodically contacted by the horn. The horn operates perpendicular to the material that is on the anvil. The horn can also be used to cut and seal. Typical plunge applications include but are not limited to: Filters | Strapping | Vertical Blinds | Bra Straps | Belt Loops | Buckles | Embossing | Hook and Loop.

Ultrasonic Traversing

When a thermoplastic material is slit ultrasonically, its edges are also sealed. Sealing the edges of a woven fabric is beneficial because the yarns are prevented from unraveling and the smooth, beveled edges prevent buildup of the roll material. When two or more layers are ultrasonically slit together, the layers will become joined. The strength of the bond is determined by the material and anvil geometry.Many factors influence the speed at which fabric can be ultrasonically slit. Some of the parameters are the geometry of the cutting wheel (anvil), the material composition, material weight and thickness.

RotarySealing

Dukane's Rotary 30kHz Ultrasonic Sonotrode (Horn) is ideal for sealing thin films and non woven materials. The unit can be easily integrated into automation. The Rotary horn design eliminates drag issues associated with conventional static ultrasonic sonotrodes. Ultrasonic bonding is a greener solution than conventional heat sealing as power consumption is greatly reduced, requires no adhesives and produces no smoke or fumes. Applications for the rotary horn include film sealing for packaging machines, bonding of nonwoven materials and many others.

 

PACKAGING

Ultrasonic packaging

What is ultrasonic package sealing?

Ultrasonic package sealing occurs when high frequency (ultrasonic) mechanical energy is transferred into two or more layers of thermoplastic materials. A strong, reliable molecular bond is formed between the layers. Nearly all packaging materials and laminates, with a thermoplastic sealing layer or coating, are suitable for the ultrasonic sealing (welding) process. Both hermetic and peelable seals can be achieved with ultrasonic sealing systems. Dukane has developed an advanced ultrasonic sealing solution. It consists of a patented - 100% digitally controlled - ultrasonic power supply and an optimized acoustical stack [transducer (converter) / booster / horn (sonotrode) / anvil. The stack components apply clamping force to the sealing area. At the same time, ultrasonic energy generates localized frictional heat sealing the packaging materials.

 

Suitable for:

The ultrasonic sealing solution is ideal for these processes and applications:

  • Pouch sealing
  • Re-sealable zipper closures
  • Form-fill seal bags - vertical and horizontal configurations
  • Cartons
  • Pour spouts on gable top cartons
  • Blister packs
  • Clam shell packs
  • Cups/trays
  • Tube seal
  • Fitments on pouches
  • De-foaming of liquids

 

 

Advantages of ultrasonic sealing

  • Short Cycle Times = Increased Though-put
  • Possibility to use the sealing process to monitor quality control
  • Low energy consumption
  • Clean and simple to maintain
  • Ultrasonics can seal through remnants like drops of liquid, or small amounts of powder or fibrous material that may be in the seal area
  • Ultrasonic process does not require adhesives and/or solvents
  • Reduced costs
  • Less energy required than traditional heat sealers.
  • Narrower weld seams are possible thus saving packaging material

Why Choose Dukane?

  • 40 + years of ultrasonic bonding experience
  • Several key industry patents and technological firsts
  • Optimized ultrasonic tooling designed and manufactured at our world headquarters in St. Charles, IL.
  • FEA analysis of complex horn designs
  • 100 % digitally controlled power supply
  • Advanced digital frequency lock & control