Ultrasonic Welding

Ultrasonic plastic welding technology

Technology

Ultrasonic plastic assembly is the joining or reforming of thermoplastics through the use of heat generated from high frequency mechanical motion. It is accomplished by converting electrical energy into high frequency mechanical motion (vibrations) that creates frictional heat at the joint area. The vibrations, when applied to a part under pressure/force, create frictional heat at the interface and cause the plastic in the joint area to melt, creating a molecular bond between the plastic components. This process is called The Ultrasonic Welding. 

Ultrasonic assembly is accomplished by converting high frequency electrical energy into high frequency mechanical motion. That mechanical motion, along with applied force creates frictional heat at the plastic components' mating surfaces (joint area) so the plastic material will melt and form a molecular between the parts. Standard 50 or 60 Hertz AC line voltage is supplied to the generator (power supply) and converted to 20,000 or 40,000 Hertz (i.e., 20 kHz or 40 kHz) AC electrical energy. This high frequency electrical energy is connected to a piezoelectric transducer (converter), which changes the electrical energy into mechanical vibrations. These vibration create heat and melt the plastics. As the plastics cools, a homogeneous molecular bond is formed between the components. This is how a strong plastic assembly by ultrasonic welding is accomplished. 

Advantages of Ultrasonic Assembly

There are many advantages to using ultrasonic assembly. It is a fast, clean, efficient and repeatable process that produces strong, integral bonds while consuming very little energy. No solvents, adhesives mechanical fasteners or external heat are required . Finished assemblies are strong and clean. Difficult materials can be assembled ultrasonically. Part assemblies are cycled quickly because the energy transferred to the joint are released as heat occurs very rapidly and is confined to the immediate joint area. The rapid dissipation of heat makes this process considerably faster than other methods of assembly.   

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