Plastic post-processing: ultrasonic welding
author: Universe plastic
2024-09-15
Ultrasonic welding is a commonly used plastic post-processing technology. It transfers heat to the contact surface of plastic parts through high-frequency mechanical vibration, causing it to locally melt and solidify rapidly, thereby achieving the welding effect.
Ultrasonic plastic welding is widely used in plastic manufacturing in the fields of automobiles, electronics, electrical appliances, and medical equipment. The following Universe Plastics Engineers share knowledge about ultrasonic welding.
Characteristics of ultrasonic welding of plastics
1. Fast
Ultrasonic welding of plastic parts usually only takes 0.5 to 1 second, and the welding effect is very fast.
2. No pollution
Ultrasonic welding of plastic eliminates the need for adhesives or solvents and reduces contamination caused by chemicals.
3. Plastics have consistent strength
The strength of ultrasonic welded joints is usually close to the bulk strength of the material and has consistent plastic strength.
4. High degree of automation
Ultrasonic welding of plastics is done automatically by ultrasonic welding machines and is suitable for mass production.
Ultrasonic welding plastic steps
Step 1: High Frequency
Vibration Through the ultrasonic welding machine, high-frequency mechanical vibrations of 20kHz to 40kHz are generated and transmitted to the plastic parts through the welding head (also called "welding fillet" or "mold").
Step 2: Local heating
The friction between plastic joints generates heat, which softens or melts the plastic.
Step 3: Cooling and solidification
The contact is maintained under pressure, and when the vibration stops, the molten part quickly cools and solidifies, forming a strong welded joint.
Ultrasonic welding plastic material types
1. Easy to weld materials
Amorphous plastics are easier to weld: ABS (acrylonitrile-butadiene-styrene), PS (polystyrene), PMMA (polymethylmethacrylate, commonly known as plexiglass), PC (polycarbonate), PVC (polymer vinyl chloride)
2. Medium welding performance materials
Crystalline plastics have higher melting points: PP (polypropylene), PE (polyethylene), PA (nylon), PBT (polybutylene terephthalate)
3. Difficult to weld materials
PTFE (polytetrafluoroethylene), POM (polyoxymethylene), TPU (thermoplastic polyurethane)
Generally speaking, crystalline plastics are more difficult to weld, while amorphous plastics are easier to weld. In addition, the hygroscopicity and thickness of plastic materials will affect the welding strength and appearance.
Key parameters of ultrasonic welding of plastics
1. Welding frequency
Usually 20kHz or 40kHz, the higher the frequency, the higher the welding accuracy.
2. Welding time
Usually 0.1 to 1 second, the shorter the time, the smaller the thermal impact on the material.
3. Pressure
The welding pressure needs to be high enough to ensure a uniform weld joint.
Ultrasonic welding plastic applications
1. Automotive industry: used for welding of instrument panels, car lights and plastic interior parts.
2. Electronic products: used for welding mobile phone casings, USB interfaces, battery casings, plastic parts of household appliances, etc.
3. Medical equipment: used for syringes, filters, catheters, plastic test tube racks, sample bottles, ventilator pipes, etc.
4. Packaging industry: food packaging containers, plastic bottle caps, containers, cosmetic containers.
5. Toy manufacturing: plastic toy shells, internal plastic parts of toys, plastic toy brackets and shells, and welded toy parts.
6. Consumer products: toothbrush handles, razors, razor casings, plastic pens, plastic glasses frames.
7. Textile apparel: seamless underwear, sportswear, seamless clothing, footwear and bags, seamless waterproof uppers.
8. Electrical communication: plastic cable connector housing, sensor housing, sensor housing.
9. Environmental filtration: water filtration equipment, water treatment equipment plastic housing, air filter, air purifier housing, plastic filter housing.
10. Construction industry: plastic pipes, PVC, PP, PE pipes, water pipes, drainage pipes, door and window accessories.
11. Stationery industry: stationery supplies, plastic pens, folders, eraser cases and other plastic stationery products.
Summarize
Ultrasonic welding is a method of precise and efficient plastic post-processing that enables high-strength bonding of plastic parts and processing into high-quality plastic products with a seamless appearance.
Dongguan Universe Plastic Factory has 15 years of plastic manufacturing experience, a professional team and advanced equipment, and can provide one-stop high-quality plastic injection molding and plastic post-processing services.
If you are choosing an ultrasonic plastic welding manufacturer, please contact us to get the latest service information!
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