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Ultrasonic welding principle

2018-04-26

Principle of Ultrasonic Welding:

When ultrasonic waves act on the thermoplastic plastic contact surface, high-frequency vibrations of tens of thousands of times per second are generated. This kind of high-frequency vibration reaches a certain amplitude, and the ultrasonic energy is transmitted to the welding area through the upper weldment, due to welding. The area, which is the interface between the two welds, has a large acoustic resistance, and therefore it generates localized high temperatures. Because of the poor thermal conductivity of plastics, they can not be distributed in time and accumulate in the weld zone, causing the two plastic contact surfaces to melt quickly and add a certain pressure to fuse them into one. When the ultrasonic wave ceases to function, let the pressure persist for a few seconds to allow it to solidify and form a solid molecular chain so that the welding can be achieved. The welding strength can be close to that of the raw material. The quality of ultrasonic plastic welding depends on the amplitude of the transducer's welding head, the applied pressure and the welding time. The welding time and welding head pressure can be adjusted, and the amplitude is changed by the transducer and amplitude. Rod decision. The interaction of these three quantities has a suitable value. When the energy exceeds the suitable value, the melting amount of the plastic is large, and the welding material is easily deformed; if the energy is small, the welding is not easy and the applied pressure cannot be too great. This optimum pressure is the product of the best pressure per 1 mm of the edge length of the welded part.


Ultrasonic metal welding principle:

The principle of ultrasonic metal welding is the use of ultrasonic vibration (above 16KHz) mechanical vibration energy, a special method of connecting the same metal or dissimilar metal. In the ultrasonic welding, the metal does not send current to the workpiece, nor does it apply a high-temperature heat source to the workpiece. Only under the static pressure, the vibration energy of the frame is converted into the friction work, deformation energy and limited temperature rise between the workpieces. The metallurgical bond between the joints is a solid state weld that is achieved without the base metal melting. Therefore, it effectively overcomes the spatter and oxidation that occur during resistance welding. Ultrasonic metal welding machines can perform single-spot welding, multi-spot welding and short-strip welding on filaments or thin sheets of non-ferrous metals such as copper, silver, aluminum, and nickel. Can be widely used in SCR lead, fuse pieces, electrical leads, lithium battery pole pieces, very ear welding.


Welding method

  1. the welding method: Ultrasonic vibration at high frequency welding head under moderate pressure, the friction surface of the two plastic friction heat and instant fusion bonding, welding strength can be comparable with the body, using a suitable workpiece and a reasonable interface The design can achieve watertightness and airtightness, and eliminates the inconvenience of using auxiliary products to achieve efficient and clean welding.

  2. Second, the riveting method: ultrasonic high frequency vibration welding head, pressing the plastic product protruding tip, so that the instantaneous heat fusion into a rivet shape, so that different materials, materials, mechanical riveting together.

  3.  Implantation: Through the preaching of the welding head and the appropriate pressure, the metal parts (such as nuts, screws, etc.) are squeezed into the reserved plastic holes, fixed at a certain depth, and the pulling force and torque can be comparable to each other after completion. The strength of the traditional mold molding eliminates the disadvantages of damage to the injection mold and slow ejection.

  4. Forming: This method is similar to the riveting method. The concave soldering head is pressed against the outer ring of the plastic product. After welding the ultrasonic vibration of the ultrasonic wave, the plastic is melted and formed into a metal object to fix it. The appearance is smooth and beautiful. This method is often used in the fixing of electronics and horns, and the fixation of lenses in cosmetics.

  5. Spot welding: A, the two plastic welding points without welding wire in advance to achieve the purpose of welding. B. For relatively large workpieces, it is not easy to design the welding line of the workpiece to be spot welded, and to achieve the welding effect, multiple points can be spot welded at the same time. Sixth, cutting seal: The use of ultrasonic vibration work principle, the chemical fiber fabric cutting, the advantages of incision smooth and clean, no wire drawing.

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