Automotive Interior Panel 28khz 800w Ultrasonic Plastic Spot Welder

28 / 35 Khz Portable Ultrasonic Spot Welding Machine for Polyester Welding

What’s the principle of Ultrasonic plastic welding?

Ultrasonic plastic welding is a technique that uses high-frequency ultrasonic acoustic vibrations to create solid-state joints between different plastic components. The principle behind ultrasonic plastic welding is quite fascinating, and it involves several steps:

1. Ultrasonic Frequency Generation: The process starts with an ultrasonic welding machine, where an electronic generator converts the electrical power supply into high-frequency electrical energy, typically between 20 kHz to 40 kHz.

2. Electrical to Mechanical Energy Conversion: This high-frequency electrical energy is sent to an ultrasonic transducer, or converter, which converts it into mechanical vibrations of the same frequency. This is achieved through the use of piezoelectric or magnetostrictive materials that change size when an electric field is applied.

3. Amplification and Transmission: These mechanical vibrations then pass through a booster, which can amplify the amplitude of the vibrations. The amplified vibrations are transmitted to the horn (also known as a sonotrode).

4. Welding: The horn, which is specifically designed for the particular application, applies these mechanical vibrations to the plastic components that are to be joined. The vibrations are transmitted into the plastic parts where they create a frictional heat at the interface of the parts.

5. Solid-State Welding: This heat causes the plastic material at the interface to melt and flow, creating a molten layer. When the vibrations stop, the molten plastic solidifies, creating a solid-state weld between the parts.

The advantages of ultrasonic plastic welding include its speed (typically less than one second), energy efficiency, and ability to weld complex geometric shapes. However, it's important to note that not all plastics are suitable for ultrasonic welding. The technique works best with amorphous plastics, while some semi-crystalline plastics could still be welded but with less strength. Certain other materials, like high-performance thermoplastics, might be difficult or impossible to weld ultrasonically.

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Application fields:

Widely used in the Automotive Industry, Electronic Industry, Medical Industry, Household Appliances, Woven Apparel, Office Supplies, Packaging Industry, and Toy Industry And So On. Such As Plastic Body Parts, Car Doors, Car Dashboard, Lights, Mirrors, Sun Visor, Interior Parts, Filters, Reflective Material, Reflective Spike, Bumper, Cable, Motorcycle Plastic Filter, Radiator , Tanks, Pallet Plates. Plastic Electronics: Prepaid Water Meters, Communications Equipment, Atheism Phone, Mobile Phone Accessories, Cell Phone Case, Battery Case, Charger, Maintenance Valve Regulated Lead-Acid Batteries, 3-Inch Floppy Disk, U Disk, SD Card, USB Connectors, Toys, Stationery: Folder, Album, Folding Boxes, PP Hollow Board, Pen Loops, Ink Cartridges, Toner Cartridges. Medical Daily: Watches, Kitchen Utensils, Oral Liquid Bottle, Drip Caps, Mobile Phone Accessories, Gold Soft Brush, Daily Necessities, Health Supplies, Children's Products, Air Mattresses, Clothes Hangers, Tool Holder, Coffee Pot, Cover And Civil Speaker Grille Metal Surface.

Consumer products, automotive components, medical devices and most all industries use ultrasonic plastic welding. Metal inserts may be secured in plastic and dissimilar materials can often be bonded with proper tooling design. ToolTex specializes in toepad welding applications and has worked on several automotive applications.