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Applications of ultrasonic welding

 

Ultrasonic welding machine is commonly used for plastics. Compared with other welding techniques, ultrasonic welding has its advantages, such as there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together, and high frequency, etc..

Ultrasonic welding is an industrial technique whereby high-frequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solid-state weld, it can be used on almost all materials, and it’s the fastest heat sealing technology available. In ultrasonic welding, the parts being welded are sandwiched between a fixed shaped nest (anvil) and welding horn, and a ~20 kHz low-amplitude acoustic vibration is emitted. The ultrasonic energy melts the point contact between the parts, creating a joint. This process is a good automated alternative to glue, screws or snap-fit designs.

The applications of ultrasonic welding are extensive and are found in many industries including electronic and electrical, automotive and aerospace, civil engineering, medical, and packaging.

Aerospace and automotive industries

For automobiles, ultrasonic welding tends to be used to assemble large plastic and electrical components such as instrument panels, door panels, lamps, air ducts, steering wheels and engine components. Some of the advantages for ultrasonic welding are low cycle times, automation, low capital costs, and flexibility. Also, ultrasonic welding does not damage surface finish, which is a crucial consideration for many car manufacturers, because the high-frequency vibrations prevent marks from being generated.

Medical industry

In the medical industry ultrasonic welding is often used because it does not introduce contaminants or degradation into the weld and the machines can be specialized for use in clean rooms. Another important application in the medical industry for ultrasonic welding is textiles. Items like hospital gowns, sterile garments, masks, transdermal patches and textiles for clean rooms can be sealed and sewn using ultrasonic welding.

Packaging industry

Packaging is perhaps the application in which ultrasonic welding is most often used. Many everyday items are either created or packaged using ultrasonic welding techniques. Sealing containers, tubes and blister packs are some common applications.

Ultrasonic welding is also applied in the packaging of dangerous materials such as explosives, fireworks and other reactive chemicals. Besides, the food industry finds ultrasonic welding preferable to traditional joining techniques because it is fast, sanitary and can produce hermetic seals. Milk and juice containers are examples of some products that are often sealed using ultrasonic welding. 

 


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