This section provides overview, applications, and principles of ultrasonic welders. Also, please take a look at the list of 9 ultrasonic welder manufacturers and their company rankings.
Ultrasonic Welder was developed in the 1960s and have been in use for more than 50 years. The ultrasonic welder consists of an oscillator and welding table, or transducer and horn, which melt and instantly bond resins and metals by applying ultrasonic vibration and pressure simultaneously. This device has a wide range of applications and is used in various fields. The features of this welding machine are that it does not use any adhesives, so the appearance after welding is beautiful. It is also environmentally friendly because it uses instantaneous frictional heat to weld, so it consumes less power and it is easy to automate, so it is highly reproducible.
The main uses of ultrasonic welders are as follows.
Ultrasonic welding can bond metals as well as plastics, and is also used to bond metal terminals and wiring and metal wires inside IC chips.
Ultrasonic welders convert electrical energy into vibration energy and apply pressure to the material to generate a large amount of frictional heat on the thermoplastic bonding surface to weld the object. If the welded object is a metal, ultrasonic vibration causes intense friction between the metals, dissolving the oxide film on the metal surfaces and mixing the metals that existed under the film to form a joint.
The following is a brief explanation of the oscillator and transducer that make up the ultrasonic welders. The oscillator is a device that converts electric power into ultrasonic vibration. The oscillator of an ultrasonic welders uses a circuit that maintains a constant amplitude so that the amplitude of the ultrasonic waves does not change depending on the type of weld material. By maintaining a constant amplitude, quality deviations in the welded product are prevented. The oscillator consists of a bolt-tightening Langevin-type transducer (commonly known as a BL transducer) that generates ultrasonic vibration and a horn that transmits the vibration. Ultrasonic welders perform welding by propagating ultrasonic waves from the horn to the welded product.
Demand for masks is growing rapidly due to the coronavirus, which is still raging around the world today.
ultrasonic welders are used in the production of masks. ultrasonic welders use ultrasonic vibrations to melt materials and weld them together to produce the twill patterns and engravings on the masks.
The use of ultrasonic vibration eliminates the need for threads and adhesives, simplifying the manufacturing process. It has been reported that ear strings can be welded to the mask part (with natural latex rubber for the rubber part and PE for the thread part).
In the future, the production of masks using ultrasonic welders will probably increase both in companies and individuals.
Ultrasonic horns are used to efficiently transfer vibration energy to the plastic parts to be welded. There are different types of ultrasonic horns, including step (high amplitude and stress type), catenoidal (intermediate amplitude and stress type), and exponential (low amplitude and stress type). Ultrasonic waves are converted into mechanical vibration amplitude energy at the transducer, and the amplitude is amplified by a transducer called a booster and transmitted to the horn.
The amplitude generated by the transducer is gradually amplified to its optimum amplitude at the horn tip. By concentrating the ultrasonic vibration at the tip of the horn, the welded object is subjected to an impact equivalent to the force of 40,000 repetitions per second (at 40 kHz), which is stronger than striking with a hammer or the like. The ultrasonic horn is made of aluminum alloy, titanium alloy, die steel, etc., depending on the welding purpose.
Depending on the model, ultrasonic welders have the following features:
*Including some distributors, etc.
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