Ultrasonic welding wiring design
The human ear could only feel about 20000Hz of the acoustic wave, frequency higher acoustic or ultrasonic
Simply put, acoustic range greater than 2 × 104Hz called ultrasonic acoustic.
Ultrasonic plastic welding principle is produced by the generator 20KHZ (or 15KHZ) high voltage, high frequency signal, through the transducer system, the signal is converted into high frequency mechanical vibration, applied to the plastic products on the workpiece surface of the workpiece, through and intrinsic molecular parts friction transmission to the interface temperature, when the temperature reaches the workpiece itself melting point, so that the workpiece interface rapidly melting, then fill in the gap between the interface, when the vibration is stopped, the workpiece while under a certain pressure cooling setting, will reach the perfect welding.
The use of ultrasonic mechanical action for ultrasonic welding, drilling, dust removal.The use of ultrasound cavitation can be used to make oil and water mixture emulsion at room temperature and atmospheric pressure, so that some cannot occur chemical reaction to proceed.The use of ultrasound in the good direction for ultrasound detection.The use of ultrasound for the transmission and reflection properties of solid ultrasonic testing, the internal structure of matter.Can also use ultrasonic biological effect of seed treatment, make agricultural increase production, can also be performed ultrasound in the treatment of some human diseases.
Areas of application: used for the welding of the thermoplastic, by replacing the head can also be used for mosaic, riveting, spot welding, such as embedded-processing technology, applied to electronic industry, the stationery industry, transport equipment, food industry, cosmetic industry, electrical industry, electronics industry, toy industry.For example, Christmas lights plastic lighter plug, high-heeled shoes and various special-shaped hard...
Large workpiece or irregular workpiece welding, such as nylon, PP, PE, injection molded parts: vehicle carbon canister, lamps, batteries, filters, bumper and a vacuum cleaner, floating ball, weld.
Ultrasonic welding technology, is a relatively new plastics welding assembly technology,
1.The sonic line cross section design, and the welding part of total volume, relative to the entire product volume ratio.
2.The ultrasonic welding on supersonic machine transfer machine technology, and ultrasound operator careful degree have great dependence.
Ultrasonic welding technology
Welding:
Referring to the generalized two products of thermoplastic welding process.When sonic to stop vibration,
The solid material is melted, the completed weld.The joint strength is close to a one-piece intergrowth material,
As long as the product of the joint surface is designed to match,
Completely sealed is absolutely no problem,
Dish in:
Melting mechanical lock is formed of a different material plastic bolt process.
Embedded:
A metallic element is embedded in the plastic products reserved hole.
With high intensity, short molding cycle rapid installation advantages!!
Similar to the design of die insert!
Bent / generation
Sonic the fitting part melting and consisting of a plastic protruding parts or plastic pipe or other extrusion parts.The advantage of this approach is that processing of fast, low pressure, good appearance and the material nature to overcome.
Point welding
Spot welding is not reserved or energy control two thermoplastic components of local welding.Spot welding can also generate a strong adhesive structure, is particularly suitable for large parts, a protruding piece of plastic or pouring thermoplastic and those with complex structure, difficult to enter the joint surface of product.
Shear
Cutting and sealing some order and disorder of the thermoplastic material ultrasonic technology.In this way the seal edge crack, and no burr, curling phenomenon.
Textile / film sealing textile products and some film seal can also be used to the ultrasonic.It can be on the film carries out tight pressing, also on textiles was neat localized shear and seal.Suture at the same time also played a decorative role.
Thermoplastic and thermosetting polymers:
The single body combined together by a process known as "polymerization".The polymer can be divided into two major categories: thermoplastic and thermosetting.Heating a thermoplastic material after molding can once again softening and molding, base experienced just state changes only. This characteristic makes decisions of thermoplastic material by ultrasonic pressure adaptability.Thermosetting material is passed through an irreversible chemical reaction, heat or pressure, again cannot make the Molded Thermosetting products softening, so has traditionally been thought of thermosetting material is not suitable for the use of ultrasound.
Influence factors of ultrasonic welding
Speaking of thermoplastic plastic welding relay, not when it comes to pressure of ultrasound on various resin requirement.The main factors include the polymer structure, melting temperature, flexibility (hardness), chemical structure.
Polymer structure
Non crystallizable polymer disordered molecular arrangement, has the obvious material gradually become soft, melting and flowing temperature (Tg glass transition temperature).This kind of resin is usually effective supersonic vibration transmission and in a quite wide pressure / amplitude range to achieve good welding.
Semi crystalline polymer ordered molecular arrangement, with the apparent melting point (Tm melting temperature) and again solidifying point.Solid state crystalline polymer is flexible, can absorb part of high frequency mechanical vibration.So this kind of polymer is not easy to ultrasonic vibration energy to the pressing surface, help to demand higher amplitude.Very high energy (high melting heat) to semi crystalline structure interrupted so that material from the crystalline state to the flow state, it also determines the type of material's melting point clear, the molten material once leaving the heat source, lower temperature will cause the rapid solidification material.So we must consider the specialty of materials (such as: high amplitude, the junction of good design, and ultrasonic fixture effective contact, and excellent work equipment) in order to obtain the ultrasonic welding success.
Melting temperature
The melting point of the polymer is higher, the required welding ultrasonic energy more.
Hardness (modulus of elasticity)
The hardness of the material on whether it can effective transmission of ultrasonic vibration is very influential.Generally speaking, the more rigid material and its transmission force stronger.
Working principle of ultrasonic:
Thermal plasticity plastic ultrasonic processing, is the use of working surface between the high frequency of friction and the intermolecular rapidly generate heat when the heat melting, enough work, stop ultrasonic vibration, the workpiece surface by welding and curing, complete processing program. Usually used in plastic working frequency of 20KHZ and 15KHZ, where 20KHZ is in the human auditory, called ultrasonic. But 15KHZ is in the range of human hearing.
Ultrasonic mechanism principle:
220V 60HZ into 15KHZ (or 20KHZ) of the high voltage electric energy, using the vibrator is converted into mechanical energy. So mechanical vibration, via a transmission, head to the workpiece, and the use of air pressure, to produce work receiving surface friction effect. Vibration and transmission device in the vibration tube, external welding head the use of air system, and the control loop, the preset conditions, lifting, to complete the operation.
Effects of ultrasonic processing factors:
1 plastic materials
2 guide to the design of
The 3 mold adjusting accuracy of 4 around the workpiece temperature
5 horn design
6 horn by amplitude
The 7 base design support
The 8 contact surface or surface design
9 work shape and size
The 10 side wall and the horizontal thickness
11 surface cleaning and processing (such as paint or plating)
12 transferred to the workpiece material on the energy
13 different materials plastic blending
14 internal and external damping factors, such as the fixture base or the contents of obstacles.