Ultrasonic Welding Of Plastics - Herrmann Ultrasonics Working Of Ultrasonic Welding

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Ultrasonic welding is particularly suitable for:

• Joining of injection-molded parts
• Embedding of membranes
• Embedding of leather, nonwoven materials, and textiles
• Staking of different types of materials
• Production of form-fit joints by swaging
• Inserting of bushes and magnets

The following variants are feasible:

Welding of molded components with joint design / Focusing of energy through the weld geometry (= energy director)

To be applied for all injection-molded parts; this process is referred to as molecular bonding. Focusing of the ultrasonic energy is performed by so-called energy directors (ERG). Energy directors may be tips or edges that must be included in the part design. The melt is formed directly between the joining parts at the contact points of the energy directors.

Energy director

Melt encapsulation

Plastic staking has been successfully used in industrial manufacturing for many years. Staking produces permanent joints with hardly any restrictions on material combinations and enables short process cycles, high efficiency, and great freedom of design and technical process planning.

Often alternative plastic joining methods, such as clipping, snapping or gluing do not work for reasons of material properties, operational safety, or efficiency.

Ultrasonic swaging is a closely related method and only differs from staking in that swaging does not use round or longitudinal shafts for processing but melts and reforms a ridge of plastic (either straight or rounded) around the part to be fastened.

Mash joint before welding

Energy focusing with energy director, see example of mash joint

Reforming using ultrasonics / Focusing of energy through the sonotrode

This is referred to as staking, spot welding or swaging. The melt develops through immediate contact between the weld surface of the sonotrode and the thermoplastic component. With this method it is also possible to join different types of materials, e.g. plastic-metal or glass-plastic, etc., by a form-fit bond.

Focusing of energy through the sonotrode

Energy focusing with sonotrode, see example of staking

BASICS OF PLASTICS

BASICS OF PLASTICS

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