Ultrasonic Welders

Category filter
Technical information sheets
01 / Ultrasonic Welding

Ultrasonic welding occurs when a normal variable load is applied to the pieces to be welded and one part is vibrated against the other by a resonator stack consisting of the transducer, and the booster at the end of which the sonotrode is attached.
The sonotrode generates an ultrasound vibration between the parts. This intense vibration generates heat and consequently the thermoplastic materials melt, ensuring the part welding and assembly.

The ultrasonic generator provides a sinusoidal electrical waveform at a frequency of between 20 and 50 kHz. Sirius Electric builds systems with frequencies of 20 – 30 – 36 – 40 kHz

Areas of
Application
Water
In this field, the use of ultrasound is relatively recent, given that many components are still made of metal. Water tightness, even at high pressure, is definitely the most important feature. APPLICATION EXAMPLES: Welding of shower units, valves, anti-scale filters, filters, tapware parts, floats, and water meters.
Technical Articles
One of the most commonly used technologies for the welding of technical articles is definitely technology that uses ultrasound. The welded parts must have very high mechanical characteristics. This field includes special plastic materials, and as a result ultrasound technology is in continual evolution. APPLICATION EXAMPLES: Welding of impellers, pinions and gearwheels, filters, ball-grips, pneumatic components, and motor parts. Metal parts are frequently used as inserts.
Automotive
There are various ultrasound applications within this field. Assemblies need to be watertight and require a good surface finish, especially for lighting components. The welding of parts for the engine compartment has to meet superior mechanical requirements. Special multiple-head welders incorporating multiple resonator stacks are frequently used in this field. APPLICATION EXAMPLES: Welding of lights, signalling elements, plugs, bulb holders, ball-grips, pushbutton parts, tanks, air ducts, dashboards and bumpers.
Household goods
Ultrasound technology has been applied for many years in this field. One of the most important characteristics of the assembly is the appearance. APPLICATION EXAMPLES: Welding of dinnerware, bodies of gas-lighters, water tanks, filters and valves for hoods, containers, plate riveting for food choppers, electrical contacts, and large fans.
Electrical engineering
There are numerous applications in this field also. Assemblies need to have a high degree of mechanical strength, and, for some applications, a good level of aesthetic finish. APPLICATION EXAMPLES: Welding of wall-sockets, plugs and pins, spools and relays, transformer casings, lamps, transparent covers for displays, ceiling lamps, speaker gratings, temperature controllers, knobs and switches.
Toys
In the toy industry, the possibilities for ultrasound use are notable considering the extensive use of plastic materials. APPLICATION EXAMPLES: Welding of articles for infants, beach balls, parts of toy musical instruments, eyes for soft toys, and cases.
Packaging
Thanks to large retail chains, ultrasound is widely used in the packaging sector. APPLICATION EXAMPLES: Welding of containers, tubes, caps, transparent valve closings, zips for PE bags, fasteners for milk and beverage cartons, stands for cosmetic products.
Medical devices
There use of ultrasound is frequent in this field. The reliability of this technology is vital within this sector. Assembled parts have to comply with specific needs and require impeccable quality. APPLICATION EXAMPLES: Welding of dialysis filters, filters for haemo-derivatives, filters for biological applications, filters for syringes, containers, disposable masks, accessories for IV bags, artificial kidneys.
Underwater
Use of ultrasound technology in this field is recent. The combination of aesthetics and watertightness for the assembled parts are the two most important characteristics for using the ultrasound technology. APPLICATION EXAMPLES: Welding of masks, mouthpieces, valves for jackets, valves for inflating small boats, straps, floaters, knife sheaths.
Lighting
One of the most widespread applications in ultrasonic welding is the welding of headlights and special reflectors.                                                        APPLICATION EXAMPLES: welding of lights for cars and motorcycles, directional lights, welding of special reflectors.
Textiles
The use of ultrasound for cutting - welding textiles and laminated products containing plastic is increasing. Precision cuts are possible using ultrasound technology. During this stage the material is cut and welded at the same time to prevent fraying. APPLICATION EXAMPLES: Cutting of tapes, filters, membranes, nonwovens, and fabrics. Cutting of special filters for the medical field. Welding of tapes, straps, and nonwovens.
Office supplies
Ultrasound technology in this field has been applied for many years. One of the most important features of assemblies is their aesthetic appearance. APPLICATION EXAMPLES: Welding of ink-jet cartridges, ball-point pens, inked printer tapes, adhesive tape dispensers, rulers, magnetic boards, photo holders, and folders.