Commonly used welding methods for ultrasonic welding

1. Ultrasonic welding
The welding head (HORN) vibrating with ultrasonic ultra-high frequency generates frictional heat on the joint surface of the two plastics under moderate pressure and melts and joins instantly. It can achieve watertightness and airtightness, and eliminate the inconvenience caused by the use of auxiliary materials, and achieve efficient and clean welding.
The design of a typical ultrasonic welding surface must have the following two functions:
1. The tongue and tenon design ensures convenient alignment during the welding cycle.
2. The welding wire is designed to be thin, but there must be enough meltable material to fuse the welding surface.
The specific design method depends on what kind of workpiece equipment is used for welding. Welding pressure, vibration amplitude and other parameters can be adjusted to ensure that the ultrasonic welding head can contact the welding surface and apply pressure. The welding head generates ultrasonic high frequency, which makes the upper workpiece vibrate thermally, so it can fuse with the lower workpiece. After the welding head stops vibrating, the pressure is maintained, and the melting position is cooled and formed. The entire welding time is mostly less than one second.

2. Ultrasonic riveting
The ultrasonic ultra-high frequency vibration welding head (HORN) is pressed against the protruding tip of the plastic product, and it instantly heats up and melts into a rivet shape, so that the metal object is riveted and fixed.

3. Ultrasonic implantation
Using ultrasonic ultra-high frequency sound wave vibration, through the conduction of the welding head (HORN) and appropriate pressure, the metal parts (such as nuts, screws) are instantly squeezed into the reserved plastic holes and fixed at the set depth. After completion, the tensile force and torsion force can be comparable to the strength of traditional molding in the mold, and the disadvantages of injection damage and slow injection can be avoided.

4. Ultrasonic spot welding
When two pieces of plastic are to be welded, due to the condition of the welded object, the fuse wire cannot be opened, and spot welding can be used for welding. It can also spot weld multiple points at the same time to improve work efficiency.

5. Ultrasonic excision
The high-speed ultrasonic vibration welding head cuts off the sharp burrs of the injection-molded plastic parts, and cuts off the injection port, so that the plastic original parts can be separated from the injection channel in an instant, and the manual cutting process is omitted. Materials suitable for ultrasonic ablation include ABS, PS, acrylic, PC, plastic steel, etc. Plastics that are too soft or elastic are not suitable for ultrasonic ablation. (The effect of the plastic material is not good when it is just injected and it has not cooled down)

6. Ultrasonic forming
The common ultrasonic welding method is similar to ultrasonic riveting. It is to press the concave welding head on the outer ring of the plastic product to make it vibrate at a high frequency, then melt the plastic and wrap it on the metal object to fix it, and the appearance is smooth and beautiful. And cosmetic lens fixation, etc.