Ultrasonic cutting and welding equipment is frequently used to produce fabric goods. They are also used to connect thermoplastic components to metals like aluminium.
Ultrasonic energy is used to join, cut, pattern, and quilt synthetic fabrics containing no more than 40% natural fabric content.
Ultrasonic welding is accomplished by converting high-frequency electrical energy into high-frequency mechanical motion. High-frequency vibrations, combined with contact force, generate heat by friction at the mating surfaces. As a result, the plastic will melt and form a bond between the parts that are being joined.
Ultrasonic cutting is accomplished by pressing the vibrating horn against a fixed anvil and allowing the horn to push through the fabric, sealing the edge. This method is used to punch holes, cut pre-cut patterns, and cut fabric strips to pre-determined lengths. Food processors slice their products as they come out of ovens, using ultrasonic knives that vibrate 20,000 times per second. The high-frequency vibration creates a nearly friction-free surface between the tool (knife) and the product, removing the possibility of sticking and pinching.
Ultrasonic welding equipment specifications
Ultrasonic cutting and welding equipment is made up of various parts:
· A power supply converts line power at 50 or 60 cycles to high ultrasonic frequency at 20 000 or higher cycles per second. These high-frequency electrical signals can change the frequency based on the ultrasonic stack (converter, booster, and horn).
· A pneumatically controlled press applies pressure to the welded parts and controls the horn’s movement.
· A converter is a device that converts electricity into mechanical vibrations with a high frequency.
· The booster transmits vibration energy, increasing its amplitude, and clamps the horn and convertor to the press.
· The vibration energy is delivered to the material to be worked on via a horn, usually manufactured from titanium or aluminium.
· An anvil or backup tool supports the work material and has channels to allow the horn to completely sever the material and seal the edge. Various ultrasonic welding fixtures hold the material in place. It is critical that the parts are aligned with the welding horn for a successful ultrasonic weld.
Ultrasonic vibrations are transmitted from the horn to the material during operation. This generates frictional heat and fuses the material at the point of contact. The material is cut through, and the edges are sealed at the same time when a cutting edge is used on the anvil.
Ultrasonic welding equipment applications
Ultrasonic welding and cutting are used to replace traditional fabric assembly techniques in clothing production in many ways.
Seams: Making seams or hems in disposable medical products is a common application. Medical garments, face masks, and other items fall into this category. A single row, double row, or triple row of stitches can be simulated using pattern wheels.
Sleeves and cuffs: To effectively weld sleeves and cuffs, cylindrical machines employ a cylindrical arm with a rotary stitch wheel and an ultrasonic system above the wheel.
Slitting or sealing: Ultrasonic slitters cut and seal the edges of synthetic or blended fabrics with precision. As a result, fraying and unravelling are almost completely eliminated.
Hand cutting: A hand-held cutter can cut straight lines or large radius curves.
Plunge cutting: A plunge cutter can cut ribbons, strips, and other materials to length.
Plunge sealing and cutting: Ultrasonic plunge sealing and cutting are performed by advancing single or multiple horns onto materials placed on a fixed anvil.
Adhesive bonding: Thermally activated materials are sandwiched between two non-thermoplastic fabrics, such as cotton, wool, or cotton-wool blends with little synthetic content. The ultrasonic vibrations cause the thermally activated adhesive to flow into the fabric fibres and join them together.
Ultrasonic welding equipment features
When used in the production of synthetic clothing and other fabric products, ultrasonic cutting and welding equipment is an excellent efficiency multiplier. Though woven and nonwoven fabrics are the most used materials for ultrasonic cutters and welders, other plastic and metal components may also be used in this process.
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