Higher-Frequency Ultrasonic Welding System Designed for Mini Part

Manufacturers have little control over operating frequency, which can only be changed by changing the ultrasonic stack. For many years, the most common system frequency was 20 kilohertz. That’s no longer the case.

At present more customers are using 15-kilohertz systems because they need to weld larger parts. Altrasonic can offers 15- and 20-kilohertz systems with a pneumatic or servo actuator and a 4,800-watt generator—its largest ever.

Finite element analysis helps us design better horns to weld larger parts But practically speaking, the horn shouldn’t be bigger than 10 by 8 inches.

Higher-frequency systems of 30-, 35- and 40-kilohertz continue to be used for smaller, delicate parts. Altrasonic makes 50- and 70-kilohertz systems (pneumatic or servo) for welding mini components.

One European medical-device manufacturer is using the 70-kilohertz servo system to weld an ultra thin component (100 micrometers) inside a very thin testing device (300 micrometers). Welding distance is 50 micrometers, and cycle time is less than 0.5 second. The system has been in operation for several months without damaging any components or devices.

Appliance and auto manufacturers like the Ultraplast digital generator because it won’t overheat in extreme operating conditions.The generator outputs up to 1,200 watts at 35 kilohertz and up to 6,200 watts at 20 kilohertz. It can be configured for fast intermittent welding of midsized and large parts. The generator is available for use with 20-, 30- and 35-kilohertz welders.

The need to weld larger parts is not the only reason suppliers have increased the power of their generators. Another reason is that thermoplastic materials are increasingly being custom blended for manufacturers.

Parts made of thermoplastic with new base resins or resin mixes present challenges for suppliers These parts have higher heat capabilities, and they require more power to weld. Manufacturers of consumer electronics products often use these thermoplastics.

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