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塑料超声波焊接

1965-12-21
  • Robert Soloff
  • Seymour Linsley
超声波焊接机在工厂环境中连接塑料部件,聚合物技术。

(图片仅供参考)

超声波焊接连接 塑料 using high-frequency acoustic vibrations, typically between 15 kHz and 70 kHz. The vibrations are applied to parts clamped under 压力振动过程中,热塑性塑料与振动器接触时会产生强烈的摩擦热。这种局部热量会迅速熔化热塑性塑料。振动停止后,熔融材料会在压力下凝固,形成牢固的固态焊接,无需使用粘合剂或紧固件。超声波焊接最适用于相容性热塑性塑料,因此在选择此工艺之前,使用塑料识别图表确认材料非常重要。

The core of an ultrasonic welding system consists of a power supply (generator), a transducer (converter) that changes high-frequency electrical energy into mechanical vibrations, a booster to amplify these vibrations, and a sonotrode (or horn) that transmits the energy to the workpiece. The process is extremely fast, with weld times often under one second. A critical aspect of successful ultrasonic welding is the joint design. Parts are often molded with ‘energy directors’—small, sharp triangular ridges on one of the surfaces. These features concentrate the ultrasonic energy, initiating a rapid melt and ensuring a uniform bond. The technique is best suited for amorphous polymers like ABS, polystyrene, and 聚碳酸酯, as their random molecular structure allows for efficient transmission of vibrational energy. Semi-crystalline polymers like polyethylene and 聚丙烯 can also be welded, but they require higher energy levels due to their ordered structure, which dampens the vibrations. The process is clean, energy-efficient, and highly repeatable, making it ideal for automated, high-volume manufacturing.

UNESCO Nomenclature: 3322
– Polymer Technology

类型

Physical Process

中断

Revolutionary

用法

广泛使用

前体

  • 雅克·居里和皮埃尔·居里发现压电现象
  • 声纳用大功率超声换能器的研制
  • 了解摩擦和生热
  • 高频电子发电技术的进步

应用程序

  • 汽车零部件(仪表板、门板)
  • 医疗器械(过滤器、导管、面罩)
  • 电子设备(手机外壳、连接器)
  • 消费品(玩具、包装)
  • 纺织品和织物连接(无纺布)

专利:

  • US3224916A

潜在创新理念

  • 超声波焊接将 RFID 标签嵌入塑料部件
  • micro-ultrasonic welding for assembling MEMS 和 microfluidic devices
  • 采用卷对卷工艺对薄膜和织物进行连续超声波焊接
  • 用于焊接异种材料的混合超声波/激光系统
  • 根据传感器反馈实时调整频率和振幅的自适应超声波焊接机
  • 利用聚焦声能的非接触式超声波焊接
  • 复合材料大型汽车车身面板的超声波点焊
  • 用于航空航天部件现场维修的手持式超声波焊接机
  • 用于可持续包装的可生物降解聚合物的超声波焊接
  • 使用超声波焊接将药物封装在聚合物壳内
相关领域:超声波焊接、声振动、摩擦焊接、热塑性塑料、声波焊头、能量导向器、聚合物连接、高频焊接、固态焊接、塑料组装。

历史背景

塑料超声波焊接

1960
1962
1963
1965-12-21
1970
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1970
1960
1960
1962-10-09
1964
1970
1970
1970
1970

(如果日期未知或不相关,例如“流体力学”,则提供其显著出现的近似估计)

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