Ultrasonic Bonding Machine is an advanced device that uses high-frequency ultrasonic vibration energy to generate friction heat at the material contact interface, causing the material to partially melt and achieve intermolecular bonding. Its core principle is that the ultrasonic transducer converts high-frequency electrical signals into mechanical vibrations. The vibration waves are amplified by the horn and act on the welding head, which transmits the vibration energy to the surface of the material to be welded.

1. High-frequency vibration achieves efficient welding

• Frequency range: The operating frequency of ultrasonic welding machines is usually 20kHz to 40kHz, of which 20kHz models are suitable for thick material welding, and 40kHz models are suitable for thin materials or high-precision welding.

• Vibration amplitude: The vibration amplitude of the welding head can reach 10μm to 50μm, ensuring that the energy is concentrated in the welding area to avoid material damage.

• Welding speed: The maximum design speed is 80m/min (Max design speed: 80m/min), and the normal speed in actual production is 50-60m/min (Normal speed: 50-60m/min), which significantly improves production efficiency.

• Precise welding and composite strength guarantee

• Pressure control: The equipment is equipped with a high-precision pressure regulation system with a pressure range of 0.1MPa to 1.0MPa, which can be flexibly adjusted according to the thickness and characteristics of the material to ensure welding uniformity.

• Compound strength: The composite strength of the material after welding can reach more than 15N/15mm, which far exceeds the traditional hot melt process and meets the strict strength requirements of medical and health products such as surgical gowns and protective clothing.

• Small heat-affected zone: Ultrasonic welding only acts on the surface of the material at a depth of 10μm to 50μm, avoiding damage to the internal structure of the material and maintaining the softness and breathability of the material.

2. Supports multi-layer material composite and pattern customization

• Material compatibility: Suitable for composite materials such as multi-layer non-woven fabrics (such as PP, PET), films (such as PE, PU), plastic films, etc., with 2-8 layers.

• Pattern customization: Supports flat and 3D pattern welding, the welding head can be customized, and the pattern accuracy reaches ±0.1mm, meeting the aesthetic requirements of high-end medical and health products.

• Machine width: Working width range 1800mm to 2800mm (Machine width: 1800-2800mm), adapted to mass production needs.

3. Automation and intelligent design

• Automatic deviation correction system: Equipped with high-precision photoelectric sensors, real-time monitoring of material offset, automatic adjustment of welding head position, to ensure welding accuracy.

• Intelligent control system: Adopts PLC+touch screen operation interface, supports parameter preset, fault diagnosis and data recording, convenient operation and strong traceability.

• Tension control: Unwinding diameter: Φ850mm and winding diameter: Φ1050mm are matched, and the tension fluctuation is ≤±2N to avoid material stretching and deformation.

4. Energy saving, environmental protection and low maintenance cost

• Energy consumption: The power of a single device is about 5kW, which saves more than 30% energy compared with the traditional hot melt process and reduces production costs.

• Noise control: The operating noise is ≤75dB, which meets the environmental protection standards of industrial production.

• Maintenance cycle: The life of core components (such as transducers and amplitude transformers) is more than 5,000 hours, reducing downtime and maintenance time.

• Modular design: Components such as welding heads and amplitude transformers can be quickly replaced to reduce maintenance difficulty and cost.

Manufacturing of medical protective equipment

• Surgical gowns: using multi-layer non-woven composite technology, welding strength ≥20N/15mm, ensuring protective performance and wearing comfort.

• Protective clothing: supports PE/PP/PET composite material welding, anti-permeability reaches ISO 16603 standard, suitable for high-risk medical environments.

• Mask: Ear strap welding strength ≥10N, welding speed reaches 60 pieces/minute, meeting large-scale production needs.

Sanitary product production

• Diapers: three-dimensional guard welding strength ≥15N/15mm, elastic waist welding uniformity ≤±0.5mm, improve product fit and leak-proof performance.

• Sanitary napkins: back adhesive composite strength ≥8N/15mm, side wing welding width up to 30mm, ensuring product firmness and comfort.

• Wet wipes packaging: composite film welding strength ≥12N/15mm, heat seal width ≥5mm, excellent sealing, extended shelf life.

Industrial material composite

• Automotive interior: non-woven fabric and leather composite, welding strength ≥18N/15mm, meet VOC emission standards, improve the air quality in the car.

• Filter material: multi-layer filter material welding, pore size uniformity ≤±5μm, filtration efficiency up to 99.9%, suitable for air purification and liquid filtration.

• Packaging material: PE/PET composite film welding, heat sealing strength ≥10N/15mm, tear resistance increased by 30%, extending packaging life.

Textile and clothing processing

• Clothing lamination: seamless lamination process, welding width up to 10mm, waterproof performance up to 10000mmH₂O, suitable for outdoor clothing.

• Home textile composite: non-woven fabric and sponge composite, welding strength ≥12N/15mm, softness increased by 20%, enhancing product comfort.

• Shoe material processing: TPU film and cloth composite, welding strength ≥15N/15mm, wear resistance increased by 50%, extending the service life of shoe materials.

Electronics and new energy fields

• Battery diaphragm: multi-layer composite diaphragm welding, heat sealing strength ≥8N/15mm, ion conductivity ≥1.0mS/cm, improve battery performance.

• Photovoltaic backplane: PET/PVDF composite film welding, weather resistance up to 25 years, reflectivity ≥90%, enhance photovoltaic module efficiency.

• Electronic tape: conductive tape welding, resistivity ≤0.1Ω·cm, bonding strength ≥10N/15mm, meet the needs of precision electronics.

Daily cleaning and inspection

• Welding head cleaning: After daily production, wipe the surface of the welding head with alcohol to remove residual materials and avoid welding head wear.

• Pressure system inspection: Check the pressure gauge and gas line connection every week to ensure stable pressure and avoid welding defects.

• Vibration system detection: Use a vibration tester to detect the vibration frequency and amplitude of the welding head every month. Calibration is required when the deviation exceeds ±5%.

Maintenance of core components

• Transducer maintenance: Check the transducer impedance every quarter. When the impedance value exceeds 50Ω, it needs to be replaced to avoid a decrease in energy transmission efficiency.

• Amplitude transformer repair: Check the wear of the amplitude transformer every six months. When the wear depth exceeds 0.5mm, it needs to be repaired or replaced.

• Bearing lubrication: Add special grease to the transmission bearing every month to reduce friction and extend service life.

Electrical system maintenance

• Cable inspection: Check the power cord and signal line every month. Replace them immediately if they are damaged or aged to avoid short circuit risks.

• PLC program backup: Back up the PLC program every quarter to prevent data loss due to misoperation or failure.

• Grounding detection: Check the grounding resistance of the equipment every year to ensure that it is ≤4Ω to ensure the safety of operators.

Mechanical structure maintenance

• Guide rail lubrication: Add lubricating oil to the guide rail every week to reduce movement resistance and ensure the movement accuracy of the welding head.

• Tension wheel adjustment: Check the unwinding and rewinding tension wheels every month, adjust the tension to the standard value, and avoid material loosening or breaking.

• Frame tightening: Check the tightening of the frame bolts every quarter to prevent the structure from loosening due to vibration.

Environmental control and safety

• Temperature and humidity management: Keep the workshop temperature at 20-30℃ and the humidity ≤60% to prevent the transducer from getting damp or overheating.

• Dust prevention measures: Install dust screens and air filters, clean them regularly to prevent dust from entering the equipment.

• Safety protection: Equipped with emergency stop buttons and grating safety devices, and their sensitivity is tested regularly to ensure the safety of operators.