20k 2600W Ultrasonic plastic welding machine for SD Card

Working Principle
The ultrasonic plastic welding machine uses high-frequency vibration waves to transmit to the two plastic surfaces to be welded. Under medium pressure, the two plastic joint surfaces are subjected to intense friction due to the action of ultrasonic waves. The friction heat causes the plastic joint surfaces to melt rapidly, thereby achieving the purpose of fusion in a very short time. The welding strength can be equivalent to the body. Through suitable workpieces and reasonable interface design, water tightness and air tightness can also be achieved.
Features
High welding accuracy: The frequency of 20kHz is suitable for welding precision, ultra-thin, and very fragile plastic parts. It can meet the welding accuracy requirements of small precision electronic products such as SD cards, ensuring that the shell of the SD card is firmly welded and has a beautiful appearance, while not causing damage to the precision electronic components in the card.
High welding strength: The power output of 2600W can provide enough energy to make the plastic shell of the SD card have a higher strength after welding, and can withstand a certain external force impact and pulling, ensuring the sealing and durability of the SD card.
Non-contact welding: Ultrasonic welding does not require the use of additional adhesives or other auxiliary materials. It is a non-contact welding method, which avoids the pollution problems caused by the use of materials such as glue, and will not have adverse effects on the electronic performance of the SD card.
High degree of automation: Equipped with advanced control systems, it can realize automated operations, such as automatic frequency tracking, automatic power adjustment, etc. The automatic frequency tracking function can track the changes in ultrasonic frequency in real time to ensure the stability of the welding process; the automatic power adjustment function can automatically adjust the output power according to the different welding materials and welding parts to improve the welding quality.
Application advantages
High production efficiency: It can quickly complete the welding process of SD cards, greatly improve production efficiency, and is suitable for large-scale SD card production. Generally speaking, a 20k 2600W ultrasonic plastic welding machine can complete the welding of multiple SD cards per minute.
Stable product quality: Since the welding process is precisely controlled by the machine, the quality of each welding is relatively stable, reducing the problems of loose welding and cold welding that may occur in manual welding, and improving the yield rate of SD card products.
Energy saving and environmental protection: Compared with other welding methods, ultrasonic plastic welding machines do not need to consume a lot of energy during operation, and do not produce harmful gases and waste, which meets environmental protection requirements.
Applicable scenarios
SD card assembly: In the production process of SD cards, it is used to weld the upper and lower shells of SD cards to form a complete sealed shell to protect the internal chips and circuits.
SD card repair: For some SD cards with damaged shells, ultrasonic plastic welding machines can be used to repair them, re-weld the damaged shell parts firmly, and restore the normal use of SD cards.

Applications:

Ultrasonic welding is most effective with certain types of thermoplastic materials. Here are the plastics best suited for ultrasonic welding:

Best Suited Plastics

Polyethylene (PE):Types: Low-Density Polyethylene (LDPE) and High-Density Polyethylene (HDPE). Characteristics: Good chemical resistance, flexibility, and low melting point make them ideal for ultrasonic welding.

Polypropylene (PP):Characteristics: High fatigue resistance, lightweight, and good chemical resistance. It also welds well due to its relatively low melting temperature.

Polyvinyl Chloride (PVC):Characteristics: Widely used in packaging and construction, PVC can be welded effectively, especially when using the right formulations.

Polystyrene (PS):Characteristics: Easy to weld, polystyrene is commonly used in packaging materials and disposable items.

Acrylic (PMMA):Characteristics: While more challenging to weld than some other plastics, acrylic can be joined using ultrasonic methods, particularly in thin sections.

Thermoplastic Elastomers (TPE):

Characteristics: These materials combine the properties of rubber and plastic, making them suitable for ultrasonic welding in applications requiring flexibility.

Beverage Bottles: Joining plastic parts, creating leak-proof seals.
Grading Cards: Attaching layers or laminates, ensuring durability and a secure bond.

Parameter

Description

Ultrasonic plastic welding is the joining or reforming of thermoplastics through the use of heat generated from high-frequency mechanical motion. It is accomplished by converting high-frequency electrical energy into high-frequency mechanical motion. That mechanical motion, along with applied force, creates frictional heat at the plastic components’ mating surfaces (joint area). This allows the plastic material to melt and forms a molecular bond between the parts.

Material Consideration
To bond two thermoplastic parts, it is necessary that the materials be chemically compatible. Otherwise, even though both materials may melt together, there will be no molecular bond.

A good example would be trying to weld polyethylene to polypropylene. Both of these semi-crystalline materials have a similar appearance and many common physical properties. However, they are not chemically compatible and are therefore unable to be welded to each other.

Like thermoplastics (i.e., materials with the same chemical properties) will weld to themselves. For example, one ABS part will weld to another ABS part.

Dissimilar thermoplastics may be compatible only if their melt temperatures are within 40ºF (6ºC) and they are of like molecular structure. For example, it is likely that an ABS part could be welded to an acrylic part because their chemical properties are compatible.

Generally speaking, only similar amorphous polymers have an excellent likelihood of being welded to each other. The chemical properties of any semi-crystalline material make each one only compatible with itself. When the materials to be welded are compatible, several other factors may affect the adhesive bonding of the parts. These factors include hygroscopicity, mold release agents, lubricants, plasticizers, fillers, flame retardants, regrind, pigments, and resin grades.

Features

1. The transducer adopts self-developed high-performance transducer with stable performance.
2. Matching Taiwan Airtec cylinder, with strong power and good stability.
3. The first dovetail groove design of the square column increases the rigidity of the mechanism, prevents backwards, and ensures the consistency of product welding. Improve welding precision.
4. Suitable for power output, suitable for welding small-sized and high-precision products, with good welding effect.
5. Alloy layer welding mold, not easy to wear, strong and durable.
6. Unique horizontal screw design, mold debugging is simple and convenient.
7. Welding limit system, the workpiece will not overflow after welding.
8. Automatically chase the frequency when starting up, without manual frequency adjustment, and automatically detect frequency abnormalities.
9. Intelligent protection, when the equipment fails, it will automatically alarm and prompt, the machine will be locked into the protection state, and then enter the working mode after the fault is cleared.
10. Dual boot mode, better protect your personal safety.

How does ultrasonic welding compare to other plastic joining methods?

Ultrasonic welding is one of several methods used for joining plastic materials, each with its own advantages and disadvantages. Here’s a comparison of ultrasonic welding with other common plastic joining methods:

1. Ultrasonic Welding vs. Adhesive Bonding

Speed: Ultrasonic welding is much faster, often completing welds in seconds, while adhesive bonding requires curing time, which can slow down production.
Cleanliness: Ultrasonic welding does not require adhesives, resulting in a cleaner process with less waste. Adhesive bonding can introduce contaminants and require additional cleanup.
Strength: Ultrasonic welds typically provide stronger, more durable joints than adhesive bonds, especially in high-stress applications.
Material Compatibility: Adhesives can bond a wider variety of materials, including different types of plastics and other substrates, whereas ultrasonic welding is best suited for thermoplastics.

2. Ultrasonic Welding vs. Heat Staking

Process Time: Ultrasonic welding is generally faster than heat staking, which involves heating a metal component to melt a plastic part and create a joint.
Precision: Ultrasonic welding offers higher precision and control over the welding process, whereas heat staking can result in more variability in joint quality.
Material Limitations: Heat staking requires specific designs and can be limited in terms of the types of plastics that can be joined compared to ultrasonic welding.

3. Ultrasonic Welding vs. Laser Welding

Speed: Both methods are fast, but ultrasonic welding can be quicker for certain applications where immediate contact is required.
Joint Configuration: Laser welding is often better for complex geometries and transparent materials, while ultrasonic welding excels in straightforward assemblies and thicker materials.
Heat Affected Zone: Ultrasonic welding typically has a smaller heat-affected zone than laser welding, which can help preserve the integrity of sensitive components.

4. Ultrasonic Welding vs. Spin Welding

Joint Strength: Ultrasonic welding generally produces stronger joints than spin welding, which relies on friction to generate heat.
Material Thickness: Spin welding is often used for thicker materials, while ultrasonic welding is more suited for thinner sections.
Application Range: Ultrasonic welding is versatile and can be used for a wider range of materials and applications compared to spin welding.