1500W 20KHZ Ultrasonic Welding Vibrator Transducer For Plastic Toy Welding

Ultrasonic waves are transformed into mechanical vibrations through transducers. The characteristics of transducers depend on material selection and manufacturing process. The performance and service life of transducers of the same size and shape are very different. The commonly used high-power ultrasonic transducer is used in ultrasonic plastic welding machine, ultrasonic metal welding machine, various handheld ultrasonic tools, continuous working ultrasonic emulsifier, atomizer, ultrasonic engraving machine and so on. Commonly used products such as 15KHz 20KHz 28KHz 35KHz 40KHz 55KHz 70KHz can also design and produce non-standard transducers according to the special requirements of customers to meet all kinds of needs.

Ultrasonic welding is an industrial technique through which a very high-frequency ultrasonic acoustical vibrations are applied to the work pieces locally and which are being confined together under the influence of high pressure in order to develop a solid-state weld, mostly used for plastics. In other words, it is the joining or altering of thermoplastics via heat which is generated from high-frequency mechanical motion. Electric energy of high frequency is converted into mechanical motion of the same high-frequency to attain welding process. This mechanical motion along with the force which is applied generates frictional heat at the plastic components’ joining surfaces. This will enable the plastic material to melt and form a molecular bond amongst the parts.

Ultrasonic Welding Process

The ultrasonic welder machine will comprise of components such as – Transducer, Sonotrode and Anvil. The complete welding mechanism will include the following steps:

A stationary clamping force is put exactly perpendicular to the interface in between the work pieces.
Then the contacting sonotrode of the welder oscillates parallel to the interface.
This coalesced effect of stationary and oscillating force generates deformation which furthers welding.

Ultrasonic energy-concentrating transducers work in a similar way to cleaning transducers. They also use prestress to counteract the expansion stress of piezoelectric ceramics to achieve large amplitude ultrasonic vibration. Because the welding transducer requires a large amount of instantaneous power, it has a high demand for materials and processes, and is a high-power acoustic wave super energy device. Usually combined with the ultrasonic horn and the working head to form a high-power, large-amplitude vibration system to complete the ultrasonic welding of plastics, metals and other materials.
Ultrasonic welding uses the ultrasonic vibration generated by the transducer to generate high-frequency friction and heat on the surface of the gap to be welded in the compressed state, thereby achieving the purpose of thermal fusion welding. Ultrasound concentrating transducers are high-power ultrasonic transducers that operate in gaps or pulses. Generally, the instantaneous peak power is used to calculate the power.

Ultrasound Concentrating Transducer Features:
1. Low resonance impedance, high mechanical quality factor, high electro-acoustic conversion efficiency and large amplitude;
2, small heat, large temperature range; small performance drift, stable work;
3. Good material reliability and long service life of the transducer.

Attention to the use of ultrasonic concentrator:
1. The frequencies of the ultrasonic transducer, the horn and the tool head must match. Generally, the frequency of the horn and the tool head should be slightly lower than the frequency of the transducer; the connection surface must ensure vertical and flatness, and increase the torque Be appropriate
2. Welding of ultrasonic transducer electrode sheet should be reliable and covered with damping glue;
3. The operating temperature of the ultrasonic transducer should be lower than 60, and the input power should be lower than the rated power.

1500W 20KHZ Ultrasonic Welding Vibrator Transducer For Plastic Toy Welding