FAQs – Ultrasonic Technology

What is ultrasonic bonding?

Ultrasonic welding directs high-frequency vibrations at two components, which are clamped together. This creates a rapid build up of heat that produces a weld, or bond, in only a few seconds without significant melting of the base materials.

For bonding synthetic textiles or filter media, the fabric passes under a horn, which directs the ultrasonic vibrations through the layers. The materials are heated up and fused together, making a finished seam or sealed edge.

What are the advantages of ultrasonic welding?

No adhesives or consumables – such as solder or thread – are needed. The weld or bond is produced quickly – usually in two to four seconds – without heating the surrounding area. This process produces ultra-reliable, repeatably accurate welds and bonds. Ultrasonic welding is environmentally friendly, produces no waste, and is economical to use.

What industries use ultrasonic bonding?

Apparel, appliance, automotive, electronics, filtration, home furnishings, medical, and packaging are just some of the industries that can utilize ultrasonic welding.

What equipment configurations are available?

Sonobond produces both stand-alone units and models that can easily be integrated into production lines.

What are the components of an ultrasonic welding system?

  1. A POWER SUPPLY, which converts line power to the high frequency and high voltage needed by the transducer.
  2. A TRANSDUCER, containing piezoelectric crystals, which changes the incoming high frequency electrical signal to mechanical vibration.
  3. A BOOSTER, which transmits the vibration energy and increases its amplitude.
  4. A HORN, which delivers the vibration energy to the weld area.
  5. AN ANVIL or NEST, which supports the parts to be welded.

Are there any health issues or hazards related to ultrasonic welding? What are the effects of ultrasonics on health?

This issue has been the subject of many studies that prove ultrasonic bonding to be safe and reliable.  In a few cases, there may be a problem with excessive noise caused by ultrasonic vibration.  In situations where noise levels exceed OSHA limits, the problem can be remedied by installing an enclosure and/or by using personal hearing protection.

Do you have the capability to produce custom machinery?

Yes.  Sonobond’s technical engineers can work with you to produce the best version of an ultrasonic machine or customer tooling for your specifications.

Does the ultrasonic equipment disturb other computerized devices installed nearby?

Very rarely.  In a few especially sensitive environments, it may be necessary to suppress EMI emissions.

Do you provide free sample welds?

Yes. Sonobond actually encourages you to send in parts so we can provide welding samples of your specific application and recommend the best unit for your needs.