How does it work?

Ultrasonic waves are generated in the generator and converted into mechanical vibrations in the converter. These are introduced into the material through ultrasonic welding electrodes. The standard frequency here is between 20 and 35 kHz, with an amplitude of 10 to 50μm. The plastic part of the material is stimulated, heated, and melted. The actual welding process is fast: due to the use of rotating tools such as anvil drums, up to 800 meters of non-woven fabric can be processed per minute. The anvil drum is used as an anvil and has a separate surface structure to precisely focus ultrasonic energy. This can achieve precise welding, embossing, or cutting effects.

A constant distance between the processed material and the tool is important for achieving optimal results. This is ensured through precise control technology. It ensures that the distance remains constant, even if the welding tool changes due to the heat generated during the welding process.

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Welding/cross sealing

Non woven fabrics can also be welded with cross sealing. Like longitudinal sealing, the welding head works in a fixed position and does not move up or down. The rotating anvil is a unique feature. It ensures that the non-woven fabric is in contact with the ultrasonic welding electrode at the correct position and is only welded there in the transverse direction. For example, this is used for the side seams of diapers.

Unlike longitudinal sealing, the structure on the rotating anvil means that the non-woven fabric is only locally connected. The advantage of doing so is that due to many target connections, the material properties remain unchanged. For example, the filtering function is not affected and the material remains elastic.

Embossing

During the embossing process, non-woven fabrics (such as cotton pads) have a unique structure that is pressed into them. This is accomplished by the anvil drum. The special characteristics of materials with different colors: the color of the lower track can be seen at the welding point. A design effect, such as a logo - without the need for additional color printing.

Perforation

Non woven fabrics can also be punched according to specified patterns. Materials can be lightly perforated using ultrasound and anvil drums, for example, in the case of wound dressings and ointments.

Cutting

Ultrasonic tools can even cut. Meanwhile, the cutting edge is sealed. For example, this is used to produce disposable gloves.

The advantages of seamless welding

Low energy cost, ultrasonic seamless sewing tools do not require heating

No adhesive pollution - saving processing and maintenance costs

Production speed up to 800 m/min, reliable welding quality

Manufacturing technology for high-quality products with consistent material properties and optimal hand feel

High stability: When using ultrasonic seamless sewing, the rotation of the welding roller and the pressure roller is completely

synchronized, with no difference in speed and angle, which will not cause fabric stretching or deformation, and the accuracy is extremely high. Due to the hot melt effect, needles and threads are not required, resulting in increased water resistance, lighter weight, and easier folding of the product.

Welding and cutting synchronization: Ultrasonic seamless sewing equipment is not only suitable for continuous sewing, but also for cutting textiles while welding, achieving automatic edge sealing.

Controllable welding: Welding rollers and pressure rollers pull the fabric, and ultrasonic welding of the fabric. Replacing the pressure roller can change the size and embossing of the weld seam, making it more flexible and convenient to use.

Widely applicable: All thermoplastic (softened after heating) fabrics, specialized tapes, and films can be welded using ultrasonic seamless sewing equipment, and the rollers are made of quenched steel to extend their service life.

Female hygiene products

Join the surface layer and guide layer together at high speed. Ultrasonic vibration energy is inputted into the welding point position in a targeted manner to achieve optimal wearing comfort. When fixing the sanitary napkin wings or attaching textile edges, ultrasound can ensure both the firmness and softness of the product.

Makeup and care

Forming welding technology is required in the production of disposable gloves of different styles. The most basic requirements for the product are smoothness, softness, no hard edges, and strong interlayer adhesion. Ultrasonic cutting can achieve no burrs and a clean and tidy cut surface. In addition, when using ultrasonic embossing, the soft surface will not be damaged.

Baby hygiene products

Ultrasonic waves can be applied in every step of diaper production: using ultrasonic waves to achieve multi-layer composite, bottom layer, and three-dimensional leg protection welding; Use ultrasound to intermittently fix the ear and fastening system. All ultrasonic working steps in diaper production are the same, with the aim of creating a good tactile sensation and ensuring the sealing of the diaper