Portable Auto Sound Absorbing Cotton Welding 28Khz Ultrasonic Riveting
What’s the principle of Ultrasonic plastic welding?
When ultrasonic act on the thermoplastic plastic contact surface, high-frequency vibrations of tens of thousands of times per second. This high-frequency vibration reaches a certain amplitude, and the ultrasonic energy is transmitted to the weld zone through the upper weldment, because the weld zone have a large acoustic resistance, so local high temperatures are generated. Moreover, due to the poor thermal conductivity of the plastic, it can not be dissipated in time and gather in the weld zone, so that the contact faces of the two plastics melt rapidly, and after a certain pressure, they are integrated into one. When the ultrasonic wave stops, let the pressure last for a few seconds to solidify it, thus forming a strong molecular chain for welding purposes, the welding strength can be close to the strength of the raw material. The quality of ultrasonic plastic welding depends on the amplitude of the transducer welding head, the applied pressure and the welding time. The welding time and the welding head pressure can be adjusted. The amplitude is determined by the transducer and the horn. These three quantities have a suitable value for each other. When the energy exceeds the appropriate value, the melting amount of the plastic is large, and the welding material is easily deformed; if the energy is small, the welding is difficult, and the applied pressure cannot be increased. This optimum pressure is the product of the length of the side of the welded portion and the optimum pressure per 1 mm of the edge. Ultrasonic welding is a high-tech technology for welding thermoplastic technology. Various thermoplastic rubber parts can be processed by ultrasonic welding without adding solvent, adhesive or other auxiliary products. The advantage is to increase productivity and reduce cost. improve product quality.
This Portable Auto Sound Absorbing Cotton Welding 28Khz Ultrasonic Riveting is customized for customer customer, it is equiped with Titanium alloy horn , horn design for auto Sound Absorbing Cotton application. we can customize all kind horn for any customized depending on your requirements or your application information.
Parameter
Item | Parameter | Advantage: | Application |
28Khz ultrasonic hand welder Straight type | ▪ 28Khz 800W ▪ Digital generator ▪ Horn customized ▪ Aluminum alloy&Steel & Titanium alloy ▪ Power Supply: 220v 50/60HZ | 1. light generator ,light hand welder.The generator 120*120*380, whole weight5KG, with generator 4kg, and the 28Khz hand welder 1kg, 35Khz hand welder 0.8kg. Suit for hand operate. 2. Special alloy metal housing, the housing of the hand-welder is light but firm, not easy to be deformed, longer it’d using life. 3. Digital generator, it can tracking the frequency itself, easy for operate. Output /welding time adjustable, suit for both hand operate and machine operate. | PP PVC Fabric woven PE ABS PS Nylon PU PET All Thermoplastic material, the thickness 8mm in max. Straight type suit for both hand /machine operate. Gun type suit for hand operate. |
28Khz ultrasonic hand welder Gun type |
35Khz ultrasonic hand welder Straight type | ▪ 35Khz 500W ▪ Digital generator ▪ Horn customized ▪ Aluminum alloy&Steel & Titanium alloy ▪ Power Supply: 220v 50/60HZ | PP PVC Fabric woven PE ABS PS Nylon PU PET All Thermoplastic material, the thickness 5mm in max. Straight type suit for both hand /machine operate. Gun type suit for hand operate. |
35Khz ultrasonic hand welder Gun type |
For better application , it is better share all the material information with me, the material, thickness, operate way, speed requirements before order . We also supply 20Khz 40Khz ultrasonic hand-weld welder. |
1. Optimized Ergonomic & Industrial Structural Design
Handheld Body & Air Cooling Design
Our spot welding gun adopts integrated lightweight air-cooled architecture specially customized for long-duration manual operation. The built-in circulating air channel wraps the transducer assembly fully, continuously dissipating heat generated during continuous spot welding, effectively solving the overheating protection issue of ordinary non-air-cooled hand-held guns after long working hours.
The grip is ergonomically curved with anti-slip wear-resistant coating, reducing wrist fatigue for workers during repetitive spot welding on automotive plastic parts, harness terminals and interior accessories. Internal wiring adopts fully shielded aviation connectors, which are dust-proof, moisture-proof and anti-interference, stable for workshop complex environment.
Intermittent Wave Control & Position Sensor Matching Structure
The gun body reserves standard sensor mounting interface to realize intermittent wave emission function: ultrasonic energy only outputs when the welding head presses down to the preset position, and stops vibration immediately when lifting off workpieces. This design avoids unnecessary idle vibration, lowers transducer fatigue loss and reduces energy consumption.
Compact split layout separates the generator from the handheld gun, the lightweight gun head realizes flexible operation for narrow space workpieces such as automobile door buckle, instrument panel plastic parts and wiring harness connectors.
Shock-absorbing Assembly Structure
We add multi-layer high-temperature shock-absorbing gaskets between the transducer and gun housing. It isolates strong vibration transmitted to the operator’s hand, greatly improving operation comfort, and also prevents loose internal components caused by long-term vibration, extending the whole machine service life.
2. High-performance Transducer Material Advantage
High-purity Piezoelectric Ceramic Core Chip
The core vibration component of our transducer uses high-density imported piezoelectric ceramic wafers with consistent dielectric parameters, narrow capacitance tolerance range, stable resonant frequency with little drift. Under continuous high-power output, the ceramic chip will not crack, age or produce obvious power attenuation. Compared with low-cost mixed ceramics, it maintains stable vibration output for thousands of hours of industrial spot welding.
Aviation-grade Rear Cover & Vibration Transfer Metal
The transducer front and rear metal blocks are forged with high-strength aluminum alloy, featuring excellent vibration conduction rate and low energy loss. The pre-tightening torque of each transducer is precisely calibrated by automatic equipment, which avoids stress concentration inside ceramics caused by uneven compression, eliminating abnormal noise and weak welding strength problems.
All internal insulation layers are made of high-temperature resistant insulating film, effectively preventing electric leakage and short circuit in humid, oil-stained auto workshop environment.
Complete Sealed Anti-corrosion Housing (Optional)
We provide two transducer versions: casing-free and full sealed housing with aviation plug. The sealed shell isolates dust, cutting fluid and volatile corrosive gas in auto workshops, protecting internal ceramic components and greatly reducing failure rate in harsh production lines.
3. Premium Tool Tip (Sonotrode / Welding Horn) Material Advantages
TC4 Medical & Industrial Grade Titanium Alloy Forging
All standard spot welding tool heads are integrally forged from TC4 titanium alloy, which meets industrial welding material standards. Titanium alloy features ultra-high fatigue resistance to high-frequency 35kHz / 40kHz vibration, far longer service life than aluminum or steel tool heads that are prone to wear and crack.
It has outstanding thermal conductivity and low heat accumulation during spot welding, avoiding burning, melting or discoloration of automotive plastic workpieces such as PP, ABS and nylon plastic fasteners.
Custom Hardened Surface Treatment
We carry out special hardening treatment on the welding contact surface of titanium tool tips. The surface hardness is significantly improved, resisting abrasion and indentation when repeatedly pressing hard plastic and thick wiring harness terminals, so the welding pattern remains clear and consistent mass welding strength is guaranteed.
Integrated One-piece Molding, Uniform Amplitude Distribution
The tool head is processed by one-piece CNC precision machining without welding splicing. The internal vibration transmission path is smooth with no amplitude attenuation dead zone. Even on small contact welding points, the ultrasonic energy distribution is uniform, which effectively prevents virtual welding, weak pulling force and uneven welding marks on auto parts.
We support customized irregular special-shaped tool heads according to customer’s product contour, matching complex curved automotive interior plastic parts spot welding requirements.
Full Summary of Comprehensive Advantages
Combining humanized air-cooled gun body design, stable high-quality piezoelectric transducer assembly and durable TC4 titanium alloy welding tool tips, our ultrasonic spot welding gun delivers stable welding strength, long service life and comfortable operation for mass automotive manufacturing. It effectively reduces defective rate, maintenance frequency and comprehensive production cost for customers.
