Glossary of terms
Adhesive bonding: the ultrasonic system is used to activate an adhesive on a tape thereby permitting the joining of parts that are not usually considered weldable with ultrasonics alone.
Anvil: the backup piece that positions and supports the parts being welded.
Booster: adjacent to the converter the booster increases the amplitude of vibration
Converter: (transducer) contains piezoelectric crystals that convert the high frequency electrical signal to mechanical vibration
Clamping force: the force exerted on the part being welded by the action of the pneumatic cylinder.
Distance measurement: requires a distance measuring device (usually an LVDT) in the welder head, Can measure pre-weld height and the compression of the part as it is welded.
Electro-pneumatic regulator: A pressure regulator that can be controlled by an electrical signal or also can produce an electrical signal proportional to the air pressure it contains.
Energy: Product of the power and the time of application, usually expressed in watt-seconds or joules.
Horn: delivers the vibration to the parts being welded.
Kilohertz (kHz): frequency of the signal. One kilohertz is one thousand cycles per second.
Kilowatts (kW): the power rating of the system. One kilowatt is one thousand watts.
Lace and pattern making: Patterned trim can be made on synthetic fabrics by the action of the ultrasonic system and a special rotary pattern roller.
LVDT: linear voltage displacement transducer..a device used to measure displacement or compression, the distance moved from a set point. For instance the LVDT produces a voltage proportional to the distance moved from the time the horn contacts the parts to the end of the weld cycle. This voltage is then calibrated to give an actual distance measurement.
Pattern roller: for rotary textile bonding the pattern roller embosses or cuts a pattern or stitch and backs up the film or fabric being bonded.
Power supply: Plugs into line power and changes the electrical signal to the high frequency, high voltage needed to drive the system. Also called Generator or Frequency Converter.
Plunge Welding/cutting: welding, or cutting, action takes place in a single pulse. The bond area or cut pattern is determined by the size and shape of the horn and anvil.
Seam welding: continuous seam welds are produced when a roller is rotated and traversed across the material to be bonded while ultrasonic energy is applied.
Shear mode or motion: The vibration direction is parallel to the plane of the parts being welded generating a shear mode or motion at the interface, essential when welding metals ultrasonically.
Sonotrode: the ultrasonic welding tip.
Splicing: term used for joining materials such as metal foil or wire to wire welds.
Spot welding: spot welds may be circular, elliptical, rectangular, annular etc in geometry. They are formed when the material is clamped between the shaped tip and anvil and ultrasonic energy is applied.
Ultrasonic: A frequency above the normal hearing range, generally accepted to be above 17kilohertz. And typically 20kHz or higher.
Ultrasonic bonding/welding: The use of high frequency vibratory energy combined with pressure to effect a bond or weld in plastics, synthetic textiles or certain metals.
Wedge-reed: Used for metal welding machines Sonobond’s wedge shaped horn has a reed or rod through it which provides the shear mode vibration and has a taper cavity to hold the welding tip or sonotrode.
Weldable materials: Textiles and plastics may be bonded if the materials are thermoplastic and compatible materials are to be joined. Weldable materials include polyester, polyethylene, polypropylene, acrylics, nylon, polycarbonate, acetate, ABS etc.
Weldable metals are usually non-ferrous alloys typically copper and aluminum alloys. Part configuration can be sheet metal or wire to wire or wire to terminal, also tubing up to 3/8-inch (9mm) diameter can be sealed without crimping and brazing.
Weldable wires include solid or stranded wires (usually fine strands of copper wire bundled together in a single protective insulating covering ).