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01 Fracture and damage defects are common phenomena
Ultrasonic plastic welding is one of the most popular plastic fastening processes.
However, during ultrasonic plastic welding, the internal ribs and pillars of the plastic parts often break, or the internal electronic components, crystals, and chip components fixed on the plastic parts are damaged by vibration. This is a very common phenomenon, and it is also one of the questions that people often ask.
Why did these ribs, pillars, electronic components, crystals, and chip components break when they were not in contact with ultrasonic welding heads or fixtures?
This leaves many engineers who are new to ultrasonic welding puzzled and may even make rough judgments that the product is not suitable for ultrasonic welding and needs to choose a more suitable fastening process.
This article will provide a systematic solution for ultrasonic welding fracture and damage based on experience and knowledge of ultrasonic welding.
02 Root cause of fracture and damage
To understand why it breaks and is damaged, it is necessary to understand the basic principles of ultrasonic welding.
Ultrasonic welding is essentially a high-frequency low amplitude vibration, with an amplitude generally ranging from 30um to 120um, or 0.03mm to 0.12mm, which is very small and visible to the naked eye.
However, the vibration frequency of ultrasonic welding is very high, commonly 15, 20, 30, or 40 kilohertz, which means it vibrates 15000, 20000, 30000, and 40000 times per second.
So, the vibration energy of ultrasonic welding is very large, and at the same time, the vibration energy is transmitted to weak positions of plastic parts, such as ribs and pillars, as well as electronic components, crystals, and chip components fixed on plastic parts, causing fracture and damage.
03 Overall direction for resolving fractures and damages
After understanding the root cause of fracture and damage during ultrasonic welding, we can start by addressing the issue accordingly.
The solution approach starts from the following three major directions:
1. Reduce energy during ultrasonic welding process
2. Increase the strength of plastic parts
3. Fragile components should be kept away from the welding area
The various solutions to solve fracture and damage problems from both the design and production ends are all approached from these three major directions.
