Ultrasonic Fabric & Film Systems and their Features - Dukane

Material Considerations

The fabrics and films best suited to ultrasonic processing contain thermoplastic materials with similar melting temperatures and compatible molecular structure. These materials have many of the following characteristics:

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• A broad melting range
• Uniform thickness
• A high coefficient of friction
• 65% min. thermoplastic content
• Sufficient rigidity and thickness to accept energy at the material interface (0. inch/0.mm minimum)

Polyester is considered to be a good material for ultrasonic applications. However, ultrasonics can produce strong, neat stitches in both Nylon 6 and Nylon 6/6. Most polyolefins (Polypropylene and Polyethylene) also have good ultrasonic welding characteristics and are one of the lightest weight materials. Characteristics of the most common thermoplastics and their typical fabric and film uses are listed below in order of preference.

Fabric Types and Films

Fabrics are classified into five categories as listed here; Films however have only one category.

Fabrics-Woven

Construction
Formed by the regular interweaving of filaments or yarns, in two directions perpendicular to one another.

Factors Influencing Weldability
Thread density, tightness of weave and uniformity of material thickness. Weld strength may vary due to the perpendicular orientation of filaments or yarns.

Fabrics – Nonwovens

Construction
Formed by bonding and/or interlocking fibers, yarns or filaments by mechanical, thermal or solvent means.

Factors Influencing Weldability
Uniformity of material thickness and thermoplastic content. The random orientation of fibers gives nonwovens excellent strength.

Fabrics – Knits

Construction
Formed by interconnecting continuous loops of filaments or yarns.

Factors Influencing Weldability
Thermoplastic content, style of knit and elasticity of material. Elasticity of knits may affect the trueness of the weld in continuous

Fabrics – Coated Materials

Construction
Fabrics and films covered with a layer of thermoplastic such as polyethylene or urethane. The base material need not be thermoplastic (e.g. coated cardboard)

Factors Influencing Weldability
Coating material and its thickness.

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Fabrics – Laminates

Construction
Fabrics and films consisting of two or more dissimilar layers in a sandwich form.

Factors Influencing Weldability
The mating surface should have a lower melting temperature than the other layers.

Films

Construction
Formed from the thermoplastic material which has been cast, extruded or blown into a film, generally under 0.01 inch (0.25mm) thick.

Factors Influencing Weldability
Film thickness, density and thermoplastic material characteristics.

Weldability

Many factors influence the weldability of the various fabric and film types. Please send in your material to our laboratory for free feasibility testing.

Ultrasonic Fabric Laminating Machine (Ultrasonic Bonding)

Description

Ultrasonic non-woven laminating machine adopts high-frequency ultrasonic vibrations that are transmitted into the nonwoven materials under pressure. These vibrations cause the contact points to melt and bond, creating a solid joint between the two parts, typically cloth and cloth, cloth and chemical fiber, plastic film and plastic film, and other materials such as cotton, nonwoven fabric, sponge, etc.

This ultrasonic lamination machine can be custom manufactured with various patterns tailored to customer preferences, and laminating size is customizable according to the material roll size.

(The machine is offered in various configurations tailored to customer’s specific needs, available in single roller, dual rollers, three rollers and four rollers. And the vibrator can be driven by mechanical system, pneumatic cylinder or hydraulic system.)

Applications

Materials: PVC tape, PE tape, EVA tape, PU latex leather, PP non-woven fabric, filter paper, nylon fabric, polyester fabric, pongee, Oxford cloth, polyester taffeta, TC fabric, and other materials containing chemical fiber;

Industries: artificial leather, non-woven fabric, thermoplastic film, chemical plastic sheet, knitting, printing, clothing lining, shoemaking, baby and adult diaper, changing mat, sanitary pad, seat cushion, non-slip mat, bulletproof vest, bedding and automotive filter material;

Features

(The machine is offered in various configurations tailored to customer’s specific needs, available in single roller, dual rollers, three rollers and four rollers. And the vibrator can be driven by mechanical system, pneumatic cylinder or hydraulic system.)

If you want to learn more, please visit our website ultrasonic machine.