When connecting from Plastics that sits down Ultrasonic welding increasingly common in many sectors. It's safe, efficient, energy saving, accurate, eco-friendly, sustainable and more. Here we present innovations such as a new process in combination with the Thermosonic bonding. Or read about how it compares to what has been predominantly used up to now heat sealing performs and how it improves the quality of the connection of critical plastic parts in the body fabricationg ensures.
Content
- Thermocompression bonding and ultrasonic welding combination
- How ultrasonic welding reduces the ecological footprint
- Automated ultrasonic welding of small series of car bodies
- Ultrasonic cutting and welding of respirators
- Control software for welding and ultrasonic welding
- Ultrasonic welding of lids of resealable beverage cans
Thermocompression bonding and ultrasonic welding combination
12.01.2023/XNUMX/XNUMX | With ultrasonic welding, the temperature and bond pressure can be reduced. This improves the bonding process, from which semiconductor production in particular benefits. For example, solder-free bonding enables flip-chip bonding Die-to-Die Bonding Technology Area Array Connections. This technique connects arrays of gold bumps located on the underside of an IC to gold-plated pads on a substrate. This simple, dry and clean assembly uses thermocompression bonding.
The Thermosonic bonding (TSB) begins with a substrate placed on a heated platen and held in place by vacuum. The chip is held by a pick-and-place tool with a die collet designed for thermosonic bonding applications. As soon as the Tresky pattern recognition has aligned the chip to the substrate, the gold stud bumps are contacted with the substrate. When the required adhesive force is reached, the current from the ultrasonic welding is applied for a defined period of time.
The Tresky Vertical technology guarantees stable and precise coplanarity and parallelism over the entire stroke of the Z-axis, which enables the production of precisely bonded chips. "In combination with the force control, an excellent bonding result can be achieved at any height, with key parameters such as force, temperature, ultrasonic welding power and process time being individually programmable," assures Daniel Schulze, Managing Director of Tresky GmbH.
In addition to an IP collet, the use of an additional one is an option channel collet when the tool access is restricted or it has to be lined up by two sides of the chip. Factors such as the cyclic movement of the collet during the US process, the sensitive chip surface and heat transfer indicate whether a collet is suitable for the TSB. The new thermosonic bonding allows the use of US power and collets, with which an excellent connection between chip and substrate can be implemented.
How ultrasonic welding reduces the ecological footprint
11.10.2022 | 
Welding or heat sealing has been used for fastening, connecting and assembling plastics since the 1950s to this day generally accepted connection technology. But is it environmentally friendly enough and suitable to reduce the CO2 to reduce footprint?
Patrick O'Sullivan, Product Specialist at Emerson, Branson Welding and Assembly recommends ultrasonic welding instead: "Ultrasonic welding has been around since the 1960s, almost as long. It is reliable and fast."
Advantages of Ultrasonic Welding
In addition, ultrasonic welding offers in terms of Sustainability many advantages. And these are the following:
- fewer power consumption
- fewer Plastic material for a reliable closure
- more efficient sealing from organically produced and recycled materials
- less waste
- save adhesives, solvent or other consumables required.
Taken together, ultrasonic welding of an assembly line results in a um 25% reduced CO2 Footprint.
Comparison of heat sealing and ultrasonic welding
At the heat sealing the surfaces of the components are held together. Heated sealing bars are applied to one or both sides. The heat flows (conduction) from the strips through the material to the sealing surface. Here the touching surfaces melt to form a bond. Controlling conduction sealing is simple: the welder selects temperature, pressure and dwell time based on the melting properties of the plastics being joined.
At the Ultrasonic welding heat and pressure are generated and used differently. Vibration with precise frequency and amplitude creates heat between the surfaces of the thermoplastic layers. The parameters force, pressure and speed are checked and the welding results are optimized based on the results. The frictional heat melts the interior of these surfaces. The permanent connection is created under the pressure.
Comparison of energy consumption ultrasonic vs. heat sealing
Because the heat required for heat sealing is generated by a resistance heated bar, the welding elements maintained at operating temperature 100% of the time. This creates a lot of heat, which is not only transferred to the welding zone, but also to the area around the sealing device and is basically lost.
Ultrasonic sensors for distance, distance and level
In the case of ultrasonic welding, on the other hand, the heat is high frequency friction generated and the sealing is completed in just 100 ms. Except during this brief period, the tool remains cool. Much more energy is required for resistance heating than for generating the ultrasonic vibrations. Table 1 shows a savings potential of 25% in power consumption.
Comparison of material consumption ultrasonic welding vs. heat sealing
In general, to ensure a quality seal, heat sealing uses a 0,5 inch weld generated. Suppose a package has a 0,5 inch weld at the top and bottom. Then a full inch of material (2,5 centimeters) is used for the weld area alone.
On the other hand, two comparable ultrasonic welds require only 0,25 inches of the overall length of the package (0,125" each at the top and bottom), saving 0,75" (1,9 cm) per package. Table 2 shows the possible material savings using a 6-inch (15 cm) bag as an example.
Other important factors
Heat-sensitive, bio-based and recycled materials: For heat-sensitive materials, to which Biopolymers based on non-fossil source materials and some recycled materials, the high temperatures and longer cycle times involved in heat sealing can lead to material damage. This problem does not exist with the ultrasonic technology, since the heating is minimal and short-term and can be controlled very precisely by the welding controller.
Less waste: Unlike heat sealers, ultrasonic welders are not affected by contamination on the weld surface. Product residues or residual oils that are in the welding area during the filling process are pressed out when the packaging is compressed and ultrasonic energy is applied. Heat sealing can compromise the integrity of the seal. In this case, the entire packaging and its contents must be discarded.
Ultrasonic compared to adhesives: So far in this article we have covered the differences between ultrasonic welding and heat sealing. However, if we want the sustainability of the ultrasonic sealing process and its total CO2-Looking at footprint, it makes sense to look at another commonly used sealing method, the use of adhesives and solvents. Ultrasonic technology does not require any additional consumables. In addition, the handling of solvents - sometimes used to bond plastics or to clean adhesive applicators - inevitably poses a significant environmental problem that should be avoided whenever possible.
Infrared heater for efficient heat processes in industry
Ultrasonic welding clearly offers important environmental and sustainability advantages over heat sealing and other techniques. However, it is not always clear from the outset which technology represents the ideal solution for a specific manufacturing application. Emerson and its Branson brand (TM) for welding and assembly systems provide support and help in decision-making.
Automated ultrasonic welding of small series of car bodies
29.01.2021 | Tuning cars is either about improving the appearance or increasing engine performance. In a cooperation with osbra Molded parts succeed by means of Ultrasonic welding from MTH the high-quality and automated connection of the critical plastic components.
Ultrasonic cutting and welding of respirators
13.05.2020 | Many companies are becoming newcomers to the mass production of Respirators, With the Ultrasonic cutting and welding Technology, respiratory masks can be mass-produced in a particularly resource-saving manner. Telsonic has adjusted to the current situation. The specialist in ultrasonic cutting and welding offers tailor-made equipment for the production of respiratory masks with significantly reduced delivery times.
Respiratory masks consist of different layers of fleece and cover material, depending on the application. Flat blanks are the starting product for the masks. They have to conform to a certain shape and be on the cut edges. Both can be implemented in one operation using ultrasound technology.
This is how ultrasonic cutting and welding work
A Form die and a tool that vibrates at ultrasonic frequency, contour parts are cut. The edge zone in the cutting area is simultaneously sealed by heating. Openings for valves or passages for looping carrying straps can also be quickly created with clean cut edges using the cutting and welding process.
No residue forms on the blade, the process is practically wear-free and requires little energy without additives such as B. Glue. In addition, the cycle times for ultrasonic cutting and welding are extremely short. The modular ultrasonic components from Telsonic can be integrated very flexibly into automatic production lines.
The Control software The ultrasound system offers various trigger functions and welding modes. With multi-level amplitude and force profiles, all cutting, separating, welding and joining operations in protective mask production can be covered in high quality - from cutting and sealing the cut edges to welding the breathing valve and fixing nasal bridges and carrying straps.
Control software for welding and ultrasonic welding
04.09.2018 | Telsonic presents the new control software “Telsoflex” with a new 12” touch panel for welding and cutting with ultrasound, which makes the ultrasound systems of the USP and TSP series fit for Industry 4.0.
For example, the panel screen can be transferred to a workstation outside of production and can be fully operated from there. The user sees the real-time data from production, can access welding results, save data on network drives or other storage media and load data sets into production manually or automatically. Multiple welding systems can also access the same data sets. Integrated support options also offer a high degree of security when quick help is needed.
The entire process cycle is controlled by the Control software monitored and the status is displayed graphically. With just a few clicks, welding parameters can be adjusted, multi-stage welding modes defined or peripherals set up, i.e. anvil, film transport, sound insulation, workpiece detection, clamping, stop, etc. Various counters for the number of pieces, stacks or batch sizes ensure the correct production quantity. User and rights management can be adapted to your own needs. The modular structure of the software also covers the user's desire for individualization.
Ultrasonic welding of lids of resealable beverage cans
23.11.2017 | In order to avoid any problems with the resealable lids for Xolution developed beverage cans the plastic components of the opening mechanism with the Aluminium of the lid, it was necessary to find a joining process that works quickly and precisely and enables short cycle times for high throughput rates. After extensive testing, the choice fell on ultrasonic welding systems from Telsonic.
Source: This article is based on information from the following companies: Emerson, MTH, Telsonic, Tresky.
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