Ultrasonic welding in comparison and in body series production
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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.
Contents
- Thermocompression bonding and ultrasonic welding combination
- How ultrasonic welding reduces the ecological footprint
- Automated ultrasonic welding of small series of car bodies
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.
Tresky vertical technology guarantees stable and accurate coplanarity and parallelism over the entire Z-axis stroke, resulting in precisely bonded chips. "In combination with the force control, an excellent connection result can be achieved at any height, whereby decisive parameters such as force, temperature, power of the ultrasonic welding and process time can be individually programmed," 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's 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
In 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.
In 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.
Emerson Branson Welding and Assembly will be exhibiting at the K 2022.
Automated ultrasonic welding of small series of car bodies
29.01.2021/XNUMX/XNUMX | When tuning cars, it's either about an optical upgrade or more engine power. Only a few tuners optimally combine both, like globally recognized finishing companies do for upscale brands. 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.
The production of painted Body Attachments for the Automotive industry is one of the core competencies of Osbra Formteile GmbH. The system partner for solutions made of plastics produces bumpers, fenders, radiator covers, sills, diffusers, wheel extensions and other panels, among other things.
The uses of Osbra are in the areas Pkw and truck to find. Customers purchase high-quality components in the vehicle color. The interior and exterior molded parts from the sought-after supplier of small and medium-sized series are of such a quality that they make a decisive contribution to the refinement and customization of high-quality vehicles. For the finishing alone, Osbra built a hall with 2014 m² of production area in 1500.
All technologies offered can be carried out on site. In addition to CNC milling, stamping technology, hot stamping and other adhesive technology, ultrasonic welding also includes Joining technologies to. When it comes to ultrasonic welding, the molded parts specialist works with Maschinenbau Technologie Herrde, or MTH for short.
Switched to automated ultrasonic welding
Until 2018, Osbra still had the welding work on components such as radiator panels and wheel arch extensions manual work implemented. While this is a quality criterion in watch production or the furniture industry, appreciation in the automotive industry is different.
According to the Sebastian Ohler, Head of Finishing at Osbra, this also applies to the supplier industry. “Manual welding is not only significantly more time-consuming than automated, it is also not process-reliable. Since switching to the automated welding with ultrasound we have delivered over 100.000 welded wheel extensions and headlight masks. This step was exactly the right one to meet the high quality requirements of our customers with increasing quantities. "
Since Osbra did not have any expertise in special machines using ultrasonic welding until 2018, those responsible called in MTH. The machine manufacturer has been grateful for over 25 years Made in Germany as a proven partner for applications in joining and joining plastics in automotive production, Medical Technology, Industrial technology and textile industry.
With the series and special solutions from Henstedt-Ulzburg in Schleswig-Holstein, the plastic components can be processed quickly, easily and sustainably. One of the basis of MTH's success is Hand welders. Connected to an ultrasonic generator, the gun-shaped devices can be used to join the thermoplastic plastic parts using ultrasonic welding.
This is how ultrasonic welding with a sonotrode works
In the ultrasonic welding process, the introduction of high-frequency mechanical vibrations causes so-called Sonotrodes or tools set in resonance vibrations. The sonotrodes then transfer the vibrations to the workpiece under pressure, which generates frictional heat. Thanks to the sonotrode, the plastic parts briefly become viscous.
Self-driving cars from the perspective of an automotive supplier
The thermoplastic components have cooled down again exact connected with each other. The working principle is the same for special machines from MTH, but the joining of the plastics is fully automated according to specified parameters. In this way, a predefined number of welding points can be applied to the components fed into the system with millimeter precision in a short time.
Company founder Mathias Herrde familiar with the associated drive- And Control Technology also made in Germany. This prevents the parts from slipping. The weld is created with pinpoint accuracy even after hundreds of thousands of cycles.
Customized ultrasonic welding systems
With the individually manufactured ultrasonic welding systems, the highest requirements of the well-known German Premium automobile brands fulfill. A brand that has been known for first-class off-road vehicles for over 40 years has set the bar very high for suppliers in terms of quality and purchase quantities for the new wheel arch extensions and the radiator grille of a modernized successful series.
dr Thomas Freudenberg, Managing Director and majority owner of Osbra and his team wanted to break new ground in production. The automotive references from MTH ensured the necessary trust for the start of the new cooperation and also outweighed the 800 km distance between the two locations.
“The cooperation with MTH was what we had hoped for. Mr. Herrde and his team not only supported us with know-how, but were also able to respond to changes in the process within a very short time quality standards to react ”, says Sebastian Ohler.
Trust thanks to quality upon acceptance
Nachdem die Acceptance of the first system Ultrasonic welding was carried out by both companies on site in the far north, but this step was dispensed with for the second order and the ultrasonic welding system for the radiator cladding was delivered directly to the Allgäu by a forwarding agent.
Mathias Herrde remembers: “We gave everything that the Special transport could drive onto the A7 as early as possible here in Henstedt. When Mr. Ohler's team called 12 hours later that everything had arrived safely at the other end of the A7 and unloaded safely, we were overjoyed. "
Both ultrasonic welding systems have been running smoothly since commissioning Two or three shifts. “Due to some changes and new quality standards on the part of our customer, we gradually had to make some modifications to both machines. Thanks to the cooperation and support from MTH, these were carried out without any problems and could be implemented quickly, ”says Sebastian Ohler.
Former rally driver Mathias Herrde is also proud of them partnership: “We were able to show again that MTH not only sets standards in workshops for the repair of plastic components for manual welding devices. In addition to our special machines for the series production of engine compartment covers, airbag caps or glove compartments, the work of Osbra proves that with automated ultrasonic welding from MTH you are also in the first league when it comes to the refinement of luxury vehicles. "
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