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In plastic ultrasonic welding, the molecules form new cross links
Ultrasonics activates the plastic molecules – friction heat is generated

Laminating of nonwoven materials using ultrasonics

The general principle of ultrasonic welding can also be applied to nonwoven materials. The thermoplastic fibers are activated by mechanical vibrations thus melting and bonding in pre-defined patterns. A weld tool, referred to as Sonotrode, transmits the vibration into the nonwoven material. In industrial applications, ultrasonic frequencies between 20 and 35 kHz are common, with amplitudes (tool travel distances) of 10 µm to 50 µm. Processing of nonwoven materials is often performed in continuous processes at high web speed. By application of rotary tools, it is possible to achieve processing speeds of up to 800 meters/minute. A specifically engraved drum is used as welding, embossing, or cutting anvil. The contour of the anvil drum focuses the energy and precisely defines the weld spots required for the respective product.

Basics

Ultrasonic joining of nonwoven materials is particularly suitable for:

  • Laminating of various layers
  • Embossing
  • Separating and seaming of edges
  • Perforating of web material

Beim Verschweißen von Bahnware geht es darum, den Abstand zwischen Material und Sonotrode konstant zu halten. Denn nur dann ist ein gutes, gleichmäßiges Ergebnis möglich. Wir bieten hierzu eine patentierte Maschinensteuerung an. Sie steuert die Verfahrbewegung der Vorschubeinheit bzw. der Sonotrode über einen Schrittmotor mit sehr hoher Positionsauflösung und erreicht damit, dass die thermisch bedingte Veränderung am Ultraschallwerkzeug ausgeglichen und die Kraft zwischen Sonotrode und Konturwalze immer gleich bleibt.

Sonotrode travel via anvil drum with contour and gap control unit MicrogapControl

Sonotrode travel via anvil drum with contour and gap control unit MicrogapControl

Joint design

Layer bonding and ADL fixation

Layer bonding and ADL fixation (topsheet and acquisition distribution layer)

[Translate to EN-US:] Wing attachment for hygiene products – wing attachment

[Translate to EN-US:] Wing attachment for hygiene products – wing attachment

[Translate to EN-US:] Side seams and leg cuffs – lamination of nonwoven and elastic materials

[Translate to EN-US:] Side seams and leg cuffs – lamination of nonwoven and elastic materials

[Translate to EN-US:] Shape-welding with maximum layer adhesion without hard edges

[Translate to EN-US:] Shape-welding with maximum layer adhesion without hard edges

[Translate to EN-US:] Embossing, laminating, and clean cutting of pads

[Translate to EN-US:] Embossing, laminating, and clean cutting of pads

[Translate to EN-US:] Attachment of diaper tabs to the diaper chassis and welding of the fastening system – tape

[Translate to EN-US:] Attachment of diaper tabs to the diaper chassis and welding of the fastening system – tape

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BASICS OF NONWOVENS
BASICS OF NONWOVENS
English USA
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PDF, 1,002 KB

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