Emerson Large-Part Vibration Welding Systems User Manual

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Vibration Welding
WELDING l STAKING l INSERTION l SWAGING l FORMING l SPOT WELDING l DEGATING l CUTTING AND SEALING
Vibration Welding
Traditional Vibration Welding and “Clean”
Vibration Welding
Vibration Welding
Vibration Welding © Branson Ultrasonics Corporation 1999
The Emerson logo is a trademark and service mark of Emerson
Electric Co. Revised and printed in the U.S.A. 4/11
Vibration Welding
Branson Ultrasonics Corporation
41 Eagle Road, Danbury, CT 06813-1961
(203) 796-0400 • Fax: (203) 796-9838
www.bransonultrasonics.com
e-mail: [email protected]
475 Quaker Meeting House Rd.,
Honeoye Falls, NY 14472
(585) 624-8000 • Fax: (585) 624-1262
Virtually all thermoplastic polymers can be welded to themselves
utilizing the vibration welding technique. Vibration welding also
offers the largest range of welding of dissimilar materials, as well
as the ability to weld different molding grades (injection molded,
extruded, etc.) to each other. Since it uses mechanical friction to
weld, the process puts as much energy as required at the interface
to melt the plastic. As long as the parts are able to be vibrated
relative to each other in the plane of the joint, the process may
be used.
This method of assembly, when compared with ultrasonic
assembly, is particularly advantageous for semi-crystalline resins
such as acetal, nylon, thermoplastic polyester, polyethylene, and
polypropylene, as well as PVC, cellulosics, thermoplastic rubber,
and elastomers, filled and reinforced resins, and those exhibiting
hygroscopic properties. Fillers such as glass, minerals, talc, and
mica do not present a problem for the process, as long as the
percentage is kept under 40%. Different grades of a material can be
welded to each other.
Vibration welding replaces ultrasonic welding in many troublesome
applications, since the ultrasonic process relies on transmitting
energy through the part to the joint interface. For example, the
ability to transmit weld energy is dependent upon the grade of
material, as well as part shape and size, the percentage of regrind,
the heat history of the plastic, as well as the color additives, melt
flow index and filler content. Vibration welding is not subject to the
same constraints, since energy is not transmitted through the part,
but rather it is generated directly at the interface.
Branson vibration welders are available for part sizes up to 70” x
36” and larger. The smallest vibration welder has a footprint of
36” by 38”. The modular component design allows components
to be integrated into automated production lines. Multiple
control levels are available, and many units are capable of
remote monitoring and diagnostics.
Material Compatibility
Equipment Configurations