Ultrasonic Rotary Process For Sewing Machine

Descripersion

Ultrasonic bonding is the process of using high-frequency compression/relaxation of materials against specially designed anvil patterns that cause them to heat at the molecular level and melt. 

Another difficulty associated with conventional rotary horns relates to weld area lengths. Essentially, the weld area length is a measure of the amount of product that can be welded in a given pass of the rotary horn. Thus, larger weld area lengths enable greater product throughput and increased profitability. In order to provide increased weld area lengths it is generally necessary to increase the weld area length of the weld section. Many conventional radial horns have. weld area lengths that are limited to approximately 2.5 inches. Using such a horn on an application requiring weld area lengths of approximately 5 inches would therefore require twice as much welding time and labor. It is therefore desirable to provide a rotary horn that has a minimum amplitude uniformity of 85 percent while maintaining a radial weld area length of 5 inches or more.

Yet another difficulty associated with conventional acoustic rotary horns relates to driving and mounting of the horn. For example, many conventional horns have a single input section for receiving the axial acoustic energy. This single input section serves as the only mechanism for driving the horn with the axial acoustic energy and limits the overall usefulness of the horn to half-wave applications. Furthermore, the horn must be mounted on one side of the weld area. When mounted in this fashion, the horn is loaded in the same manner as a cantilever beam. Conventional single mount designs have been estimated to produce weld forces of 150 pounds or less before deflections become too excessive and cause uneven welding. The result is often a lower pressure weld which, in turn, results in less ultrasonic energy being imparted to the target parts. Less ultrasonic energy being imparted to the weld surface ultimately reduces product line speeds. It is therefore desirable to provide a rotary horn that has mounts located on each side of the weld area, in the same manner as a simply supported beam, to increase weld pressure and the transfer of acoustic energy to the welded parts. The simply supported horn can support five times as much force as the cantilever style mounting method for the same deflection. The mounts in the simply supported mounting method could be polar or nodal mounts.

The above and other objectives are provided by an ultrasonic rotary horn in accordance with the present invention. The rotary horn has a first radial weld section, and a first axial input section operatively coupled to the first radial weld section for receiving a first axial acoustic energy. The first axial input section has a first coned section such that the first axial input section and the first radial weld section convert a portion of the first axial acoustic energy into radial acoustic energy. The radial acoustic energy is in phase with the first axial acoustic energy. The use of a tapered geometry for the first axial input section allows the rotary horn to be designed without reliance on the Poisson ratio effect and complicated tuning cuts.

It need be assembled on the ulltrasonic sewing machine, and drive by an other rotary horn.

Characteristics:

1. Seamming,trimming and embossing without glue, thread or other consumables
2. More faster and cost effective than traditional sewing machine and adhesive ways
3. Eliminates fraying or unraveling of bonded edges and seams
4. Multifunctional and thousands of designs available
5. Requires minimum training and maintenance
6. Super strong ultrasonic power meets the needs of different fabric thickness

RPS-SONIC specializes in manufacturing ultrasonic seam welding solutions for rotational systems.

Parameter:

Application

• Fast and cost-effective weaving;
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• Resilient seams;
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• No need for consumables such as tape, clips or glue;
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• Constant results;
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• No cooling times and reduced maintenance costs;
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• No shooting time for the stapler tool;
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• Edging in one operation
• No need for needles, thread, spools and any activities related to color matching, inventories, winding and trimming;
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• Environmentally-friendly because it does not need any adhesives and solvents;
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• Edges get sealed without leaving any stitch holes, thus preventing penetration from chemical agents, bloodborne pathogens and other particles.

Advantage:

Instead of needles, thread, glues or other adhesives, ultrasonic sewing equipment uses a patented rotary system, coupled with high-frequency vibrations, to bond synthetic or blended materials containing up to 40 percent natural fibers.

Resembling a traditional sewing machine, the  ultrasonic sewing machine channels the ultrasonic vibrations between a horn and rotating wheel, producing a localized heat buildup which causes the synthetic fibers to soften and fuse. This creates a strong molecular bond that’s impervious to moisture. Explains Alleman, “the resulting barrier seams are sealed, secure, ultra-reliable and soft-to-the-touch without the safety issues caused by stitch holes, glue gaps, fraying or unraveling.”