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超聲波焊接技術經驗解析

我們在進行超聲波焊接 作業時，经常由于操作不当而无法满足制品使用需求，根据我们的维修经验，産品不良主要集中在強度無法達到欲求標准；制品表面産生傷痕或裂痕；制品産生扭曲變形或白色状（打白）；制品內部零件破壞；制品产生溢料或毛边；制品熔接后，产生尺寸不稳定六个方面。

找到問題，才能解決問題。只有准確判斷制品不合格原因，才能及時有效處理。

医疗器械

1、強度無法達到欲求標准

超聲波 焊接作业的强度绝不可能达到一体成型的强度，只能说接近于一体成型的强度，而其熔接强度的要求标准必须仰赖于多项的配合，因此使用超聲波塑焊时，需要考虑材料的兼容性、塑料材质熔点差距、塑料材质的密度。

2、制品表面産生傷痕或裂痕

超聲波作业中会产生高热能直接接触塑料産品表面与振动传导两种情形，因此需要考虑功率输出（段数）、熔接时间、动态压力等配合因素，来克服此种作业缺失。

3、制品産生扭曲變形

制品産生扭曲變形的原因主要有体与欲熔接物，因角度或弧度无法相互吻合、産品肉厚薄(2mm 以內)且長度超出60mm以上、産品因射出成型压力等条件导致变形扭曲三種原因。

4、制品內部零件破壞

超聲波熔接后发生産品破坏的原因有：超聲波熔接机功率输出太强；超聲波能量扩大器能量输出太强；底模治具受力点悬空，受超聲波传导振动而破坏；塑料制品高、細成底部直角，而未設緩沖疏導能量的R 角；不正确的超聲波加工条件；塑料産品之柱或较脆弱部位，开置于塑料模分模在线。

5、産品产生溢料或毛边

超聲波熔接后産品发生溢料或毛边的原因如下：超聲波功率太强；超聲波熔接时间太长。

空氣壓力（動態）太大；上模下壓力(靜態 )太大；上模(HORN) 能量擴大比率太大；塑料制品導熔線太外側或太高或粗。

6、産品熔接后尺寸无法控制于公差内

在超聲波熔接作業中，産品无法控制于公差范围，有下述原因：

機器穩定性(能量轉換未增設安全系數；塑料産品变形量超出超聲波自然熔合范围；治具定位或承受力不稳定；超聲波上模能量扩大输出不配合；熔接加工条件未增设安全系数。

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更多的超聲波塑料焊接材料我们可以通过分析表进行初步了解，如果您有关超聲波熔接作業的更多問題，歡迎您進入靈科超聲波官网/ 進行在線咨詢，我們將竭盡所能爲您解惑。

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