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超聲波焊接原理

影響超聲波焊接的因素有哪些

超声波焊接机熔接産品时常会遇到一些不良问题，影响生产的进程及産品质量。如何解决超声波塑胶焊接设备在産品焊接过程中造成的不良呢？一起來看看。

1、超聲波焊接對原材料的要求

? 聚合物结构：

将单体结合在一起的过程称为“聚合”，聚合物基本可分为两大类：热塑性和热固性。热塑性材料加热成型后还可以重新再次软化和成型，
基所經曆的只是狀態的變化而已-這種特性使決定了熱塑性材料超聲波壓合的適應性。熱固性材料是通過不可逆反的化學反應生成的，再次加
热或加压均不能使已成型的热固性産品软化，所以传统上一直认为热固性材料是不适合使用超音波的。

? 材料相融性

塑料的熔接特性

? 影响超声波焊接效果的其他因素
有吸水特性的材料,例如：聚碳酸脂、聚砜、尼龙。
塑料加入混合物料后因应注意混合物的比例
有问题的脫模剂：硅脂类、特富龙、內部润滑剂、色粉、再生料、防火剂等。

2、超聲波焊接設備與夾具設計對焊接效果的影響

? 超声波塑料熔接机的主要部件：换能器、增幅器、焊头。超聲波增幅器和焊头的主要材质为：钛合金或铝合金。

未标题-1

? 根据産品大小选择适当频率的焊接机

? 超聲波焊頭表面振幅設計
焊接头表面振幅 = 换能器表面振幅 x 调幅器增益 x 焊接头增益

3、塑料件的結構
为了获得完美的産品外观、牢固可靠的焊点，必须遵循三个主要设计方向：
一、最初接触的两个表面必须小，以便将所需能量集中，并尽量减少所需要的总能量（即焊接时间）来完成熔接。
二、找到适合的固定和对齐的方法，如塑料件的接插孔、台阶或企口之类。
三、焊头需直接接触并覆盖全部焊接区域，以满足焊接点所需的能量传导。

4、焊接線設計

焊接线是超声波直接作用熔化的部分，其基本的两种设计方式：能量导向、剪切设计。具体可参考文章“超聲波焊接線工藝圖解”

5、超聲波焊接制程控制

在超声波熔接作业中，産品表面产生伤痕、结合处断裂或有裂痕、产生溢料或毛边、熔接后尺寸无法控制于公差内等不良时，首先要检查
設備參數控制，並通過合理的實驗來優化執行參數（預壓力、下降速度、延遲時間、熔接時間、引用介質覆蓋（如ＰＥ袋）、模治具表面處
理（硬化或鍍鉻）、機台段數降低或減少上模擴大比等），以獲得良好的品質。超聲波在塑料件中傳播，塑料件或多或少對超聲波能量有吸收
和衰減，從而對超聲加工效果産生一定的影響，塑料一般有非晶體材料之分，按硬度有硬膠和軟膠之分，還有模數的區分，通俗地來說，硬度
高，低熔點的塑料超聲加工性能優于硬度低、高熔點的塑料。因此，這就牽涉到超聲波加工距離的遠近問題。

超声波焊接时産品断裂怎么办

超聲波模具調試

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