Ultrasonic energy is an important tool for sealing,
slitting, forming, and converting textiles, nonwovens, and film
materials for many diverse industries and end uses.
The
ultrasonic process is versatile - you can seam, cut, slit, trim, tack,
emboss, or cut and seal simultaneously. The process is fast - sealing
more than 600 feet per minute! It is simple and efficient, with no
needles, threads, or other consumables. And, it is flexible. The
equipment may be bench or table mounted, or integrated into your
automated line.
For the "sewn" products
industry, there are many advantages with ultrasonic sealing,
including:
Fast, economical, strong seals.
No consumables such as staples, adhesives, or clips.
Consistent results - from start-up to end of run
No warm-up time, costly temperature maintenance, or recovery time.
Single operation cut and seal with no raw edges.
Eliminates needles, threads, bobbins, and associated color matching, inventory, winding, and trimming.
Noncontaminating, eliminates toxic glue or solvents.
Edges
are sealed with no stitch holes preventing penetration of chemicals,
bloodborne pathogens, and particulates as required by OSHA.
For all its flexibility and versatility, most ultrasonic production is done using two basic modes of operation - plunge or continuous - with variations depending on the application. Sealing and cutting can be done in either mode. In the plunge mode, the ultrasonic horn operates perpendicularly to the material and fuses the layers together in the pattern of the stationary anvil. This technique can be used to simultaneously cut and seal the edges of material. Typical applications using this mode include bra straps and buckles, buttonholes, collar stays, darts, strapping, embossing, grommets, belt loops, filter media (woven and nonwoven), zipper stops, and vertical blinds.
With the continuous mode,
material is moved beneath a stationary horn. Most slitting applications
are done in the continuous mode. Ultrasonic slitting produces an edge
that is smooth, durable, and clean, with no discoloration of the
fabric. Ultrasonics prevents unraveling of knitted or woven materials
by sealing the slit edge. The sealed edge is tapered without a bead
that would add unnecessary bulk.
Two models of "sewing" machines are available. These fabric sealing systems "sew" and/or slit knitted, woven, and nonwoven man-made thermoplastic materials without needle or thread. Machine configuration and the location of the horn and anvils enable flexibility and tight turns in sealing and/or cutting. This also provides an un-obstructed view of the fabric in the processing area.
Typical applications for the systems include protective garments, disposable hospital gowns, shoe covers, face masks, infants' nursery garments, filters, bags, curtains, sails, and web splicing. Sealed edges and seams with no stitch holes prevent penetration of chemicals, liquids, blood-borne pathogens, or particulates, thus providing a benefit over conventional stitching methods.
The photo above shows the Model FS-90. Also available (details below) is the Model FS-180 which features the anvil above the table and the ultrasonic horn below it.
Branson
Ultrasonics Corporation has developed the Model FS-180 Ultrasonic
Fabric Sealing System for bonding, laminating, and sealing. The
equipment seals knitted, woven, and nonwoven thermoplastic materials
without adhesives, chemical binders, staples, needle, or
thread.
The
stand-alone system has been redesigned with the sealing anvil
positioned above the work area, which allows the operator to more
easily view the bond as it is created.
Materials
suitable for processing with the FS-180 include 100% synthetics such as
nylon, polyester, polypropylene, polyethylene, modified acrylics, some
vinyls, urethane, film, coated paper, and synthetic blends with 35-50%
non-synthetic fiber content.
Typical
applications for the FS-180 include bed covers, protective garments,
disposable hospital gowns, shoe covers, face masks, infant nursery
garments, diapers, filters, bags, curtains, vertical blinds, sails,
aircraft insulation blankets, and web splicing.
Features of
the FS-180 include:
Top-mounted rotating sealing anvils.
Forward-angled head assembly, to allow better visibility and room for the material to be moved.
Increased throat and height, which allows for additional visibility and ease in processing bulkier materials.
Stronger, heavier support assembly, which minimizes deflection.
An optional backpuller to ease operator handling during in-line processing.
Rotary drum
equipment (right), where the "anvil" is a patterned rotating drum,
operates in the continuous mode in excess of 500 feet per minute. This
equipment can create wide webs by passing multiple layers of material
between a rotating patterned drum and an array of ultrasonic
heads.
Bedspread and mattress pad
quilting, window shades, strapping, tenting material, medical
disposables, and bag material utilize continuous processing.
Another
innovative product is the Branson Radial Actuator, designed for
high-speed continuous welding of thermoplastic films and fabrics. It
utilizes true radial ultrasonic vibration -- ultrasonic vibrations are
normal to the surface of the horn. Because the horn can roll
tangentially with the material, drag and puckering effects are
eliminated, so higher speeds are obtainable compared to traditional
stationary horns. Materials can be processed at rates up to 1000 feet
per minute. Applications for the Radial Actuator include continuous
ultrasonic bonding where high speed is needed and puckering or drag
effects from stationary horns is problematic. Also, weld patterns can
be engraved on the horn's surface allowing ultrasonic bonding along
locations not possible with stationary horns.
For specialized automated equipment for textiles, nonwovens, filtration and film applications, Branson partners with Chase Machine & Engineering, Inc., in West Warwick, RI, who builds the following systems utilizing our ultrasonic components: Ultrasonic Laminating Equipment, Ultrasonic Slitting Equipment, Ultrasonic Embossing Equipment, Ultrasonic Splicing Equipment, Ultrasonic Cut to Length Equipment, Film, Fabric, and Filtration Applications
Materials suitable for ultrasonic processing include 100% synthetics such as nylon, polyester, polypropylene, some polyethylenes, modified acrylics, some vinyls, urethane, films coated paper, and synthetic blends with up to 35-50% non-synthetic fiber content. Materials may be woven, nonwoven, knitted, or laminated. The ultrasonic process preserves a fabric's good "hand."
For assistance or other technical information, contact our headquarters applications laboratory at 203-796-0368. You may also contact our Textile and Film Technical Center in Lawrenceville, GA, at 770- 962-2111.
Chances are we've seen an application like yours and know the best way to produce it.
With the continuous mode,
material is moved beneath a stationary horn. Most slitting applications
are done in the continuous mode. Ultrasonic slitting produces an edge
that is smooth, durable, and clean, with no discoloration of the
fabric. Ultrasonics prevents unraveling of knitted or woven materials
by sealing the slit edge. The sealed edge is tapered without a bead
that would add unnecessary bulk.
Two models of "sewing" machines are available. These fabric sealing systems "sew" and/or slit knitted, woven, and nonwoven man-made thermoplastic materials without needle or thread. Machine configuration and the location of the horn and anvils enable flexibility and tight turns in sealing and/or cutting. This also provides an un-obstructed view of the fabric in the processing area. 
The photo above shows the Model FS-90. Also available (details below) is the Model FS-180 which features the anvil above the table and the ultrasonic horn below it. 
Branson
Ultrasonics Corporation has developed the Model FS-180 Ultrasonic
Fabric Sealing System for bonding, laminating, and sealing. The
equipment seals knitted, woven, and nonwoven thermoplastic materials
without adhesives, chemical binders, staples, needle, or
thread.
Rotary drum
equipment (right), where the "anvil" is a patterned rotating drum,
operates in the continuous mode in excess of 500 feet per minute. This
equipment can create wide webs by passing multiple layers of material
between a rotating patterned drum and an array of ultrasonic
heads.
Another
innovative product is the Branson Radial Actuator, designed for
high-speed continuous welding of thermoplastic films and fabrics. It
utilizes true radial ultrasonic vibration -- ultrasonic vibrations are
normal to the surface of the horn. Because the horn can roll
tangentially with the material, drag and puckering effects are
eliminated, so higher speeds are obtainable compared to traditional
stationary horns. Materials can be processed at rates up to 1000 feet
per minute. Applications for the Radial Actuator include continuous
ultrasonic bonding where high speed is needed and puckering or drag
effects from stationary horns is problematic. Also, weld patterns can
be engraved on the horn's surface allowing ultrasonic bonding along
locations not possible with stationary horns.
