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.
Ultrasonic Slitting 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.
Ultrasonic Sewing 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. For more information on the FS-90, click here.
Branson's FS-180 Ultrasonic Fabric Sealing System 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.
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 Bonding 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.
Radial Actuator
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 bondings 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.
Automation Integration
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.
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. 
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 bondings 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.
