Sonics X-Press Integrated Welder - Manual (Page 7)

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I N S T R U C T I O N M A N U A L • M O D E L X - P R E S S
6
I N T R O D U C T I O N
The X-Press integrated welders, models XPT and XPE, are 20 kHz ultrasonic
benchtop presses with built-in microprocessor-controlled power supplies.
O V E R V I E W O F U L T R A S O N I C P L A S T I C S
A S S E M B L Y
WHAT IS ULTRASONICS?
Ultrasonics refers to vibrational waves with a frequency above the human
audible range which is usually above 18,000 cycles per second (Hz).
PRINCIPLE OF ULTRASONIC ASSEMBLY
The basic principle of ultrasonic assembly involves conversion of high
frequency electrical energy to high frequency mechanical energy in the form
of reciprocating vertical motion which, when applied to a thermoplastic,
generates frictional heat at the plastic/plastic or plastic/metal interface. In
ultrasonic welding, this frictional heat melts the plastic, allowing the two
surfaces to fuse together; in ultrasonic staking or insertion, the controlled
flow of molten plastic is used to capture or lock another material in place
(staking) or encapsulate a metal insert (insertion).
ULTRASONIC ASSEMBLY SYSTEMS
“Sonics” ultrasonic assembly systems are generally composed of the fol-
lowing major elements: a power supply, converter, booster, horn, pneumatic
press/actuator and holding fixture, as detailed in the diagram on the next
page. A review of this diagram will help you understand the basic elements
involved in the assembly process and their relation to each other.
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