Sonics H540 E - Manual (Page 30)

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I N S T R U C T I O N M A N U A L • H A N D H E L D W E L D E R S
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SPHERICAL STAKE
The spherical stake is preferred for bosses with an O.D. less than 1⁄16 inch
(1.6 mm). It is also recommended for rigid crystalline plastics with sharp
highly defined melting temperatures, for plastics with abrasive fillers, and for
materials that degrade easily.
HOLLOW STAKE
Bosses with an O.D. in excess of 5⁄32 inch (4 mm) should be made hollow.
Staking a hollow boss produces a large, strong head without having to melt
a large amount of material. Also, the hollow stake avoids sink marks on the
opposite side of the component, and enables the parts to be reassembled
with self-taping screws, should repair and disassembly be necessary.
KNURLED STAKE
The knurled stake is used in applications where appearance and strength are
not critical. Since alignment is not an important consideration, the knurled
stake is ideally suited for high volume production, and is often recommended
for use with a hand held ultrasonic spot welder.
Knurled tips are available in a variety of fine, medium and course
configurations.
BEFORE HIGH PROFILE AFTER
2.12d
.75d
METAL
PLASTIC
HORN
d 2d
BEFORE LOW PROFILE AFTER
.8d .375d
HORN
.5d
.5d
BEFORE AFTER
METAL
HORN
H=1.6 d2 .5d1
.5d
d2 =
d1
2
d2
BEFORE AFTER
METAL
PLASTIC
HORN
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