Ultrasonic Welding Molding Horns

Ultrasonic Welding Molding Horns

Sonotrode, also known as the horn or sonotrode in an ultrasonic welding system, is a critical component that amplifies and focuses the high-frequency vibrations generated by the transducer to the welding area. Here's a detailed explanation in English:

1. Basic Definition:

• The sonotrode is essentially the business end of the ultrasonic welding system, responsible for transferring the vibrational energy to the materials being welded.

2. Working Principle:

• Mechanical Vibration Transfer: The sonotrode amplifies the vibrations produced by the piezoelectric transducer and evenly distributes them to the welding area. This creates frictional heat at the interface of the materials, facilitating their fusion.

• Precision Control: The design and manufacturing of the sonotrode often involve FEM (Finite Element Method) calculations to ensure optimal oscillatory behavior. Advanced laser measurement techniques are used to measure and record amplitude distribution, ensuring precision during the welding process.

3. Applications:

• Sonotrodes are widely used in various fields, particularly in the automotive industry for battery assembly connections, tab welding, fuse welding, and more. They can weld similar and dissimilar metals, metal to non-metal, plastics, and materials with significant thickness differences.

4. Performance Characteristics:

• High Precision: CAD/CAM calculated algorithms ensure precise 3D contour manufacturing for high-precision welding needs.

• Longevity: Special surface treatment processes extend the lifespan of the sonotrode.

• Efficiency and Energy Saving: Ultrasonic welding does not require external heating sources, consumes less electrical energy, and offers fast welding speeds, enhancing production efficiency.

5. Technical Advantages:

• Broad Material Compatibility: Capable of welding various types of materials, including highly conductive, thermally conductive materials, and difficult-to-weld metals.

• High-Quality Weld Joints: The physical and mechanical properties of the weld metal remain unchanged微观ly, providing stronger and more stable joints compared to resistance welding.

• Environmentally Friendly: No need for adhesives, fillers, or solvents, making the process environmentally friendly and free from contamination.

In summary, the sonotrode is a crucial tool in ultrasonic welding systems, playing a vital role across multiple industries. As technology advances, the performance and application scope of sonotrodes continue to expand.

Sonotrode Examples 

All mold plates are customization to meet different products design and accuracy.

 Samples and 3D drawing are required for making horn and bottom mold accordingly.

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