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塑料件中与靈科超聲波焊頭接觸面設計

返回列表 來源：发布日期： 2022.03.11

1、塑料件焊頭接觸面設計
注塑件可以設計成任何形狀，但超聲波焊頭不能隨意制造。形狀和長度可能會影響焊接頭的頻率、振幅和其他參數。焊頭的設計需要一個基准面，即根據其工作頻率確定的基准頻率面。參考頻率平面通常占焊接頭表面的70%以上。因此，注塑件表面的形狀應小于整個塑料表面的30%。

具有滑動和弧形過渡的塑件表面可適當放寬標准，突出位置應位于塑料部件的中部或對稱設計盡可能遠。塑料部件的焊接頭的接觸表面應至少大于焊接表面，焊接位置應盡可能對齊。焊頭接觸面過小（如圖6所示）會造成較大的損傷和變形，焊接效果不理想。

當焊頭表面有損傷線或形狀與塑料件稍有不同時，焊接時會在塑料件表面留下疤痕。避免方法是在焊頭和塑料零件表面之間墊一層薄膜，如PE膜之類的。

2、近距離和遠距離焊接
近距離焊接是指焊接位置與焊頭接觸位置之間的距離在6mm以內，而遠距離焊接大于6mm。超聲波焊接中的能量在塑料零件的傳輸過程中會衰減。在低硬底塑料中，衰減也很嚴重。因此，在設計過程中應特別注意將足夠的能量傳輸到加工區域。

遠距離焊接適用于硬膠（如PS、ABS、as、PMMA）等。一些半結晶塑料（如POM、PETP、pBTB、PA）也可以通過適當的形狀設計用于遠距離焊接。

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