Ultrasonic Welding Question
Ultrasonic Welding Question
(OP)
I am very unfamiliar with Ultrasonic Welding of plastics and I was wondering if it is suitable for an application I have. I want to run wire through a flat piece of plastic. I am curious to find out if it is possible to sandwich the wire between two pieces of plastic and ultrasonically weld them together with the wire running through the weld. If so, would this weld make a hermetic seal around the wire? Can it be done with insulated wire? Again, I have no experience with ultrasonic welding and any advice would be helpful.






RE: Ultrasonic Welding Question
I think your concept is possible using those technologies.
Chris DeArmitt PhD FRSC CChem
www.phantomplastics.com
Consultant to the plastics industry
RE: Ultrasonic Welding Question
Given reasonable part design, you may get a decent bond over solid wire insulated with varnish.
I would not expect success with stranded wire or thick insulation.
Mike Halloran
Pembroke Pines, FL, USA
RE: Ultrasonic Welding Question
Chris DeArmitt PhD FRSC CChem
www.phantomplastics.com
Consultant to the plastics industry
RE: Ultrasonic Welding Question
Beware the sales people.
Mike Halloran
Pembroke Pines, FL, USA
RE: Ultrasonic Welding Question
And I know salesmen well... A salesman can do anything. So he says.
And thanks for your help guys.
RE: Ultrasonic Welding Question
Some plastics respond better than others.
The design of the joint matters a lot.
If you intend just laying the wire between two flat sheets I doubt you will have real success.
A grove for the wire to run would help.
Small ridges running alongside the grove would help as it concentrates the energy to the area you want it and provides extra melted material at the joint.
Using the same material as the insulation has obvious advantages, or at least a compatible material.
I don't have lists of such.
Regards
Pat
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RE: Ultrasonic Welding Question
Cheers
H
www.tynevalleyplastics.co.uk
RE: Ultrasonic Welding Question
I think 10mil is American code for 0.010" maybe.
Regards
Pat
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RE: Ultrasonic Welding Question
Dan - Owner

http://www.Hi-TecDesigns.com
RE: Ultrasonic Welding Question
RE: Ultrasonic Welding Question
Regards
Pat
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RE: Ultrasonic Welding Question
Thanks again.
RE: Ultrasonic Welding Question
Also I have only done it with type 6. type 6.6 will be slightly more difficult.
Sunbeam vibration welded their 35% gf66 water tanks for their steam and dry irons back in the late 70s early 80s.
The example I have done is a yacht floating winch handle. It has quite a few designs and brand names. Titan and Lewmar are two names it's sold as. You should be able to see them at any ships chandeliers anywhere in the world.
It is best welded within a few hours of moulding.
If moulded days later the parts need to be dried first.
The PC I have welded was 10% GF for the top of a surf board finbox
Regards
Pat
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