What are the factors to consider when choosing a plastic welding equipment?
How to choose plastic welding equipment
Plastic connections are generally available in two ways: bonding and soldering. Generally speaking, the bonding process has low production efficiency, is not aesthetically pleasing, and the adhesive has certain toxicity; while the welding process has relatively high production efficiency, beautiful weldment and high welding strength, the plastic welding process has become more and more extensive. Applications.
First, pick the right solderable material. In the actual production process, only thermoplastics with the same or similar molecular structure can be welded. On the welding surface is the chemical combination between the molecules, so the closer the matrix material is, the better the welding effect. At the same time, the content of the filler in the plastic has a great relationship with the weldability and quality of the weld, which change the physical properties of the material. When the filler content exceeds 30%, the insufficient ratio of surface plastics and insufficient intermolecular fusion may reduce the weld sealing property.
Secondly, appropriate welding methods should be adopted according to the type of materials, the shape of the products, and the cost. According to the different heating and softening methods used, plastic welding can be divided into several types, such as external heating source, mechanical movement and electromagnetic softening.
First, the welding technology softened by the external heating source:
1, hot plate welding
Hot plate welding is a kind of welding method in which the two planes to be welded are melted and softened by a flat electric heating plate, and the electric heating plate is quickly removed, and the two planes are combined and applied to the cooling, which is suitable for the ultrasonic refractory non-rotating workpiece or the large plastic workpiece. The welding method has high welding strength and the shape design of the welded parts is relatively easy, such as automobile water tank, automobile tool box, automobile combination lamp, washing machine balance ring and the like.
2, hot air welding
When the hot air flow is directly blown to the seam area, the filler wire and the seam area of ​​the same material as the base material are melted, and the filler material is melted together with the plastic to be welded to form a weld bead. The advantage of this welding method is that the welding equipment is light and easy to carry, but the welding skill of the operator is relatively high.
3, hot rod and pulse welding
These two techniques are mainly used for the welding of thin plastic films. And the two methods are similar, the two films are pressed together, and the welding is completed by the instantaneous heat generated by the hot rod or the nickel-chromium wire.
Second, the method of softening through mechanical movement to complete the welding:
The mechanical motion welding method is a fully automatic welding process, which uses the heat generated by the two workpieces under friction to melt the plastic on the contact surface, and is fixed until the condensation is firm, requiring special welding equipment. Once the correct welding parameters are determined, the operator can stabilize production. The advantages are: fast, flexible, stable welding process and no need of flux or protective gas, no harmful gas or slag, and the welding quality of the product is guaranteed. According to the movement track, it can be divided into linear type and rotary type: the straight type can be used for the welding of the straight weld and the flat weld, and the rotary type can be used for the welding of the circular weld.
1. Ultrasonic welding
Ultrasonic welding is to generate a high-frequency sine wave signal by a signal generator, which is converted into high-frequency mechanical vibration energy by a transducer, and then the amplified vibration is coupled to the plastic part to be welded via a horn and a welding head, under high pressure. The high-frequency friction causes the plastic contact surface to instantaneously melt at a high temperature. After the ultrasonic wave stops, the two plastic parts cooled by the short-term pressure-holding are welded together, and the welding process generally takes less than one second, and the welding is strong.
It can be compared with the body, and is widely used in various industries such as electronic appliances, auto parts, packaging, plastic toys, stationery, daily necessities, and handicrafts. When welding plastic products, do not add any adhesive, filler or flux, nor consume a large amount of heat source. It has the advantages of simple operation, fast welding speed, high welding strength, beautiful weldment and high production efficiency. In addition, the ultrasonic welding process can also achieve riveting of plastic and metal parts. Therefore, ultrasonic welding technology is becoming more and more widely used.
2, rotary friction welding
The mechanical energy is converted into heat energy by the relatively high-speed rotational friction of the workpiece, so that the contact surface of the workpiece to be welded is heated to be heated, and then melted and pressurized to be welded together. Compared to ultrasonic welding, the process is not limited by the size and material of the workpiece, and the welding strength is higher than other plastic welding processes, almost close to the strength of the plastic body. It is suitable for welding of rotary body parts such as filter core, plastic cup, float ball, toy ball and shower head.
Third, the welding method of softening the surface by electromagnetic action:
1, high frequency welding
High-frequency welding is a high-frequency induction heating technology using the principle of electromagnetic induction. The plastic product is inductively heated to the induction body or magnetic plastic buried inside the plastic part, so that the welded plastic generates heat in the fast alternating electric field and is to be welded. The part quickly softens and melts, which in turn fills the interface gap and is complemented by a perfect mechanical device for perfect welding. Suitable for welding of stationery clips, inflatable items, waterproof clothing and blood bags.
2, infrared welding
This technique is similar to hot plate welding, where the two parts that need to be welded are fixed close to the hot plate but not in contact with the hot plate. Under the action of heat radiation, the joint portion is melted, then the heat source is removed, the two portions are butted, and pressed together to complete the welding. This method does not produce welding slag, no pollution, and has high welding strength. It is mainly used for welding of piping systems with high precision such as PVDF and PP.
3, laser welding
The principle is that the beam generated by the laser passes through a beam path system composed of a mirror, a lens or an optical fiber, and is focused on the area to be welded to form a heat-acting zone. The plastic in the heat-acting zone is softened and melted, and is melted in the subsequent solidification process. The material forms a joint, and the parts to be welded are connected. It is usually used for welding of light-transmitting materials such as PMMa, PC, aBS, LDPE, HDPE, PVC, Pa6, Pa66, PS, etc., adding carbon black in the heat-affected zone. The equal absorber enhances the endothermic effect. Plastic laser welding has many advantages: fast welding speed and high precision; automation and precision CNC are easy to implement. Therefore, plastic laser welding technology has been widely used in the fields of automobiles, medical equipment, packaging and so on.
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