Customized solutions for joining plastics are gaining in importance. Modern developments in plant engineering, digitalization and design, through to entire process variants, give the visitors to the K 2019 halls new insights into contemporary and future solutions to the challenges in the field of joining technology.

Plastics Joining Technology Characterized by Flexibility, Individualization and Digitalization

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Weld Your Way

The use of bio-based plastic materials – accompanied by high prices, new packaging designs and frequent technical refinements – present packaging manufacturers with a whole range of challenges. As more biopolymer packaging makes its way to the market, ultrasonic welding is proving its worth in sealing these import new polymers. Today, modern vertical form, fill and seal machines (VFFS) are capable of sealing through the package contents.

Reducing waste due to weld failures, Branson ultrasonic components for VFFS systems by Emerson can seal directly through package contents and other contaminants at the sealing point of a wide variety of product packages

Ultrasonically Welded Seals for Sustainable Packaging

Ultraschallschweißen

A Perfect Fit

In search of a faster method of adhesion lamination and a better solution to thermal lamination, Polifilm has developed a new technology that utilizes a corona station in the production of stand-up pouches in one example.

Sample pouch manufactured from an MDO/PE mono-material composite and labeled by digital printing.

16:9

Room Temperature-Sealing Film

Extrusion

Kunststoffverarbeitung: Verfahren

Beschichten, Kaschieren, Laminieren

Corona Replaces Lamination

The tabletop system EvoWeld Mini is precisely tailored for processing small batches such as prototypes or assemblies with low volumes.

EvoWeld Mini is a new compact tabletop system for laser welding of plastics. 

Laserschweißen

Compact Machine for Laser Welding

In new joining processes for FRP, their matrix is heated. Predicting the effects of this process is possible with the appropriate simulation.

The prediction of the heating behavior of FRP is very interesting for modern joining techniques.

Simulation

Software

Andere Werkstoffe

Faserverbundwerkstoffe

Simulation of Composites’ Heating

Herrmann Ultraschall: with the right parameters, welding results comparable to those achieved with conventional plastics can be obtained.

The results of an initial study by Hermann provide a promising answer to the weldability of recyclates. There is no visible difference between test specimens made from conventional and recycled plastics.

Herrmann Ultraschall Presents a Feasibility Study

Kunststoff-Rezyklat

Kunststoff Werkstoffe

Ultrasonic Weldability of Pure Recyclate

How ionizers from SMC reduce static charge: Problem-free processing of plastic films and adhesive application without disturbing particles.

SMC‘s IZS41 series ionizers reliably reduce the electrostatic charge in H&H Maschinenbau‘s adhesive application systems.

Sondermaschinenbau

Kunststoffverarbeitung: Maschinen und Komponenten

Sondermaschinen

Secure Hold for Adhesive Technology

Rinco Morocco will act as a center for the African continent for the developer and manufacturer of ultrasonic welding machines and ultrasonic cutting systems, based in Switzerland.

Rinco Ultrasonics sees great potential for its ultrasonic welding and cutting systems in Africa.

Schneidmaschinen, Kunststoff

Schweißmaschinen, Ultraschall

Unternehmen

kunststoffe.de

Rinco Ultrasonics Expands to Morocco

Joining methods often call for creativity – especially when small series are involved. Herrmann Ultraschall  has developed an ultrasonic welding machine for a control unit manufacturer that inserts 18 brass female connectors into a plastic frame with high precision. The system has not only slashed cycle times and eliminated most of the manual work stages, but is also highly versatile. Re-tooling to weld inspection windows into plastic housings takes just a few minutes, thanks to its quick-change functionality.

The blade sonotrode enables the brass female connectors to be inserted into the plastic frame simultaneously – and not individually in succession. 

Welding Small Batch Sizes Economically Using Ultrasonics

Well Embedded

Sonotronic Nagel GmbH is set to grace this year‘s K event and showcase its range as a one-stop supplier of ultrasonic technology.

Lightweight, ultra-dynamic and fast: the XYZ module is a simple and affordable alternative to 6-axis industrial robots.

kunststoffe-international.com

Production Machines from a Modular Kit

At Fakuma 2023, Rinco will present its solutions for joining and separating plastics. Among other things, the Electrical Motion ultrasonic welding machine will be on display, which now has a software upgrade and additional functions.

Spice shaker made from bio-based plastic. 

Ultrasonic Welding of Bio-Based Products

Existing joining methods are having to satisfy increasingly demanding requirements and must be refined continuously. This article presents some unique new approaches and solutions tailored to specific components and applications. 

Schweißanlagen

Joining Technology (Trade Fair Report Fakuma 2008): Bonding with Sensitivity 

Forward Technology, Cockato, MN, USA, a manufacturer of standard and custom plastic welding equipment and testing systems, has announced the introduction of a new high-speed orientation spin welder designed for smaller diameter and more difficult applications that require delivery of rotational speed at high precision. The spin welder HS-OSW is targeted for manufacturers of small-diameter components (down to 0.125 in/ 0.08 mm) such as fittings, tubing, and fuel lines for the medical, automotive, and industrial markets. 

For Joining of Small-Diameter Parts 

High-Speed Servo Spin Welder HS-OSW 

Infrared Welding, Ultrasonic Welding, and Heat Staking

Suppliers in the joining technology sector exhibited their wide variety of options at K 2022.  These ranged from mobile high-tech devices in a case to individually automated machine concepts  suitable for high-volume production.

Suppliers in the joining technology sector exhibited their wide variety of options at K 2022.

Many of the manufacturers do not just offer a single technology but provide solutions across the entire process chain. In addition to the actual joining process itself, these solutions also include assembly, testing, and packaging. In this article, Kunststoffe international reports on some of the product highlights at K show.

As a contactless process, infrared welding offers undoubted advantages over vibration and hot plate welding. The contactless heat transfer allows particle-free, non-stick welding of plastics.

With its new, patented “InfraMerge” process, Polymerge has launched a revolutionary development in infrared welding. For the first time, a 3D printing process is used to produce the InfraMerge emitter. This makes it possible to produce a ceramic emitter in virtually any geometry, which simplifies adaptation to the particular component contours. With operating temperatures up to above 1400 °C, these are very high-performance emitters.

With its latest generation of Ultrasafe soundproofed welding machines, Herrmann Ultraschalltechnik offers an ergonomic workstation with a larger operating area and flexibly adjustable lifting door. The unit provides a protected work environment in which components can be welded safely in the shortest possible time (Fig. 1).

Instead of a having a narrow viewing window, the entire front side of the Ultrasafe with a very large viewing window lifts up to provide a significantly larger working area. This affords new flexibility for operation and loading, and for changing the tools and cleaning. An electrically height-adjustable work table can be optionally ordered. This allows the workstation to be adapted quickly and individually to the body size of the user.

All-in-One Machine for Punching, Embossing and Joining

Frimo offers a wide range of technologies. It is always exciting when several processes are combined in a single unit. A good example of this is the CombiCut, which is used for the production of exterior components.

The part, such as a bumper, is loaded by the operator onto an ergonomically designed sliding carriage. After the cycle is started, the part is moved into the punching position. During the punching and radius embossing operation, the CombiCut can be loaded with attachments, such as parking assistants, fog lamps or tow hitch openings. These can then be attached to the punched part in a separate joining station by adhesive bonding or ultrasonic welding. If necessary, the part can be repositioned before joining.

Joining Electronic Components  to PC Boards

One of the highlights on the Emerson stand was a Branson GPX PulseStaking platform for heat staking (Fig. 2). The GPX range, which consists of three standard machines and a handheld unit, permits greater design freedom. This makes it possible to join more complex, delicate components to plastic moldings. The unique, instantaneous heating/cooling process is designed to meet today’s increasingly challenging applications. These include parts made of dissimilar materials with complex 3D geometries, closely spaced features, and fragile or heat-sensitive components. Examples of such parts include soldered components or sensors, as well as parts incorporating a number of blended, glass-reinforced, chrome-plated or metallized plastics. The advantages of the PulseStaking process come into their own particularly for applications such as medical devices, motor vehicle interiors and exteriors, electronics, and PC boards, as well as many other uses.

Laser Welding System for  Large Components

The new Maxi laser welding system from Leister is universally suitable for laser welding large components such as headlights or bumpers. The system can also be used in the textile industry to weld waterproof outdoor clothing. Its modular design allows it to be adapted to individual customer requirements. At K, the workstation was equipped with a 6-axis robot (Fig. 3). In addition to the drawer version, the system is available with a rotary indexing table or for transfer belt applications.

Emerson Automation Solutions AVENTICS GmbH 

https://www.emerson.com/branson

Herrmann Ultraschalltechnik GmbH & Co. KG 

https://www.herrmannultraschall.com

Leister Technologies AG  

https://www.leister.com

FRIMO Group GmbH  

https://www.frimo.com

Ausgabenartikel

Contactless heat transfer with 3D-printed ceramic emitter. New concept for infrared welding from Polymerge – here used for an automotive tail light.

Fig. 1. The ergonomic design of the  Ultrasafe offers a larger operating area and greater flexibility. 

Fig. 2. For low energy consumption – the Branson heat staking platform.

Fig. 3. View of the laser welding workstation from Leister – equipped with a 6-axis robot at K show.

Highlights Fügen_su

Infrared welding, ultrasonic welding, and heat staking

Trend Report: Joining Highlights at K 2022

Read the German version of the article in our magazine Kunststoffe or at <a href="https://www.kunststoffe.de/a/fachartikel/gute-fuegung-3168180" target="_blank">www.kunststoffe.de</a>

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Schröder, Susanne

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