35Khz high amplitude ultrasonic sewing machine with rotary
horn ItemParameterFrequency 35KHZPower800WWidth of
horn11.5mm,15mm (customized)Rotary horn diameter
107.5MM106MMAmplitude 25μm22μmRotary horn materialRapid steel
TitaniumHardness58HRC 30~32HRCAn OverviewIt is amazing to see what
ultrasonic energy can achieve in joining, cutting, patterning, and
quilting on synthetic fabrics. These and more operations are done
without the use of thread or adhesives and at speeds much greater
than can be reached with sewing machines - as much as four times
the speed!How does it work? As the fabric passes under the
machine's horn, ultrasonic vibration causes the materials to heat
up and fuse together. Without any additional glue or heat, the seam
is finished. When used with cutting edge tooling, the vibration
cuts through the fabric and seals the edges of the cut to eliminate
any fraying at the edges.Sewing machine operators quickly adjust to
this threadless sewing technique. Modular systems are available for
integration into automated textile manufacturing equipment and web
handling equipment.Plunge welding or cutting is accomplished by
placing the material over a fixed anvil and having the horn or tool
descend to the fabric. This approach is used to punch holes, such
as buttonholes, to cut fabric strips to preset lengths, or to join
pieces together.Principles of OperationEvery ultrasonic unit
contains the following five elements:1. A POWER SUPPLY which
takes line power at 50 or 60 cycles and changes it to high
ultrasonic frequency at 20,000 cycles per second or even higher.2.
A CONVERTER which contains piezoelectric crystals which change
the incoming high frequency electrical signal to mechanical
vibration.3. A BOOSTER which transmits the vibration energy
and serves to increase its amplitude in much the same way as volume
control on a radio.4. A HORN which delivers the vibration
energy to the plastic film or fabric to be worked on.5. AN
ANVIL or backup part which supports the work piece and, in the
case of textiles, takes the form of a pattern wheel or non-rotating
cutter wheel depending on the application.The ultrasonic vibration
is transmitted from the horn to the material. developing frictional
heat where they touch. This momentary heat fuses the edges of the
fabric. If double plies are present, the plies join together. Where
a cutting edge is used on the anvil, the fabric is cut through and
the edges sealed at the same time.MaterialsMaterials may be 100 %
synthetic or blends with up to 40 % natural fibers. Nonwovens,
woven, stretch woven or knit materials can be bonded and cut or
slit. Acrylics, acetates, polyester, nylon, polyethylene,
polypropylene, spandex and PVC are all suitable for bonding or
cutting. In general, the higher the synthetic content, the easier
it is to cut and seal with ultrasonic energy.Some fabrics may be
directional; that is, the fibers in one direction have a different
composition than the fibers in the other direction. This may lead
to different results depending on the direction of the cut and
seal.Making seamsOne of the most common applications is to make
seams or hems in medical disposable products. These include medical
garments, drapes, wipes, face masks, among others. The most
commonly used machine is the Seamstar. Pattern wheels can be
changed to simulate a single row, double row or triple row of
stitches.Extra sealing and neater appearance is seen when an edge
cutter on the same pattern wheel is used to trim the edge as it is
stitched. This feature also guarantees that the edge of the seam
and the seam itself are perfectly parallel… a bonus quality feature
at no extra labor cost. Sealing the seam edge also provides the
benefits of overcasting without the cost.With an air-driven edge
guide, the Seamstar can be operated with minimum supervision. Just
manually feed the materials and straight lines or slight curves can
be joined with no operator adjusting or guiding.Most of the
familiar attachments can be used with the Seamstar; folders of
almost every type can be used with this stitchless sewing
technique.Stitch patterns available include solid lines, dots,
single stitch, double stitch, zigzag, knurl, slant, rope,
serpentine, flower and leaf patterns. The patterns are machined or
etched into the rotating anvil.Sleeves and CuffsCylinder machines,
both off-the-arm and around-the-arm styles, are available. These
machines use a cylindrical arm with a rotary stitch wheel and an
ultrasonic system above me wheel. The fabric is fed between the
pattern wheel and the ultrasonic system. The off-the-arm model is
used for making tubular pans, such as sleeves, pant legs or
continuous tubes. The fabric can be fed through a folder to give a
lapped seam or a double felled seam, for instance. The ultrasonic
pattern wheel then determines the stitch pattern.The around-the-arm
configuration can be used to seam collars and cuffs, or to set
elastic in pant legs, cuffs and similar shapes. Again, a variety o
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