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Ultrasonic In the Road of Packaging 1

  • 2019-08-12

Ultrasonic In the Road of Packaging 1

From the time thermoplastic films were first developed, they have made heat sealing a mainstay for packaging designers. It has been adapted widely for sealing everything from thin-wall food and snack bags to clamshell packages for hardware, electronics, and many other applications. But as heat-sealing technology has matured and packaging materials have evolved, package designers have come to recognize some limitations in this common and widely used packaging method.

With application challenges arising and ordinary heat sealing processes not delivering as hoped, more and more package engineers are looking at alternatives. Chief among them is heat sealing’s more sophisticated and adaptable cousin, ultrasonic welding. There are a host of reasons why many are considering this option, including:

• Contamination due to failed seals, leading to leaks and packaging losses.

• Inadequate control and repeatability of the heat-seal process.

• Increased demands on production driving higher packaging line speeds and faster processing.

• Changes in packaging materials due to cost, performance, or environmental factors.

• Long times spent changing packaging lines, resulting in lost time and productivity.

• Concern about high electrical consumption and cost.


Heat vs. Ultrasonics

Heat seals are simple: Package material or film surfaces are held together, and heated sealing bars are applied on one or both sides. Heat flows (conduction) from the bars through the material to the seal interface, where the mating surfaces melt to form a bond. Conduction sealing controls are straightforward, with temperature, pressure, and dwell time selected based on the melt characteristics of the thermoplastics being joined.



Ultrasonic welding also joins thermoplastic films and materials, but it generates and applies heat and pressure differently. It generates heat by applying a vibration with a precise frequency and amplitude between the surfaces of the thermoplastic layers. The frictional heat melts the interior of these surfaces and, under pressure, creates a permanent bond.



Ultrasonic welding expands the range of control available to create a seal because, within the time required to make a seal, it enables greater and more precise variation in the way heat energy is applied to the sealing surfaces. The main control parameters in ultrasonic welding are shown below:

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