US-501 operation manual
US-501 R02 13.07.09 Display version 4, PLC version 4
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> Principle of Ultrasonic Welding
Ultrasonic energy is a form of physical vibration. The commonly used vibration frequencies are 20
kHz, 30 kHz, 35 kHz and 40 kHz. Different materials exhibit different behaviors under ultrasonic
vibration. Synthetic material generates internal heat under ultrasonic vibration. The US-501
machine generates vibration on the surface of the horn. Fabric with at least 50% synthetic material
is placed on the surface of the horn. A special tool called cutter bit is press against the horn so that
fabric between the horn and the cutter bit is exposed to vibration. The heat generated in the fabric
portion under pressure is heated up instantly and the temperature is high enough to melt the fabric,
hence resulting in an ultrasonic cut.
US-501 is engineered to careful manage this vibrating energy in order to slice fabric consistently in
single layer or multi-layer application.
During single layer operation, fabric is melted and separated resulting in a fray free edge. While
during multi-layer operation, layers of fabrics are cut but at the same time the edges of the fabric
are melted and fused together resulting in a ‘weld’. This process is sometimes referred as a ‘cut and
seal’ or ‘line bonding’ operation.
