Hangzhou Powersonic Equipment Co., Ltd. |
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20khz Sewing Machine with rotray horn for continuous fabric/ PU/ Non-woven welding
An Overview
It 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 Operation
Every 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.
Materials
Materials 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.
parameters:
Output power : 2000W |
Power Input : 200V/50Hz |
Output frequency : 15KHz |
Working temperature : -10-28C |
Working speed : 0-8m/min |
Equipped pattern mould : 0-100 mm |
Size of machine ( L * W * H ) :1300 * 600* 1260 mm |
Weight of machine : 150 Kg |
Making seams
One 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 Cuffs
Cylinder 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 of patterns is available, from single row up to
three rows of stitches or solid lines.
On the around-the-arm machine an edge cutter can be used to trim
the edges for a neater appearance and to prevent fraying.
Special Seams
The effect of special seams, such as top stitching or zigzag
stitch, can be achieved by the pattern wheel design. Let your
imagination be your guide.
Slitting/Sealing
Ultrasonic slitters cleanly cut and seal the edges of synthetic or
blended fabrics, eliminating the disadvantages of hot wire or
rotating knives. Fraying, unraveling, or beading along the cut edge
are eliminated.
Slitters may be mounted on a loom to cut the non-selvedge edge of
woven fabric. Equipment is available to operate at the slow speed
of weaving looms without burning or beading me fabrics. With
special framework and motor drive, crosscuts can be made on the
loom.
Web Handling Equipment
Many designers and manufacturers of web handling equipment are able
to coordinate the requirements for adding ultrasonic slitters and
cutters to their equipment.
Slitters may be installed on a loom to trim and seal the edge of
fabric or to slit wide fabric into thinner strips. A single system
with a bar horn and multiple cutting modules can cover about 20 to
25 cm wide fabric. Multiple systems can be used to cover wider
widths of fabric. This technique is used frequently for slitting
garment labels; it provides an attractive sealed edge with a soft
feel to the skin. Fine fabrics with a high percentage of synthetics
can be slit at high speeds up to 100 m per minute or more. Heavier
fabrics require a slower speed.
With appropriate framework and motor drive, cross-cuts can be made
on the loom for cutting to a selected length. Special high-power
rotary system modules are available to cut and seal heavier weight
materials, such as automotive carpeting.
If a particularly broad sealed seam is required it is sometimes
preferred to pre-compress the material using one ultrasonic head,
and then slit me center of the sealed area using either a second
ultrasonic head or a mechanical cutter. This technique has been
used to produce lint-free wipes.
Nonloom Applications
An extra fine filter fabric used in the medical industry is made in
a long thin tubular form. A very high frequency. low power
ultrasonic cutter is used to slit the tube into shorter sections by
placing the ultrasonically vibrating cutter against a circular
mandrel which rotates the long regular part.
Ultrasonic systems can be used to slit computer ribbon, plastic
films, filters, fabrics, nonwovens, pads, and quilted fabrics.
When a double layer of fabric is ultrasonically slit, the materials
fuse together along the cut line. This is a perfect way of joining
fabrics and sealing the edges together where a high strength bond
is nor needed or where later finishing work is needed. A quilt
maker uses this technique to compress and seal the edges of quilts
and mattress pads which later have piping or skirting attached.
Hand Cutting
A hand-held cutter is available for cutting straight lines or
gentle curves by hand or using a simple guiding mechanism. One
application is for a small flag and pennant manufacturer. Cutting
the edge of the flags ultrasonically eliminates the former
requirement of folding and stitching a seam along the edges,
producing an attractive flag without excessive labor cost.
A modular version of the hand cutter has been used with a robot arm
to perform fairly high-speed cutting of a circular part Iying on a
steel table.
Plunge Cutting
A plunge Cut operator can be used to cut-to-length ribbons, belts,
etc. Widths up to about nine inches can be considered. A plunge
approach is used together with a commercially available strip
measuring device to preselect the length of ribbon and
ultrasonically cut a diamond shape at the preselected length,
forming two ribbon ends with an inverted "V" shaped end. Straight
cuts are made on tubular-shaped padded material used for patient
restraints, This tubular part is folded and ultrasonically seamed
before being ultrasonically cut to length. When cutting the double
layer, the seam is also made, an advantage over a mechanical cut.
The waistband of men’s slacks is cut and seamed ultrasonically to
give a pleasing finish to the cut edge without sewing.
Belts are edge-seamed and then automatically cut to length
ultrasonically by using a triple cutter wheel on the Seamstar
sewing machine and plunge cutting to length. This permits two belts
to be made at a time using two layers of fabric, cutting each edge
and the center and then cutting to length.
Plunge Sealing and Cutting
Ultrasonic plunge sealing and cutting are accomplished by single or
multiple horns advancing onto the materials which are placed on a
fixed anvil. The horns are generally flat faced titanium with a
carbide coating and a maximum width of about 25 cm. The desired
pattern is usually machined or embossed on the anvil which is made
of heat treated steel. Production rates of 20 pieces per minute are
possible with manual feed. Automatic feeding may be used to
increase or sustain higher rates.
Applications include buttonholes, eyelets or grommet-like patterns
cut and sealed from single or multiple plies. For instance, pet
collars have several spaced holes punched in them using a flat horn
and a series of spaced punchlike tools in the anvil. Other
practical uses include fabric and vinyl belts and collar stays.
Splicing or sealing applications include the joining of hook and
loop such as Velcro® to itself or to other fabrics permitting the
attachment of loops, traps or buckles. Splices can be made straight
or on the bias. A stitch pattern can be achieved, if desired. A
plastic stiffener is inserted into a folded nonwoven fabric and the
edges sealed using a plunge welder for a first aid splint; tapes
are attached and eye shields attached to a surgical face mask; ties
are attached to a nonwoven medical gown, all using the plunge
welding technique.
A special machine is available for adding a plastic collar to a
filter bag. The machine uses multiple heads (up to six) to weld
through the fabric to the collar. Production rates up to 180 pieces
per hour are achievable.
Equipment includes 20 kHz units at power levels up to 3000 watts,
35 kHz equipment at power levels co 900 watts and a small 70 kHz,
90 watt unit for very light work. Units are available with
microprocessor controls for control and monitoring of the welds by
time, energy or distance.
Adhesive Bonding
Heat-activated materials are placed between two fabrics that are
nor thermoplastic. such as cotton or wool or blends with little
synthetic content. The ultrasonic vibrations cause the
heat-activated material to flow into the fibers of the fabric,
joining them together.