JOINING | INNOVATION
Finding the right bond for moulders’ needs
New developments in welding of moulded parts include servo-driven ultrasonics and the potential for joining recycled plastics. David Eldridge finds out what’s new
The injection moulding market for joining technolo- gies continues to grow as companies need to find innovative ways to bond components that are technically challenging. Solutions also need to tick boxes for sustainability and cost control. Leading companies in the field have been further developing systems using ultrasonic, laser and heat staking tech- nologies. Materials companies have also announced new products designed for laser welding. Rinco Ultrasonics, a leading global manufac-
turer of ultrasonic welding equipment, says that keeping energy costs under control is a motivation for companies when buying joining technology. “We see continuing strong growth for joining equipment as injection moulders look to enhance their operations with cost-effective manufacturing strategies,” says Rinco. “Ultrasonic welding contin- ues to play a key role in plastics manufacturing as moulders focus on optimal design and perfecting secondary operations.” The trend for injection moulders to make thinner walled parts helps save material costs. This creates welding challenges to avoid destroying the parts or internal components, which the company has answered with the introduction of a servo-driven system which has tight control to meet these requirements.
Rinco says its eMotion servo-driven ultrasonic welder provides control of all seal parameters through the entire process cycle, enhancing performance and repeatability in all applications. It says: “This is a high-value addition to our product line. It helps push the limits of what our customers
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can achieve in weld quality and repeatability.” It continues: “The electrical motion welding system enables users to finely regulate the weld, using precise positioning of the horn, along with the applied welding force to the welding rate. This means considerably better results in welding, punching, cutting, and sealing of moulded thermo- plastic parts, nonwovens, and synthetic textiles.” Another key feature of the eMotion system is a high-performance PC that is operated via a 12-inch adjustable touchscreen, with the welding process triggered through an ergonomically designed two-hand operation. Rinco says: “The unique capabilities of servo control allow for dynamic adjustment to the weld velocity during the cycle. Further, adjusting the weld amplitude while simultaneously shifting the joining velocity results in the strongest possible welds with the least possible part marking.”
Rinco conducted a study on an automo- tive assembly bonding dissimilar materials (PA-12 to PC/ABS), that compared an
Right: Rinco Ultrasonics says the trend for
injection moulders to make thinner walled parts creates welding challenges
May 2023 | INJECTION WORLD 37
Main image: Rinco Ultrason- ics has
developed the eMotion
servo-driven ultrasonic welder
IMAGE: RINCO ULTRASONICS
IMAGE: RINCO ULTRASONICS
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