Technical

Information
PW-7

Ultrasonic Welding Characteristics

General Description
The ability to ultrasonically weld textiles and KNITS—Textiles formed by interconnecting contin-
films depends on their thermoplastic content and uous loops of filaments or yarns.
the desired end result. This data sheet defines the • Factors Influencing Weldability: Style of knit,
weldability, in general terms, of the more common thermoplastic content, and elasticity of con-
textiles and films. (The term ‘welding’ refers to all struction.
types of bonding and sealing, as in point bonding
of fabric or continuous sealing of film.) FILMS—Thermoplastic material that has been cast,
The table on the reverse side indicates relative extruded or blown into a film, generally under
weldability characteristics for the more common 0.010" (0.254 mm) thick.
textiles and films. • Factors Influencing Weldability: Film thickness
(at least 0.0005" [0.013 mm] thick), density,
Material Construction and Factors and thermoplastic type. Applied
Influencing Weldability Technologies
COATED MATERIALS—Textiles and films covered
The major categories of material construction with a layer of thermoplastic, such as polyethyl- Group
of thermoplastic textiles and films are: wovens, ene or urethane. Base material need not be ther-
nonwovens, knits, films, coated materials, and lam- moplastic (i.e., coated cardboard or paper).
inates. 41 Eagle Road
• Factors Influencing Weldability: Coating mate- Danbury, CT
Following are definitions of each of the con- rial, thickness, and substrate characteristics.
06813-1961
structions as well as factors of each type that influ-
(203) 796-0349
ence their relative weldability. LAMINATES—Textiles and films consisting of two Fax (203) 796-9838
or more layers in a sandwich form. E-mail: info@bran-
WOVENS—Textiles formed by the regular inter- • Factors Influencing Weldability: Thermo- sonultrasonics.com
weaving of filaments or yarns. plastic type and content.
• Factors Influencing Weldability: Yarn density, Textile and Film
thermoplastic content, tightness of weave, uni- Welding Characteristics
formity of material thickness. Weld strength Unlike welding of rigid plastic parts, the ultrasonic Technical Center
may vary according to the orientation of yarns welding of textiles and films relies on a pattern or
or filaments. 1665 Lakes Parkway
design on the tooling (i.e., the face of the horn, the Suite 107
anvil, drum, or stitching wheel) to focus the ultra- Corporate Lakes
NONWOVENS—Textiles formed by bonding sonic energy and produce a melt. (Refer to Branson Lawrenceville, GA
and/or interlocking fibers, yarns, or filaments data sheet PW-45 for patterns.) In general, favor- 30043
by mechanical, thermal, or chemical means. able material characteristics that will help to ensure (770) 962-2111
• Factors Influencing Weldability: Uniformity successful ultrasonic welding or bonding are: Fax (770) 962-3720
of material thickness and thermoplastic con- E-mail:
tent. Random orientation of fibers gives non- • 65% thermoplastic content (minimum) BUCGA@bransonul-
wovens excellent strength. • Uniform thickness trasonics.com
 Relative Ease of Welding welding (near-field welding refers to a joint or
interface 0.25 inch [6.35 mm] or less from the
The codes in the table below indicate relative
horn contact surface), and are usually point-to-
ease of welding for the more common thermoplas-
point contact (i.e., continuous sealing).
tic materials. The ratings do not relate to the strength
of the weld obtainable. Use this table as a guide only, Note, also, that certain materials (e.g., foam)
since variations in the materials and their form may weld better in the plunge mode (as on a
may produce slightly different results. bench-top welder), than in the continuous mode.
This is because there is no hold time (cool down
Note: These ratings may differ from character-
under pressure) in continuous bonding, and some
istics of rigid plastic welding. This is because textile
material structures may require a slower buildup of
and film welding are considered very near-field
heat and pressure to prevent material destruction.

Coated
Material Woven Nonwoven Knitted Materials Laminates Films
Acrylic 4 — 4 — — (c)
EVA — — — 2 — 1 (e)
Nylon 2 2 2 2 2 2
Polyester 2 1 2 1 1 1
Polyethylene — 1 – 1 1 4-5 (a)
Polypropylene 1 1 2 1 1 1
PVC 3-5 — — 3-5 3-5 3-5 (b)
Saran — — — 1 — 1 (e)
Surlyn — — — 1 — —
Urethane — — — 1 — 1 (d)
Natural Fibers 2 2 2 2 2 —
with Fusibles
Code: 1 = Easiest; 5 = Most Difficult
Note: Categories left blank (—) indicate that the materials are not generally seen in this form.
a Thin polyethylene film (less than 0.003" [0.076 mm]) is generally considered poor for ultrasonic welding, because
it has a low coefficient of friction and tends to break down or degrade during welding.
b PVC sheet or fiber is difficult to predict due to the broad range of additives used in its manufacture. Plasticizers are
often added to PVC to increase flexibility. As the content of plasticizer increases, the ability to ultrasonically bond
PVC can be inhibited.
c Acrylics can be ultrasonically tacked or cut. Continuous bonding is generally unsatisfactory due to e m b r i t t l e -
ment and low strength.
d Thermoplastic urethane (ester base) coated materials exhibit excellent strength when bonded ultra-sonically.
Thermosetting urethanes (ether base) will degrade when subjected to ultrasonic energy.
e Cut and seal only.

Typical Applications
Following are some typical applications using ultra- PVC: Films, outdoor furniture, shrink packaging,
Branson sonics: tarpaulins.
Worldwide Acrylic: Filters, awnings, blankets, knitting yarns, Urethane: Rainwear, coated materials.
Headquarters garments
Nylon: Carpet, sports gear, food bags, filters, gar-
Contacting Branson
41 Eagle Road ments, hook and loop material, seat belts. In addition to our worldwide headquarters in
Danbury, CT Polyester: Conveyor belts, filters, garments, lami- Connecticut, you can contact our Textile and Film
06813-1961 nates, mattress pads, packaging, quilts. Technical Center in Georgia:
info@BransonUltrasonics.com Polyethylene: Laminates, packaging film, reseal- Branson Textile and Film Technical Center
able bags. 1665 Lakes Parkway, Suite 107 Corporate Lakes
Polypropylene: Bags, carpet backing, outdoor furni- Lawrenceville, Georgia 30043
© Branson Ultrasonics ture, snack food packaging, tents, upholstery, (770) 962-2111 FAX (770) 962-3720
Corporation, 1981 Email: BUCGA@bransonultrasonics.com
Revised and Printed in
disposable garments.
U.S.A. 2/03
www.Branson-PlasticsJoin.com