NONWOVENS
High Processing Speed And Consistent Quality For Nonwovens
Processing of nonwovens, composite materials, textiles and paper demand continuous production applications that combine high-speed and maximum precision.
How Does Ultrasonic Nonwoven Bonding Work?
The ultrasonic bonding system for nonwoven materials consists of an engraved anvil drum and an ultrasonic system with acoustic stack (converter, amplitude coupler and sonotrode). The acoustic stack is mounted above the rotating anvil drum leaving a small gap between the surface of the rotating anvil and the sonotrode. The sonotrode constantly expands and contracts (amplitude) 20,000 times per second. As material passes through the gap, force and amplitude are applied to the material. During the expansion cycle, sufficient compression is applied through the material against the raised bonding points of the anvil drum creating surface friction to melt the nonwoven materials. During the contraction cycle the gap is increased allowing the material to move through the gap without material jams. Ultrasonic bond strength is controlled by constant web speed, constant amplitude and consistent force applied to a specific anvil drum pattern.
Continuous Ultrasonic Technology Can Be Used In A Wide Range Of Applications
- Bonding, cutting and sealing in machine direction and cross machine direction in one step.
- Creating durable laminates of multiple layers, even of different materials
- Embossing of trade marks, logos or decorative elements, e.g. for automotive seat covers and car interior lining
Advantages And Benefits Of The Nonwoven Bonding Process
- Consistent material characteristics; bonding and cutting with ultrasonics eliminates thermal distortion of the nonwoven material and maintains softness, loft and air permeability of the material
- Ultrasonic laminating allows for the bonding of materials with different melting points
- Ultrasonic bonding produces environmentally friendly laminates. The laminates do not contain any adhesives or other consumables making them recyclable
- Consistent weld quality even when laminating multiple layers of different materials or when bonding intermittently in cross machine direction
- The ultrasonic nonwoven bonding technology offers immediate system availability without heat-up time, fast set-up and reduced energy consumption
- Major cost savings as a result of minimized scrap after machine start up and shut down
- High production speeds with ultrasonic nonwoven bonding
Why Herrmann Ultrasonics Is Right For You
Herrmann Ultrasonics patented NON-CONTACT / NON-WEAR technology with MICROGAP control automatically compensates for thermal expansion and maintains a constant force between sonotrode and anvil drum. MICROGAP with Force Sensor that is integrated in the actuator unit, constantly measures the bonding force the sonotrode applies to the nonwoven material. When the sonotrode and anvil drum thermally expand, the gap between sonotrode and anvil drum changes, increasing the bond force applied to the material. The MICROGAP controller compares the actual weld force to a programmed target force and adjusts the position of the sonotrode until the actual weld force equals its target value. In combination with Herrmann's patented sonotrode mount, the force control is perfectly suited for intermittent nonwoven bonding applications. Through continuous research and development, Herrmann Ultrasonics offers rotary sonotrodes that synchronize with the rotation of the anvil. Both anvil drum and sonotrode can be engraved with bonding patterns to meet special application requirements for nonwoven and textile processing.
In our modern application laboratories we can evaluate your products and demonstrate our capabilities. Please provide us with your requirements inquiery so that we can discuss it with you in greater details.
NONWOVENS bonding systems
