The working principle of the Bison Ultrasonic Welding Machine

The Bison ultrasonic welding machine achieves material connection based on 'ultrasonic vibration + friction heating + molecular fusion'. The core components of the equipment are the ultrasonic generator, transducer, amplitude rod (amplitude adjuster), and welding mold (welding head):

1. Energy conversion: The generator converts mains electricity into a high-frequency electrical signal of 15 - 40kHz, which is then transformed into mechanical vibrations of the same frequency by the inverse piezoelectric effect through the transducer (piezoelectric ceramics/magnetostrictive materials);

2. Amplitude amplification: The amplitude rod amplifies the tiny amplitude (several micrometers) output by the transducer to the required welding amplitude (10 - 50μm) through acoustic design;

3. Friction heating: The welding head transmits the high-frequency mechanical vibrations to the surface of the workpiece, causing rapid heating (plastic welding usually reaches 200 - 300°C within 2 - 3 seconds) at the contact interface under pressure (0.1 - 5MPa, adjusted according to the material), melting the material;

4. Molecular fusion: After the vibration stops, the hold-pressure cooling phase allows the molten material molecules to rearrange and crystallize, forming a solid joint and completing the welding.

Industry Applications

(A) Consumer Electronics

• Core applications: Mobile phone/tablet casings (plastic-to-metal snap welding), charger/data cable interfaces, smart wearable devices (earphones, bracelet casings), laptop battery packs (plastic shell sealing);

• Value points: High-speed welding (1 - 5 seconds per cycle) adapts to production line pace, no glue/screw contamination, ensuring the appearance and waterproofing of electronic products (IP67 level sealing).

(B) Automotive Manufacturing

• Core applications: Engine periphery (intake manifold, oil pan plastic parts), interior trim (dashboard, door panel trim), new energy battery packs (cell support, shell sealing), headlight assemblies (lampshade and base);

• Value points: High-strength welding replaces traditional connections, improving structural reliability; ultrasonic welding has no thermal radiation, suitable for engineering plastics such as PP, PA, ABS, contributing to automotive lightweighting.

(C) Medical Devices

• Core applications: Syringes/infusion sets (luer connectors, piston welding), hemodialyzers (membrane components and plastic shells), medical catheters (multi-chamber tube splicing), reagent bottles/culture dishes sealing;

• Value points: The welding process is clean (no debris, chemical residues), conforming to ISO 13485 medical standards; precise control ensures the sealability and biocompatibility of the device.

(D) Packaging Printing

• Core applications: Plastic packaging (sealing bags, anti-counterfeiting caps), paper-plastic composite packaging (milk tea cup lids, food trays), label/nameplate welding (plastic card holders with metal labels);

• Value points: Rapid sealing (0.5 - 2 seconds) improves packaging efficiency, ultrasonic welding consumes no materials, reduces production costs, suitable for fast-moving consumer goods demand in the food, daily chemical industries.

(E) Home Appliances and Furniture

• Core applications: Washing machine balance rings, refrigerator condenser tube shells, plastic door and window profiles splicing, bathroom products (toilet seat components, shower head connectors), furniture plastic accessories (drawer guides, chair legs);

• Value points: Replacing glue/screws simplifies the production process; welding strength ensures the durability of home appliances, suitable for multi-material household products such as PP, PVC, PET.