For all its flexibility and versatility, most ultrasonic production is done using two basic modes of operation - plunge or continuous - with variations depending on the application. Sealing and cutting can be done in either mode. In the plunge mode, the ultrasonic horn operates perpendicularly to the material and fuses the layers together in the pattern of the stationary anvil. This technique can be used to simultaneously cut and seal the edges of material. Typical applications using this mode include bra straps and buckles, buttonholes, collar stays, darts, strapping, embossing, grommets, belt loops, filter media (woven and nonwoven), zipper stops and vertical blinds.
Ultrasonic Slitting
With the continuous mode, material is moved beneath a stationary horn. Most slitting applications are done in the continuous mode. Ultrasonic slitting produces an edge that is smooth, durable, and clean, with no discoloration of the fabric. Ultrasonics prevents unraveling of knitted or woven materials by sealing the slit edge. The sealed edge is tapered without a bead that would add unnecessary bulk.
Ultrasonic Sewing
Two models of "sewing" machines are available. These fabric sealing systems "sew" and/or slit knitted, woven, and nonwoven man-made thermoplastic materials without needle or thread. Machine configuration and the location of the horn and anvils enable flexibility and tight turns in sealing and/or cutting. This also provides an un-obstructed view of the fabric in the processing area.
Typical applications for the systems include protective garments, disposable hospital gowns, shoe covers, face masks, infants' nursery garments, filters, bags, curtains, sails, and web splicing. Sealed edges and seams with no stitch holes prevent penetration of chemicals, liquids, blood-borne pathogens, or particulates, thus providing a benefit over conventional stitching methods.
