ASSEMBLY METHOD

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Ultrasonic welding is a well-known technology applied in light manufacturing. Creating high-frequency ultrasonic vibration, applied to two different pieces made of plastic, welds them together and results in a perfect bond. Here is some information to figure out ultrasonic welding.


Principle

The frequency of ultrasonic welding is between 20 and 40 kHz. These very high-frequency vibrations can pass through the surfaces between the two plastics, producing high temperatures and softening the surface of plastics. Once the vibrations are stopped, this melted material cools and solidifies to bring out the joint.

 Advantages

Fast and high Efficiency: The process of ultrasonic welding is done within a few seconds, which is suitable for large-scale production.
High Strength: The formed joints are of high mechanical strength, hence able to bear large forces.
No Additives: After using ultrasonic welding, no adhesives or other auxiliary materials are therefore necessary. In that case, it can decrease costs and reduce pollution.
High precision: This technique is allowed to bond highly precisely, so it's applicable for complex, fine components.
Environment Friendly: Ultrasonic welding doesn’t emanate any toxic gases. Thus, it is environment-friendly.


Applications

Ultrasonic welding has wide applications in bonding several plastic components in lights. Some of the applications include


Bonding Lenses and Housings: Can bond transparent or semi-transparent lenses to the housing
Fixing Lenses and Reflectors: Fix the optical lenses and reflectors in place
Assembling Internal Components: Fixtures used to attach internal brackets, heat sinks, and light guides.


This process is best suited for thermoplastic materials, which include:


Polycarbonate PC
Polymethyl Methacrylate PMMA
Polypropylene PP
Acrylonitrile Butadiene Styrene ABS


Steps of Operation
Workpiece preparation: Put the plastic parts in the fixture of the ultrasonic welding machine.
Setting Parameter: Setting the parameters of the ultrasonic welding machine, such as the vibration frequency, vibration amplitude, time of welding, and pressure.
Start Welding: Turn on the ultrasonic welding machine to operate the welding.
Cool and Remove: At the end of welding, cool down the material and let it solidify before removing the workpieces.

Maintenance
Equipment Checks: The ultrasonic machine is checked regularly so that the machine runs smoothly.
Cleanliness of Welding Head: The welding head is cleaned regularly so that impurities do not accumulate, which will affect welding quality.
Test Bond Strength: To assure the quality of welding, all normal test bond strengths are carried out.

Conclusion

In automobile light manufacture, ultrasonic welding technology can be applied because it is a very fast process with the capability of developing welds that are high in strength and precision. Being a very correct material combination in conjugation with a correct set of operating parameters, ultrasonic welding will go on to make high-quality bonds that come up to the stringent requirements in manufacturing automotive lights.