ultrasonic tube sealing system
Ultrasonic technology has evolved from ultrasonic plastic welding and ultrasonic metal welding to applications in plastic packaging edge sealing, plastic tube sealing, and metal tube sealing.
Principle
1. The transducer of the ultrasonic welding equipment converts high-frequency electrical signals (typically 20-40kHz) into mechanical vibrations, which are amplified by a booster and transmitted to the welding horn (upper mold).
2. The welding horn presses down onto the sealing area of the plastic packaging (such as the PE or PP material at the tail of a toothpaste tube). The high-frequency vibrations (tens of thousands of times per second) cause intense friction between plastic molecules, generating heat that rapidly raises the plastic temperature to its melting state (exceeding the material’s melting point, e.g., PE melts at approximately 110-130°C). This allows molecular chains to flow and diffuse into each other.
3. The molten plastic cools and solidifies under the pressure of the welding horn, forming strong sealed tube joints suitable for various industries. that achieve a tight seal at the tail.
Advantages
- 1. 100% airtight, watertight, anti-microbial, anti-oxidation: High-frequency vibration directly fuses plastic molecules to form a continuous and gap-free sealing line, effectively blocking air, moisture, and microorganisms to extend product quality.
- 2. Efficient production: Single welding takes about 1 second, much faster than hot plate sealing (3-5s) and pulse sealing (2-3s). The modular design allows free integration with automated systems for fully automatic sealing.
- 3. High precision and consistency: Hyusonic ultrasonic sealing machines use digital power output with a control precision of 0.01mm, setting strict thresholds for multi-dimensional parameters (time, energy, position) to ensure high-standard welding consistency.
- 4. Clean and low-cost: Ultrasonic sealing machines generate no chemically polluting gases, ensuring environmental cleanliness throughout. For cosmetics, food, or daily products, this eliminates harmful emissions, complying with FDA standards.
- 5. Suitable for thin-walled and high-precision packaging: Ultrasonic energy concentrates on the contact surface, with minimal thermal impact on 0.1-2mm thin-film packaging (e.g., toothpaste tubes with ~0.3mm wall thickness), preventing deformation or heat-induced spoilage of contents (e.g., skincare with active ingredients).
- 6. Aesthetic and customizable sealing: Welding horns can be designed with smooth surfaces or patterns (e.g., brand logos, anti-slip ridges), ensuring flat, scorch-free sealing edges to enhance product grade (meeting aesthetic requirements for premium facial cleanser packaging). Production dates or batch numbers can also be printed on the sealing area for traceability.
Is ultrasonic sealing better than heat sealing?
Ultrasonic sealing and heat sealing each have their own advantages and disadvantages, specifically depending on application scenarios and requirements. Ultrasonic sealing is more suitable for thin, heat-sensitive materials (such as certain plastic films and aluminum foil composites) because it generates heat through high-frequency vibrational friction, with heat concentrated on the sealing surface. It has little impact on surrounding materials and is less likely to cause burning-through or deformation. Heat sealing (direct heating), on the other hand, is more suitable for thick materials, multi-layer structures, or high-temperature-resistant materials, but it may cause damage to heat-sensitive materials due to heat diffusion.
Principle
Ultrasonic sealing technology is based on the mechanical and thermal effects of ultrasonic vibration energy. The ultrasonic welding horn vibrates at high frequency and presses against the end of the metal tube, causing the contact surface of the tube to generate local heat (temperature can reach 30%-50% of the metal’s melting point). The metal tube deforms and is pressed together. Meanwhile, the vibration energy breaks the oxide film on the metal surface, exposing clean metal lattices, which promotes atomic diffusion and bonding, thus completing a firm and tight sealing weld.
Advantages
- 1. High efficiency: Ultrasonic vibration energy can complete the sealing of metal tubes in milliseconds. Compared with traditional welding (such as resistance welding and laser welding), the production efficiency is increased by more than 30%, making it particularly suitable for mass production lines.
- 2. Clean and low energy consumption: No solders or flux are added during welding, avoiding chemical pollution. With high energy utilization, it can save more than 50% of energy compared with laser welding, meeting the requirements of green manufacturing.
- 3. High-strength sealing: The seal formed by atomic diffusion and bonding can achieve 80%-90% of the base metal’s strength, with excellent sealing performance to effectively prevent gas and liquid leakage. For example, the sealing of refrigerant pipes can withstand pressures of tens of megapascals without rupture.
- 4. Low cost: No solders are required, and the modular simple structure ensures long service life of core components with low maintenance costs. Meanwhile, eliminating post-welding processes (such as cleaning and grinding) reduces overall production costs.
Conclusion
Whether you’re sealing plastic or metal tubes, ultrasonic sealing offers a highly efficient, clean, and reliable solution. Hyusonic’s advanced plastic tube sealing systems and metal tubing sealer machines are designed to meet high production demands across cosmetics, pharmaceuticals, and industrial applications.
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