Trinetics Group Finds a Way to Minimize Problems Associated with Ultrasonic Welding

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Recent studies prove that methodology can be used to minimize problems associated with ultrasonic welding of printed board assemblies.

Thirty year-veteran welding company Trinities Group Inc. has hit the drawing boards again. As one of the foremost welding solution providers for various industries in Florida, the company’s recent discovery with methodology has capsized the problems associated with the ultrasonic welding of printed board assemblies.

Ultrasonic welders deliver high frequency vibrations to bond and seal two or more materials into a unitized package. These welders require specially designed tips or horns to transfer ultrasonic vibration energy that bonds the parts. Typical vibration frequencies are in the range of 20,000 or 40,000 hertz; the specific range of frequencies found to be the causation of damage to certain electronic components.

It has been reported that rejection rates of up to 10 percent per run can occur when ultrasonic welders are utilized to weld plastic housings’ that surround PCBs. The input capacitor appears to be the most vulnerable component subject to ultrasonic damage. Furthermore, the same problem arises when quartz clocks are welded, resulting in resonant frequency changes to the crystal.

Damage is believed to be the result of high frequency oscillations transmitted to a particular component. In some cases certain frequencies, specifically near 40 KHz, have been incorporated to reduce rejection rates, but not by a significant degree.

Consequently, these results indicate that ultrasonic frequencies are not totally capable of insuring low rejection rates when utilizing ultrasonic welding equipment.

A unique solution to this problem has recently been employed to significantly reduce post weld rejection rates. This technology incorporates a vibration-less Infra-Red weld process that seamlessly joins plastics in a hermetic seal. Some of the advantages of this technique include:

  •     No vibration
  •     Minimize weld rejection rates
  •     Low operational costs (low amps)
  •     Handle immediately after welding
  •     Eliminate expensive horn and converter replacements
  •     Ease of handling pre and post weld

The intrinsic worth and added performance of Infra-Red welding technology offers the user a quantum jump in cost savings, functionality and efficiency. Trinetics Group Inc., located in Melbourne FL, a leader in the engineering development industry in operational performance of IR welding technology, anticipates a more beneficial future for ultrasonic welding with their latest find.

About the company:

For over 30 years, Trinetics has satisfied the plastic welding needs of both major corporations and small businesses throughout United States and abroad. Trinetics Group's plastic and metal welding systems are designed and built with the philosophy of providing the right equipment for the application. Allied Signal, HoneyWell, Dell Computer, Gateway Computer, IBM, Cuno, Whirlpool, Stanadyne and General Electric are just a few who have benefited from their experience and expertise. Trinetics offers several lines of high-tech patented welding equipment, starting with standalone bench models to fully automatic assembly systems. They do ample research into prototyping product development prior to producing equipment.

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Michael Munnings
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