Ultrasonic Lamination and Embossing for Nonwovens - Dukane

Excellent for Processing Lofty Webs or Materials

Enables bonding through lofty nonwoven structures that contain SAP (superabsorbent polymers) and other non-thermoplastic elements, thereby minimizing or eliminating the need for costly, messy and performance-inhibiting adhesives.

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Faster Processing Speeds

Enables faster bonding capability due to rotary components. Rotary ultrasonic bonding is capable of more than 800 meters per minute in some applications.

Increased Operational Efficiency

When the cost of operating and maintaining the adhesive applicator equipment is eliminated, labor and utility costs will decrease.

Product Design Flexibility

Embossing can be done during the lamination process or separately. Anvils are often customized with intricate patterns such as logos and other designs.

Material Cost Savings

Ultrasonic technology provides cost savings by providing the option of purchasing less expensive, lighter weight nonwoven materials and elastics. This is because there is no bleed-through due to the adhesive.

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Improved Product Comfort

Eliminating adhesive allows the finished product to be softer, odor-free, and offer more breathability. It also enables the use of lighter weight fabrics so the final product is thinner and has reduced visibility when wearing.

Increased Sustainability

Ultrasonic bonding consumes less energy because it replaces hot melt delivery and application systems with a highly efficient ultrasonic energy source. Furthermore, there are fewer toxins in the landfill after the product is used.

Ultrasonics are produced in the generator and transformed into mechanical vibrations in the converter. These are introduced into the material by sonotrodes. The standard frequencies here are between 20 and 35 kHz with an amplitude of 10 to 50 μm. The plastic portion of the material is stimulated, heats up and is melted. The actual weld process is fast: Thanks to the use of rotating tools such as anvil drums, up to 800 m of nonwovens can be processed per minute. The anvil drum serves as an anvil and has an individual surface structure to focus the ultrasonic energy precisely. This allows exact weld, embossing or cutting results to be achieved.

A constant distance between the material being processed and the tools is important for optimal results. This is guaranteed via the precise control technology. It ensures that the distance always remains the same, even if the weld tools change due to the heat generated during the weld process.

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