Ultrasonic Inserts

Ultrasonic Inserts, also known as Ultrasonic Welding Inserts or Ultrasonic Threaded Inserts, are specialized fasteners used in ultrasonic welding processes. These inserts are designed to be embedded into plastic parts using ultrasonic energy, creating a strong and reliable threaded connection within the plastic component. Ultrasonic inserts offer several advantages and are widely used in various industries for their efficiency and effectiveness.

Purpose and Function:

The main purpose of ultrasonic inserts is to provide a threaded connection within plastic parts. These inserts are designed to be inserted into pre-moulded holes or slots in the plastic component. During the ultrasonic welding process, the insert is vibrated at a high frequency, creating friction that melts and bonds the plastic around the insert. This forms a secure and permanent threaded receptacle within the plastic part, allowing for the easy attachment of screws, bolts, or other fasteners.

Features and Benefits:

1. Strong Threaded Connection:Ultrasonic inserts create a strong and reliable threaded connection within the plastic component, ensuring durability and stability in the assembled product.
2. Time and Cost Efficiency:The integration of inserts during the ultrasonic welding process eliminates the need for post-welding operations, such as drilling or inserting separate fasteners, saving time and reducing manufacturing costs.
3. Uniform Distribution of Stress:Ultrasonic inserts ensure that stress is uniformly distributed throughout the plastic component, reducing the risk of cracking or failure under load.
4. Versatility:Ultrasonic inserts are available in various sizes and thread types, allowing for flexibility in design and application.
5. Compatibility with Different Plastics:Ultrasonic inserts can be used with different types of plastics, including thermoplastics like ABS, PC, PE, PP, and more.

Installation:

The installation of ultrasonic inserts involves the following steps:

1. Preparation:The plastic part is first moulded or pre-drilled to create a hole or slot for the insert.
2. Insertion:The ultrasonic insert is placed into the pre-moulded hole or slot.
3. Ultrasonic Welding:During the ultrasonic welding process, the ultrasonic horn applies high-frequency vibration to the insert, creating friction and heat. This heat melts and bonds the plastic around the insert, forming a secure and permanent threaded connection.

Applications:

Ultrasonic inserts find applications in various industries, including electronics, automotive, consumer goods, and more. They are used in products like electronic housings, automotive components, medical devices, and various other plastic parts that require strong threaded connections.