Ultrasonic Die Cutting
Ultrasonic
die cutting involves a metal 'horn' made to vibrate like an audio
speaker, but at an ultrasonic (outside human hearing range) frequency.
When this vibration is applied to a material with a die under it,
heat and pressure are generated. This will cause sealing of thermoplastic
materials (either the edges of a single layer or bonding of multiple
layers) and cutting given the proper blade configuration.
The most common uses of Ultrasonic is for sealing where the materials
to be welded are sandwiched between the ultrasonic horn and an anvil.
In the last few years, many applications have been developed to cut
and seam materials between an ultrasonic horn and a rotating or not
rotating blade. This operation is much like a sewing machine.
CRC has taken the technology to the next logical step. We apply the
vibration of the ultrasonic horn to the material against a rotary
die. This means that we can die cut and seal two dimensional shapes
in a continuous process. This leads to higher productivity and the
possibility of making larger and more complex shapes. At this point,
we are still limited to 4 inches (100 mm) wide and about twice that
length.
Ultrasonic die cutting is particularly desirable for:
-
Cutting thermoplastic material that tend to fray when cut or
handled (this method seals the edges)
-
Making 'tea bags' and filter with clean, dependable sealed edges,
free of charring and discoloration.
Ultrasonic rotary die cutting has its limitations:
