Sonotronic GmbH

iSONIC ECO TM: Tabletop machine

iSONIC ECO TM Ultrasonic power with dual drive option – electric or pneumatic Ultrassonic in perfection The iSONIC ECO TM, electric or pneumatic, masters ultrasonic welding, riveting, embossing, cutting and sealing. Compared to conventional thermal welding processes, the use of ultrasound is characterized by its energy efficiency, as no tool heating is required. However, if the application requires it, thermal or non-contact welding methods can be used. The combination of efficiency and flexibility makes the iSONIC ECO TM the perfect solution for application processes in the automotive, plastics, technical textiles and packaging & food industries. Drive technologies as required Which drive do you prefer? Electric or pneumatic? The iSONIC ECO TM is designed to offer both options. With its slim design and versatility, this tabletop machine remains flexible for your individual application processes. The electric drive demonstrates its outstanding efficiency in movement tasks, while the pneumatic drive shows its strengths in holding times. Various cylinder sizes are available to ensure maximum force.

iSONIC WAVE BRM: Double-sided roll seam module

Plastics Toys

100 % fun thanks to safe welding processes with ultrasonic Product safety is an absolute priority in this industry. Other requirements for toys are functionality, protection against injuries, but of course also the beautiful appearance. Ultrasonic welding passes the absolute endurance test in this respect. This is also the case, for example, with the toys from Bruder GmbH. With the aim of ensuring that the Personal Water Craft does not sink, Bruder Spielwaren GmbH & Co. KG has found a reliable partner in the field of plastic joining in SONOTRONIC.

Plastics Sports equipment

Solid connections with ultrasonic without needle and thread Ultrasonic technology is used primarily for welding tapes to injection molded parts of sports articles, for example ski goggles. A spot sonotrode is used to weld the elastic strap and the injection-molded part in a material- and space-saving manner. An absolutely tight connection is created. In addition, the elastic bands of ski goggles are also cut using ultrasonic. The cut edges are sealed and embossed during cutting so that the material does not fray. Fleece and Velcro straps can also be welded on with ultrasonic in a shapely and flexible manner. The resulting seam is firm and flat. For example, the Velcro fastener on ski jumping gloves is welded on with ultrasonic. In the fashion industry, fine and elastic materials (consisting of at least 70% synthetic fiber) are "sewn" with ultrasonic without needle and thread. In this process, continuous spot welding replaces the thread. The elasticity in the material is retained, and the overlap seams are gentle on the skin, not noticeable and flat, guaranteeing a high level of wearer comfort.

Plastic Medical

Ultrasonic welding technology for demanding applications with high quality requirements The Federal Institute for Drugs and Medical Devices defines medical devices as products with a medical purpose that are intended by the manufacturer for use in humans. Medical devices include, for example, infusion accessories such as drop sensors. A special seam design in conjunction with a contour sonotrode enables a watertight weld here. In this product, the lid is welded with a finely grained surface without damaging the visible side. Ultrasonic technology offers versatile solutions for applications in the medical sector. The use of ultrasonic is also an established process for the classic production of face masks, as well as for the manufacture of FFP masks and hygiene and protective equipment. These applications can be found here: Industries » Technical Textiles » Nonwoven.

Plastics Office supplies

High production output through the use of ultrasonic welding technology In the case of office products, ultrasonic is used for shape and separation welded products such as sleeves, insert pockets, cases, exercise book covers, and many more. A great advantage of using ultrasonic welding technology is the very flat and stable weld seams, which guarantee a visually perfect product. Even printer cartridge housings can be ultrasonically welded and score with absolute tightness and perfect function.

Plastics Electronics

Joining of small or large components - without imprints or impairment of the function We receive tasks from the electrical industry in the fields of electronics, electrical engineering and telecommunications. Here, the task is often very complex, the parts sensitive. The perfect function of the parts must not be impaired during the machining process, a beautiful appearance for housings, but also tightness are among the requirements. The gentle process is a particular advantage of ultrasonic. In addition, the ultrasonic process offers precise control of the welding or cutting process with high repeatability and precision. Ultrasonic makes it possible to achieve tight and undetachable joints in a very small area and in just a few milliseconds. For example, switches and buttons are sealed impermeably to external influences, even without an additional sealing ring. Alternatively, other technologies such as thermal forming (riveting), hot-air welding or infrared riveting can be used or used in combination to supplement ultrasonic technology.

Plastics White goods

Economical production with low energy consumption White goods is the technical term used in the trade for household appliances such as refrigerators, washing machines, dishwashers, stoves and other household appliances. SONOTRONIC's ultrasonic technology more than meets the high demands in this area in terms of process reliability and appearance. In the manufacture of a washing machine door, ultrasonic is used to rivet the two injection-molded parts, the carrier and the panel, together and securely fix the sight glass in between. In order to determine the production-related variations in the material thickness of the glass body, a displacement measuring system measures the actual height of the parts before each welding process and thus determines the necessary welding depth. This not only guarantees the optimum joining of the materials, but also ensures quality assurance in the production of the washing machine doors.

Plastics Automotive engineering

Sustainable processing of automotive parts for the engine compartment as well as exterior and interior For the automotive industry, our technologies are mainly used in special machines. But we also offer ultrasonic components for existing or new machine concepts for the various parts in the vehicle – even demanding part shapes can be realized. Together with our development department, we solve your requirements precisely and with the highest quality.

Components - Feed units (VE)

For the fixation of the ultrasonic oscillating units The feed units are mainly used in special machine construction in industries such as the automotive industry or other plastics processing industries, the textile industry as well as in packaging machine construction and the food industry. For the various applications, they can be easily integrated into existing or new machine concepts.

Components - Parts nests

Individual production of all parts nests in our internal special department The parts nest is the form-bound counter bearing to the sonotrode or the welding tools. In the finest precision work, we geometrically adapt the nests to the workpiece to be machined and the required vibration behavior. Based on original parts or on the basis of customer-specific CAD data, the nests are individually designed 100 % in-house and then manufactured,

Components - Sonotrodes

Design and production – complete in-house production The sonotrodes guide the ultrasonic vibration into the workpiece. We manufacture the sonotrodes individually tailored to the respective application and customer requirements and proceed with the development based on many years of experience and supported by the finite element method (FEM). The design of the sonotrodes depends on the ultrasonic application (welding, cut & seal, riveting, embossing, punching, cutting) and the properties of the workpiece to be processed.

Components - Boosters

Reinforcement or transformation pieces with the highest precision The SONOTRONIC component program includes boosters (amplitude transformation pieces) for ultrasonic frequencies of 20 kHz, 30 kHz and 35 kHz in various ratios. The booster is part of the ultrasonic oscillating unit, which consists of the components converter, booster and sonotrode. In the oscillating unit, the booster is interposed between the converter and the sonotrode.

Components - Converter

Different frequencies for optimal welding results SONOTRONIC offers converters with three different frequencies: 20, 30 and 35 kilohertz, with outputs from 1,200 to 4,000 watts. There is a wide range of different variants for different applications, and waterproof types are also available. Depending on the application, the ultrasonic converters are equipped with four or six disk ceramics. The latter are mainly used in the packaging industry and for continuous ultrasonic applications. Via the disk ceramics, the vibrations are optimally transmitted to the ultrasonic tool (sonotrode), so that short process times and high process reliability are achieved. The high-quality housings are very robust and durable and have different HF interfaces.

Components - Generators

Fast and precise control of ultrasonic processes What does the generator do? The ultrasonic frequency is generated in a generator. The generator converts energy from the electrical network into a high-frequency sinusoidal oscillation of 35 kHz or 20 kHz and transmits this to the oscillating structure, which consists of the converter, the booster and the sonotrode. Optimized control processes generate optimum ultrasonic oscillations.