Ultrasonic welding for sound components
Combining ultrasonic welding with adhesives ensures the best possible component properties for public transport vehicles
JA Kay, a subcontract manufacturer of plastic thermoformed components, uses ultrasonic welding to ensure PSV component safety and performance life.
The interior panels of public transport vehicles must not only be functional and aesthetically pleasing for their drivers and passengers but also able to withstand the rigours of constant use. The materials chosen for these sometimes complex components have to be robust, but more importantly the joining processes used to assemble the parts need to guarantee safe operation and longevity.
J A Kay’s 28,000 sq ft manufacturing facility in Darwen houses the very latest in thermoforming and finishing technology. The specialist automotive sector is just one of J A Kay’s markets and the company produces a diverse range of parts for interior and exterior trim, dash boards and fascias, plus sub assemblies for drivers cab doors and emergency exit doors.
Traditionally these, often large, ABS and Polypropylene components were assembled and joined using a 2 pack acrylic adhesive. Using ultrasonic welding technology as a complementary joining process, has brought significant production benefits.
The typical joining process now comprises of alternate short sections of ultrasonic spot welds and adhesive beads. This combination of generic material bonding and surface area bonding provides excellent strength and stiffness with a high resistance to bending stresses.
This joining procedure means that fewer sash clamps are required allowing greater access for the operator. With the assembly secured by ultrasonic welding, the part can be safely handled and stored whilst the adhesive is curing, providing a better work flow and freeing up valuable space on the assembly benches.
J A Kay uses a Telsonic hand-held ultrasonic welding system to perform the spot welding tasks on a range of interior trim components. Applied to low volume, high mix, product ranges or large complex 3 dimensional components this provides a quick, clean and efficient solution.
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