PE film for Protection during Ultrasonic Welding

The Importance of Using a Buffer PE Sheet in Ultrasonic Welding In today's competitive market, the visual appeal of your products is crucial to your reputation. Consistently producing attractive and high-quality parts is essential. This is where the use of a buffer sheet in ultrasonic welding becomes important.

•    What is a Buffer Sheet?
  A buffer sheet is a thin film, akin to a heavy-duty clear plastic wrap or a sandwich bag, positioned between the ultrasonic tool (horn) and the part being welded. The buffer sheet material should differ from the parts being welded. Polyethylene film, for instance, is often used with ABS plastic parts. While Mylar can also serve this purpose, it is generally more expensive.
•    Benefits of Using a Buffer Sheet
  The main purpose of a buffer sheet is to protect the part from marks or damage during welding. It helps to lessen the effects of mold imperfections or variations when the ultrasonic horn makes contact with the part. By filling gaps due to contouring where the molded part doesn't perfectly match the horn, the buffer sheet minimizes markings caused by flaws like sinks, warpage, and other irregularities.
•    Suitable Applications
  Many parts benefit from using a buffer sheet during ultrasonic welding. High-value internal electronics, personal electronics, medical devices, and automotive controls and instrumentation are prime examples. Consumer goods requiring high aesthetic standards, such as appliances, also gain significantly. When welding painted or decorated parts, a buffer sheet helps reduce the risk of marking these surfaces. Whenever high quality and appearance are essential, incorporating a buffer sheet into the welding process is a wise choice. Using a buffer sheet in ultrasonic welding is a straightforward and effective method to enhance the quality and appearance of your products, ensuring they meet the high standards your customers expect.
•   Availability
  This film is typically manufactured at specific thicknesses but can be custom-produced to meet unique application needs. The film is available in widths ranging from 2 inches to 82 inches, depending on the application's requirements.

Our 50 micron specialised PE film is highly suitable for applications using 20000 Hz (20KHz) of vibration frequency during their ultrasonic welding process of thermoplastics. Other grades of films are available for different levels of vibration frequencies. Most common thermoplastics compatible with our film - Polyethylene (PE), Polypropylene (PP), Polyvinyl Chloride (PVC), Polystyrene (PS), Polyethylene Terephthalate (PET), Polycarbonate (PC), Acrylonitrile Butadiene Styrene (ABS), Nylon (PA), Polyether Ether Ketone (PEEK) and Polyphenylene Sulfide (PPS). The PE buffer film, also known as a protective sheet, comes highly recommended by experts as the optimal and cost-effective solution for addressing weld marks or flash marks on thermoplastics during ultrasonic welding processes. It is widely regarded as the best choice to mitigate these issues effectively.