Ultrasonic systems for processing technical textiles
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Ultrasonic systems for processing technical textiles
Textile processing with ultrasound
Sustainable technology with convincing advantages
By its innovative, eco-friendly developments, such as ultrasonic thermofixing and ultrasonic washing, SONOTRONIC
is setting new standards in the field of textile finishing. Additionally, we offer machines and components for making
up textiles.
A unique technology for Appealing seam geometries Environmentally friendly process
various applications When developing the ultrasonic tools Compared with other thermal proces-
Many applications and processes in and anvils, we individually adapt the ses, the energy consumed in ultrasonic
the textile industry are optimised by seam geometries to our customers’ re- welding is low. Energy is not supplied
the advantages of ultrasonic techno- quirements and to the properties of continuously, but only when welding
logies. Our technologies for welding, the various materials. When separa- takes place. The cost of maintaining
roll seam welding, cutting, punching, ting thermoplastic textiles, punched and and cleaning the duly adapted ultraso-
and embossing of textiles by ultrasound trimmed edges are already neatly sea- nic systems is even reduced, because
have already become established in the led during the separation process by the the ultrasonic tools are self-cleaning
market. We also incorporate various action of ultrasound. and not contaminated by textile resi-
ultrasonic technologies into individual, dues.
special textile processing machines,
which we build for customized appli-
cations.
Ultrasonic system for slitting
with fixed sonotrode
Advantages
Consistent quality
Visually appealing seam design
Simultaneous edge sealing
Cold tools
No machine heating up times
M
aterials are not heated or dest-
royed when the machine stops
No vapour generated
New methods for the finishing
Ultrasonic system for
continuous slitting Very short process times
P
rocess control and reliability by
monitoring welding parameters
E
nvironmentally friendly and
No vapour produced Innovative finishing processes
energy saving
Another advantage of ultrasound is with ultrasound
that no harmful vapours are produced SONOTRONIC has also transferred the
during the process. Because the ul- positive characteristics of ultrasound to
trasound tools themselves are cold, the another application and developed a
material only becomes warm in the join new method for the finishing of narrow
or separation area. At the same time the fabrics: the patented ultrasonic thermo-
machine requires no warming up time fixing and ultrasonic washing.
and the work pieces are not damaged
when the machine is stopped. Components, standard
and special machines
More efficient processes with As experts in ultrasonic technology, we
results that can be validated develop and manufacture the princi-
Processing and tooling times are very pal components ourselves. We use our
short for our ultrasonic systems. This ultrasonic technology in standard and
sharply increases the productivity of special machines in the textile indus-
textile processing machines. Conti- try. In addition, our ultrasonic systems
nuous monitoring of the welding para- and components can be incorporated
meters guarantees process control and in existing installations or new machine
reliability. They can be transmitted to concepts. In this, we work closely with
external EDP systems via one interface. well-known partners in the textile in-
dustry.
Joining with ultrasound
Good seam resistance and appealing seam geometries
Ultrasonic welding can be used anywhere in textile processing where thermo- Advantages
plastic materials are used.
J oining elastic and non-elastic
Applications Joining without additives textiles
Ultrasonic welding is used to join nar- and vapours
No pinhole perforations
row fabric or technical textiles of various The heat required for welding is gene-
kinds, as well as for welding injection rated directly in the join of the material. Visually appealing seam design
molded parts to textile materials, e.g. As a result, no additives, such as thread
elastic tapes with carriers for sports or adhesives are needed. Compared Individual anvil or sonotrode
items, clamping elements or filters for with other thermal welding processes, embossing
the domestic products and automobile ultrasound has the advantage that no (including company logos)
industries. harmful vapours occur and energy is
only supplied to the tool during the wel- Very rapid welding times
Strong welds without perforation ding process.
Process control and reliability
Compared with other joining processes,
ultrasonic welding is particularly suita- Material only heated in the join
ble if quick welding times and excel-
lent process reliability are required, or Cold welding tools
if pinhole perforations and subsequent
taping are to be avoided. Ultrasonic No vapour generated
welding is also characterized by appe-
Environmentally friendly
aling visual design and the quality and
and energy saving
strength of the welds.
Punching and trimming with ultrasound
Simultaneous edge sealing means high cut quality
Specially adapted ultrasonic tools and ultrasonic trimming and punching Advantages
systems from SONOTRONIC make them very versatile.
C
onsistent punching and
Applications Continuous separation welding trimming quality
Amongst other things, ultrasonic with fixed sonotrode
N
eatly sealed cut edges without
punching and trimming is used to As an addition to the ultrasonic roll
fraying
cut-to-length and perforate narrow ther- seam systems, SONOTRONIC has
moplastic fabrics or non-woven fleeces expanded its portfolio with a compact N
o thickening of the cut edges,
in various sectors. system for continuous separation wel- no subsequent ironing required
ding with fixed sonotrode. The sys-
Sealed cutting edges with tem is particularly suited to blanks and C
ut&Seal in the case of
no fraying edge trimmings of broad textile fabric. multi-layer textiles
Ultrasonic technology improves cutting
quality and performance. Moreover it Reduced punching force
is possible to seal the fabric simulta-
E
xcellent process control
neously by ultrasound during cutting
and reliability
or punching, which results in neat trim
edges and prevents the material from C
ontact switch-off when
fraying. The direct mode of action of sonotrode and anvil touch
ultrasound means that no heating
or cooling down periods are needed Cold punching and cutting tools
when starting and stopping the machine
or when changing tools. No vapour generated
Environmentally friendly
and energy saving
Ultrasonic washing
Highly efficient, environmentally friendly process
Apart from making up, ultrasound is also used in the finishing of textiles. Advantages
SONOTRONIC has adapted the technology to washing and has developed in-
novative ultrasonic washing units. R
eduction of water and energy
consumption
Applications Efficient process
Washing in “cold” water
Ultrasonic washing is ideal for the ener- Simply passing through an ultraso-
gy-efficient washing out of sizing agent nic washing unit is enough to replace Reduced use of chemicals
and spinning oils prior to dyeing and for several baths of conventional, highly
removing non-fixed dye particles from tempered systems. At the same time More flexibility
narrow fabrics or broad fabrics, ropes the washing distance is shorter and
or cord, after thermofixing. because ultrasound is used, water and H
igh shortening of the washing
energy consumption, as well as the use process
of chemicals are reduced when was-
Compact machine design
hing.
Increased efficiency as a result
Incorporation in machines of several units being connected
Depending on the type of fabric or de- one behind the other
gree of soiling, one or more directly
connected ultrasonic washing units
can be linked into finishing processes.
Because of the compact design, subse-
quent installation in existing systems or
incorporation in new machine concepts
is a simple matter.
Embossing with ultrasound
Individual embossing of patterns and logos
With ultrasonic embossing, individual texts or logos can be stamped with little
force into, for example, artificial leather, corsetry or non-woven fleeces. Ultra-
sonic embossing units are used as built-in components both in standard and
special machines in the textile and automotive industries.
Little force and embossing time
Advantages
The thermoplastic material is heated by
the ultrasonic oscillations, with the re- Short embossing time
sult that the amount of force used in ul-
trasonic embossing is significantly less Little application of force
than in mechanical processes. The so-
notrode presses the heated material E
nvironmentally friendly and
into the anvil, by which it is very quickly energy-saving
transformed on the surface. The result
is top-quality, visually appealing em-
bossings.
Ultrasonic thermofixing
Energy-efficient textile finishing
SONOTRONIC’s ultrasonic fixing units fundamentally revolutionize and ratio- Advantages
nalize the finishing of narrow fabrics.
Reduced energy consumption
Heat generation right in the material Incorporation in machines
T
hermofixing and calandering
With patented ultrasonic thermofixing, In order to make use of the advanta-
by ultrasound
the material is continuously drawn ges of ultrasonic technology for ther-
through between an anvil, which ge- mofixing, the ultrasonic units can be Facility to develop new products
nerates a regulated contact pressure, incorporated into existing systems or
and the sonotrode. Several ultrasonic new machine concepts. The number F
lexible reaction to market
units connected one behind the other of units required is dependent on the demands
rapidly generate the necessary heat material and process. Product and ap-
in the material for thermofixing and plication-specific parameters can then M
inimum use of material in the
calendering without long preheating. be retrieved from the control, so that machine
drafting devices at the drawing-in and
E
fficient handling of small
A clear reduction pulling off ends bring about optimum
quantities of material
in energy consumption shrinkage or stretching.
Long preheating and the associated ef- R
apid starting and stopping of
fective loss of energy are eliminated. Materials the machine almost without loss
In all, the energy input when thermofi- Ultrasonic thermofixing is suitable of material
xing by ultrasound is reduced by up to for finishing ribbons, yarns, twisted
90 percent, compared with conventio- threads, ropes and cords. The opti- Compact machine design
nal processes. mum effect is achieved with materials
made from synthetic textiles, such as
High degree of flexibility PA, PES, PP, aramid, Dyneema®, fila-
Ultrasonic thermofixing is particularly ment glass yarn, non-woven and also
distinguished by its flexibility: Because fabric mixtures.
there is only little material in the ma-
chine during thermofixing, it is possible
to process even small quantities of ma-
terial by ultrasound.
Your partner for textile processing with ultrasound
Technology and system integration in one unit
As your partner for textile proces- Individually adapted and specially Tested quality
sing solutions with ultrasound, we will designed ultrasonic systems We satisfy customer requirements by
accompany you from product develop- For the various requirements and custo- continuous quality and environmental
ment through to product launch. mer requests, we individually adapt our management in our company, accor-
innovative ultrasonic systems or pro- ding to the tried and tested standards
Experience in solving textile duce special one-off designs. We de- DIN EN ISO 9001 and DIN EN ISO
processing problems velop and manufacture our systems to 14001.
In our technical application laboratories, be fitted both into new installations and
we deal with your problems concerning into existing ones. We have also been
textile making up and finishing and con- working with partners for many years,
duct experiments, trial runs, and de- who use our ultrasonic components in
velopment projects on your behalf. In their textile machines.
finding the optimum solution, we apply
the latest analytical and test methods.
With our many years of experience and
our special know-how in the field of ul-
trasonic technology, we are also able to
solve difficult problems concerning joi-
ning, separating, embossing, washing,
or thermofixing of thermoplastic textiles.
Sustainable ultrasonic technolgy
by SONOTRONIC
Linked with success.
vorbehalten!
to change!
SONOTRONIC Nagel GmbH Industry solutions
Headquarters ■ Automotive
Änderungen
Becker-Goering-Str. 17-25 ■ Plastics
76307 Karlsbad ■ Packaging & Food
08-2020 © SONOTRONIC Nagel GmbH ▪ Subject
Germany ■ Technical Textiles
Phone: +49 72 48 91 66-0 ■ Environmental
Fax: +49 72 48 91 66-144
info@sonotronic.de Products
www.sonotronic.de ■ Special machines
■ Standard machines
SONOTRONIC, Inc. ■ Ultrasonic systems
Branch USA ■ Ultrasonic components
31132 Century Drive
Wixom, MI 48393, USA Technologies
Phone: +1 248 987 5970 ■ Ultrasonic
Fax: +1 248 987 5964 ■ Infrared
02-2021
info@sonotronic.com ■ Hot plate
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