Hampshire based Talley Group Limited have a long heritage in the field of medical device manufacturing. The company’s sustained growth in markets around the world allows constant investment in their state-of-the-art engineering and production facilities here in the UK. Developing new products however, often means a detailed review of the processes that will be used to achieve the rigorous quality and compliance standards required within the sector. In the case of a new and large ABS polymer Compact Canister, Talley Group turned to ultrasonic welding experts Telsonic UK to develop the weld joint design and weld process required to meet the specific needs on this product.
The challenges with this new product included the requirement to achieve a leak proof and hermetic seal around the periphery and profile of the product. This included the right angle corners, internal baffles and a circular central cap on the product, which measures 156mm in width and 160mm in length. In this application, the Talley Group design specification needed modifications to conventional joint designs, and due to these characteristics, precise ultrasonic weld process control is required. Understanding that it can often be difficult generating good quality, homogeneous polymer melt, with right angled corners and using conventional ultrasonic welding techniques, Telsonic set out to develop an alternative design and process solution.
The key to this solution lies in the comprehensive range of weld parameter settings, available as standard within the Telsonic USP3000P Welding Press, enabling Telsonic to configure and maintain the critical parameters required during the welding process.
Telsonic also designed a “Mother / Daughter” composite Sonotrode with a working amplitude targeted at the higher limit for the ABS material so as to induce a fast polymer melt flow at the weld joints. As part of the solution development programme, an FEA analysis was performed on the highly complex aluminium composite sonotrode prior to manufacture to ensure low stresses and equal amplitude on the working faces.
The production sonotrodes included 15 aluminium anodised “daughter sonotrodes” that covered the periphery, internal baffles and the central cap area of the Compact Canister moulding which in turn was supported during welding by a 3D aluminium machined nest. The production solution purchased by Talley Group includes a Telsonic USP3000P ultrasonic welding machine fitted as standard with a pneumatic proportional valve, linear encoder and force transducer. The machine is fully guarded and complete with light curtains to comply with current safety standards and built on a fabricated work-stand.
Telsonic UK offer a comprehensive range of ultrasonic modules and systems for a variety of metal and plastic welding, sealing, food cutting, textile cutting and cleaning applications.
For more information please contact:-
Telsonic UK Limited
12a – 15 Birch Copse
Telephone – 01202 697 340
E-Mail – [email protected]
Web – www.telsonic.com