Jentschmann uses 35 kHz ultrasonic technology for cutting textiles, foils and plastics. This application is called ultrasonic cutting.
But how does the ultrasonic cutting process work?
Jentschmann uses mainly two methods for ultrasonic cutting.
With the first method, the materials are cut directly with a suitable wedge-shaped horn – either by moving the horn or the material to achieve the desired cut.
The cutting edge separates the substrate, and fuses / seals the edge of the substrate.
When cutting with the ultrasonic horn (sonotrode) an anvil plate is needed to reflect the sound and get the substrates in vibration to produce heat. One example of this technology is the Jentschmann fabric-cutting machine Cumasix ™ – see photograph.
With the second method, the Jentschmann rotary horn is used for ultrasonic cutting.
The rotating sonotrode transfers the sound through the substrate to be cut to an anvil cutting wheel. In this case the anvil wheel performs the function of separating the material and sealing the edges. The ultrasonic cutting wheel has the geometry of the desired cutting / sealing angle.
One example of the rotary ultrasonic cutting process is when separating and sealing filter media for the production of activated carbon filters.
Using a rotary horn for ultrasonic cutting has the advantage of reducing resistance during the cutting operation to minimize displacement of embedded materials (e.g. activated carbon), and eases material handling.
The ultrasonic cutting method can also be used for cut-welding.
In this case, two layers of substrate lying upon one another get cut at the same time. At the cut line the substrates are separated but the edges are bonded together – hence it is called “cutweld”.
Ultrasonic cutwelding is used in applications where, in addition to the sharp cut, a clean edge to edge weld (without any overlap) is needed.
The advantages of ultrasonic cutting at a glance
- Clean separation of materials with sealed edges
- Cutting and edge sealing in one process
- Ultrasonic welding without overlap
- Continuous cutting method using the rotary horn
- Large variety in the cut / edge sealing design
- Material density at the edges
- Air and Watertight seams are producible
- Accurate reproducibility of the welding results
- Very low power consumption
- No emissions
- High process speed
The ultrasonic cutting is suitable for applications such as
- Cutting of fabric (both woven and nonwoven), textiles and films
- Cutting of awning fabrics made of Acrylic, Polyester, Screen and Soltis
- Cutting of fabrics for the clothing industry
- Cutting of filter materials
- Cutting of conveyor belts
- Manufacture of industrial protective clothing
- Manufacture of sports clothing
- Manufacture of backpacks and bags