Lower costs and a cleaner environmental footprint are key benefits to using ultrasonic
As innovation continues in the nonwovens industry, new opportunities for ultrasonic grow—especially as manufacturers continue learn more about the value of the technology.
Following is a look at the latest innovations from some of the key suppliers of ultrasonic technology in the nonwovens industry.
1.Ultrasonic is used for cleaning and for mixing
Ultrasonic is used in many different fields. Industrially, ultrasonic is used for cleaning and for mixing, and to accelerate chemical processes. An ultrasonic cleaner works mostly by energy released from the collapse of millions of microscopic cavitation near the dirty surface. The bubbles made by cavitation collapse forming tiny jets directed at the surface. An ultrasonic cleaner uses ultrasound (usually from 20–400 kHz) and an appropriate cleaning solvent (sometimes ordinary tap water) to clean delicate items. The ultrasound can be used with just water, but use of a solvent appropriate for the item to be cleaned along with the soiling enhances the effect. Cleaning normally lasts between three and six minutes, but can also exceed 20 minutes, depending on the object to be cleaned.
2. Nonwovens industries such as filter, textile, medical and consumer are turning to ultrasonic for welding, laminating, embossing, perforating and cutting. Ultrasonic allows for an efficient, continuous and closed loop process with increased productivity, making consumables such as adhesives, unnecessary.
Hygiene applications have an increased interest in ultrasonic technology, as they look to manufacturers for odorless, softer and quieter products.
Sustainability is always at the forefront of the nonwoven industry and continues to be a driving force in product development. Ultrasonic welding technology is considered an environmentally friendly technology, using up to 75% less electric energy than other bonding methods. Bonding of various materials with ultrasonic does not require any consumables, making glue-free diapers a realistic and attainable achievement.
Ultrasonic technology is probably the most eco-friendly way to assemble hygiene and disposable products. Ultrasonic machines utilize high-frequency vibratory waves to soften and fuse synthetic and nonwoven fibers together, creating a strong molecular bond without stitch holes, glue gaps, fraying or unraveling. Since machines seam and fuse the edges of the material, there is only a minimal amount of material that needs disposal. Traditional sewing or gluing leaves excess material that must often be cut off and discarded.” In addition to eliminating the use of costly consumables such as thread or adhesives, ultrasonic assembly methods can increase production output, since it is up to four times faster than sewing and up to 10 times faster than gluing.
