超声波焊接结构设计焊焊接筋的角度120 90 60 45 超声焊焊接结结构l基本型WW 64W 4W 8Basic Energy Director超声焊焊接结结构l阶梯型1.50.50.050.5( 0.5 )60 Step Joint超声焊焊接结结构l阶梯型Before AfterChisel energy director 45 0.015 to 0.019” tall (0.4 to 0.5mm)0.060” ( 1.50 mm)W8 +0.010” to 0.025” (0.25 to 0.64mm)Chisel Edge超声焊焊接结结构l阶梯型0.80.370.030.4( 0.5 )45Step Joint超声焊焊接结结构l阶梯型0.400.170.030.20( 0.30 )Step JointJoin Design到ED為10mm 以下（0.5）1.50.50.050.560 R型肉肉厚達厚達 1.5 1.5 mm mm 程度程度時時肉肉厚厚 1.0 1.0 mm mm 程度程度時時Join Design0.3（0.03）0.4（0.5 ）45 60 1.0R型很重要肉厚肉厚約約 0. 0.8 8 mmmm以下以下時時Join Design30 450.250.03( 0.4 )0.50.40.8肉厚肉厚 0.7 0.7 mmmm以下以下時時Join Design 防止位置偏移(斷差)0.70.25( 0.5 )( 0.9 )防止位置偏移防止位置偏移 引引導導孔孔防止位置偏移防止位置偏移 引引導導加厚部加厚部( 0.7 )阶梯型设计及用处l防止溢料l改善外观阶梯型设计例子榫槽型设计例子超声线及火花纹设计Branson/Mold-Tech Texture DesignationPattern DepthEnergy Director HeightBranson300 Branson450 Branson6000.003” 0.0045” 0.006”0.005”-0.011” 0.012”-0.017” 0.018” and up熔接強熔接強度提高度提高咬花面咬花面加工加工0.130.29 75 m 0.300.44115 m 0.45 以上150 m提高強度方式：超声线及火花纹ED 高度咬花面深度可防止横向滑動超声线及火花纹样板刀边型加上火花纹超声熔化效果无火花纹有火花纹超声焊焊接结结构l阶梯型Continuous Criss-Cross Energy Director超声焊焊接结结构l榫槽型 3.01.50.62.00.7( 0.7 )角度 3 5 Tongue & Groove超声线设计的限制l某些塑胶材料不能有效焊接特別是“半晶性”塑胶材料焊接l解决方法剪切型剪切连接（Shear Joint） 设计InterferenceBefore After FixtureDepth of WeldMin. Lead-in 0.020” (0.5mm)剪切连接的焊接深度l一般 1.25wl最少 0.5wl最多 1.75w45 2.00.8 以上0.050.4WWShare Join 超声焊焊接结结构l剪切型45 2.00.8 以上 0.050.4Maximum Part DimensionInterference per Side (Range)Part Dimension ToleranceLess than 0.75” (18mm)0.008” to 0.012” (0.2 to 0.3mm)+ 0.001”(+ 0.025mm)0.75” to 1.50” (18-35mm)0.012” to 0.016” (0.3 to 0.4mm)+ 0.002”(+ 0.050mm) Greater than 1.50” (35mm)0.016” to 0.020” (0.4 to 0.5mm)+ 0.003” (+ 0.075mm)Shear Joint0.8 以上2.00.050.3Share JoinW0.80.80.40.03Shear JointW超声焊焊接结结构l剪切型0.10.5 0.250.10.250.5Shear JointShear Joint Interference Maximum Part DimensionInterference per Side (Range)Part Dimension ToleranceLess than 0.75” (18mm)0.008” to 0.012” (0.2 to 0.3mm)+ 0.001” (+ 0.025mm)0.75” to 1.50” (18-35mm)0.012” to 0.016” (0.3 to 0.4mm)+ 0.002” (+ 0.050mm)Greater than 1.50” (35mm)0.016” to 0.020” (0.4 to 0.5mm)+ 0.003” (+ 0.075mm)剪切设计例子剪切设计例子剪切设计的长处l焊接強度高,防水效果佳l减少“假焊”现象出現l适合大多数塑料材料剪切设计的限制l要求高精准度的塑件l需要较強的支持l焊接面多为正多边形或圆形