Ultrasonic Sewing Method

Ultrasonic sewing method is one of the alternatives to conventional sewing methods used for fast and clean welding of different textile surfaces and this method has become an issue that has been emphasized in recent years. Ultrasonic energy provides savings, efficiency and clean production opportunities in the area where it is used. Ultrasonic power, which is used in many areas of textile, is one of the effective methods used to combine garment pieces in a garment business. Many problems encountered in traditional sewing have reached destructible levels with ultrasonic sewing.

Ultrasonic is defined as sound waves at frequencies above about 20 kHz or at a level that the human ear cannot hear. The basis of ultrasonic joining process is based on using high frequency vibration to join materials in thermoplastic structure. As a result of vibration, an increase in temperature occurs in the material, with this temperature increase, the material melts and combines and forms a bond. Although ultrasonic sewing is an energy-saving method, it is seen as a method that is easier to recycle since materials such as thread used in conventional sewing methods are not needed. Ultrasonic bonding method is used in different industry branches such as automotive, textile, apparel, medical, packaging, electronics, filtration. Although ultrasonic energy is involved in various processes in the textile industry, it has been used for the first time to create mattress cloths and bed covers, and today it is an important method used to sew, cut, shape textile surfaces and film surfaces and turn them into products.

Vibrations that form the basis of ultrasonic sewing create a rapid increase in temperature in the material. This increase in temperature causes the material to melt and bond and form a bond. Ultrasonic sewing machines are similar to conventional sewing machines in terms of structure, but do not have parts to carry needles and threads. The working principle of the device is to convert electrical energy into high frequency mechanical vibration. High frequency electrical energy is transmitted to an electromagnetic converter, which converts high frequency electrical vibrations into vertical mechanical vibrations. This vertical movement emerges from the other end of the converter and is transferred to the horn, which transmits mechanical energy to the parts to be bonded. The most important task in binding the fabrics to each other in the assembly process falls on the parts called “horn” and “anvil”. The fabric passing between the horn and the anvil releases heat by rubbing against each other due to high-frequency mechanical vibration energy. This heat of friction causes the synthetic fibers in the material to melt and stick. When the fabric moves away from the vibration energy, with a sudden heat loss, this adhesion becomes permanent and an ultrasonic seam is obtained that is not frayed and does not have the danger of detachment.

The terms interlining, nonwoven, fiber and non-woven fabric are all used for the same type of fabric. This fabric is produced from Polypropylene raw material. It is a non-woven fabric. It is a recyclable and environmentally friendly material. It is economical and can be produced in any desired color. It can be produced as antistatic, non-flammable or flammable. With the restriction of the use of plastic bags as of the beginning of 2019, nylon bags began to be replaced by different bag types. Interlining nonwoven bags, which are the leading ones, are also produced by using ultrasonic sewing method. Before the fabrics are cut, ultrasonic sewing is applied to the cut areas.

There are many studies on ultrasonic sewing in recent years. In the studies on the subject, various properties of fabrics sewn with ultrasonic sewing and conventional sewing were examined and compared. Ultrasonic sewing takes place in various sectors as an advantageous joining method in terms of both ease of use, fast joining process and no need for production materials such as needle and thread. Because it is an economical sewing method, it is frequently preferred especially for disposable nonwoven textile products (medical masks and gowns, bags, fabric napkins, etc.). It is used in combining clothing pieces, ie for sewing purposes, especially in marine garments such as swimwear due to its high seam strength and waterproof seam. Considering the results in general, it is known that ultrasonic sewing method can find more usage areas by determining the optimum fabric structure and appropriate production parameters where high strength is not required and where high fabric hardness may be advantageous. One of the most important areas of use today is the production of medical surgical gowns. With the ultrasonic sewing method, nonwoven fabrics are bonded to each other with a sealing feature. This feature Covid-19 etc. It is of vital importance in the production of surgical medical garments in protection against viruses. Different sewing formats can be provided with interchangeable sewing patterns in our ultrasonic sewing machines. Besides, the horn rotation speeds and welding speeds of our machines can be adjusted and can operate at high speeds such as 24 meters / minute.