Welding plastic inlet ducts

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MGS Technical Plastics Ltd is using a Telsonic twin-head ultrasonic system to weld inlet aperture mouldings into left and right hand blow moulded ducts.

The HDPE (high density polyethylene) blow moulded ducts have PP (polypropylene) injection moulded apertures at each end of the part. These apertures are designed to engage with a nominal clip fit to produce an initial, loosely held sub-assembly.  A supporting twin spot weld, on one side of the large aperture end of the assembly, is also required to maintain the integrity of this sub-assembly until the parts are finally assembled into the vehicle.

The ultrasonic process offers a fast, consistent and repeatable process, capable of penetrating these thick walled parts. Other, mechanical fix methods such as staples were ruled out as being unsuitable. The process also fits the recyclability requirement of the parts as no further fixing methods or materials are used. The materials are dissimilar, preventing a true fusion weld, however a spot-weld through the HDPE into the PP moulding at two strategic points creates a mechanical locking action of sufficient strength to retain the assembly until it is finally presented to the vehicle on the production line. 

On the machine, the component nests have 3D CAD cut location features, accommodating a pair of left and right hand parts in each cycle. These in turn are mounted on a sliding table that is fully interlocked with an auto start and power out facility. Actuator driven integral clamping arms ensure repeatable location and tight closure of the parts, important aspects of the spot welding process.

Telsonic UK supported MGS Technical Plastics Ltd at all stages of the project. This included the in-house sub-contract manufacture of pre-production assemblies whilst the production machine was being built.

www.mgsplastics.co.uk

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