Application: Punching holes in bumpers
Punching
produces neat holes in bumpers
For
the purpose of punching neat holes into paint-coated bumpers, important global
automotive suppliers rely on ultrasonics technology developed by TELSONIC AG,
Switzerland. With a comparatively small power input, a sonotrode punches
complex shapes in the required quality. The external, visible side is not
affected in any way. Furthermore, the process produces a neat curve of the
paint coat with a defined radius. The process can be fully automated and
produces the shapes required for fitting the sensors for distance control and
parking assistants or headlight cleaning systems and side markers.
"Our
ultrasonic punch technology does not leave any marks on the highly sensitive
visible side of the fully paint-coated plastic bumpers that are ready for
installation", emphasises Wolfgang Ott, Head of the Plastic Welding
Department at TELSONIC. The process developed by the Swiss ultrasonics pioneers
produces neatly punched shapes in plastic car bumpers measuring 2.5 - 4 mm in
thickness. The OEM customers demand punches without any marks whatsoever on the
extremely sensitive visible side of the paint-coated bumpers, which are usually
manufactured from PP-EPBM. Globally active first-tier suppliers use this
ultrasonics technology - which is suitable for automated applications - to
produce high-quality results.
Top quality
with small power input
Compared to
mechanical technologies, this punching process requires considerably less
power. This means that significantly less space is needed for the design of the
required matrix, which can also be produced by the users themselves. That makes
it easier to fully automate the jointing process. The embossing and punched
shapes are produced in one highly precise and careful process using 20-35 kHz
components. The frequency depends on the size of the punched hole. In this
ultrasonic punching process the cutting clearance is not critical. The
generators have an output of between 1.2 and 2.4 kW and the components can
easily be used to construct a bespoke system solution.
The results of
the ultrasonic punching process are significantly better than those achieved with
alternative mechanical processes. Furthermore, the defined formation of the
leading radius can be produced in the same work cycle. The paint coat is gently
drawn into the punched holes without leaving any discernable traces, damage or
fluff. As a result, within a very short space of time, the reliable and
tried-and-tested ultrasonic punching process developed by TELSONIC AG has
become the process of choice for producing punched shapes in plastic bumpers.