Chengguan ultrasonic welding technology innovates the automotive lighting manufacturing industry

In the modern era of rapid development of automobile manufacturing, the manufacturing process of headlights, as the core components of vehicle safety and aesthetics, is undergoing revolutionary changes. Chengguan Ultrasonic Welding technology is gradually becoming the preferred welding solution for high-end automobile manufacturers with its high efficiency, precision and environmental protection. This innovative technology has greatly improved the sealing and durability of headlight products .

Pain points of traditional processes and advantages of ultrasonic welding

Traditional headlight assembly mostly uses gluing or hot plate welding processes, which have many insurmountable defects

Problems with the gluing process : The gluing process not only relies on the curing time of the glue, resulting in a lengthy production cycle, but the performance of the glue is also easily affected by temperature and humidity. Long-term use may cause aging and falling off, which directly affects the sealing of the headlights and increases the risk of water ingress and fogging. At the same time, the harmful substances volatilized by the glue will also pollute the production environment and fail to meet environmental protection requirements.

Limitations of hot plate welding: Although hot plate welding can achieve Plastic Welding, it is easy to cause local overheating when the hot plate contacts the workpiece, causing problems such as material deformation and burning, especially significantly damaging the dimensional accuracy of the precision optical components of the headlights. In addition, the process has low heat conduction efficiency, long welding cycle, and the residual molten glue on the hot plate will contaminate subsequent workpieces, making it difficult to ensure the consistency of mass production, which restricts the quality and efficiency improvement of headlight manufacturing.

Ultrasonic welding

1. Principle

Through the mechanical vibration of high-frequency ultrasound, the plastic contact interface is quickly heated and melted to complete efficient welding.

2. Advantages

(1) The welding speed is extremely fast and the production efficiency is high.

(2) High welding precision, especially suitable for small parts.

(3) No glue or solder is required, which is environmentally friendly and low cost.

3. Applicable lamp types

(1) Welding of small components inside headlights, such as lenses or light guides.

(2) The combination of precision parts, such as the complex structure inside the lamp body.

Chengguan ultrasonic technology has significant advantages. It can achieve 5μm high-precision welding, ensure good sealing and tight fit of the headlights, avoid defects such as pores and cracks in traditional welding, and extend the service life; it can weld a variety of thermoplastics such as PP and PC, and adapt to headlight parts with complex shapes and structures; the welding process is fast and can be completed within a few seconds, and it has low energy consumption and does not require auxiliary products, reducing production costs; the equipment is highly automated and can be integrated into the production line to reduce manual intervention and errors. However, it also faces problems such as inconsistent welding strength, deformation of parts, cracks, and difficult precision control, which can be dealt with by optimizing parameters, designing molds, controlling processes, improving mold precision, and adopting advanced control systems.