Uncovering the peel strength performance of multi-layer ultrasonic weld seams in PVC-coated hybrid textiles for weather protection

Abstract

Ultrasonic welding is a fast and efficient solid-state welding process widely used in various industries. This study focuses on optimizing seam quality and peel strength in multi-layered hybrid textile materials using continuous ultrasonic welding. The influence of welding process parameters (pressure force, power, and speed) on multi-layered peel strength is examined. Three-by-three experimental designs for two and three-layer weld seams with 6 and 12 mm welding widths were developed and applied using superimposed seam type. The impact of varied factors on multi-layered peel strength was analyzed statistically and explored their corresponding tendencies in the relationships. Numerical optimization and analytical models were used to determine parametric levels for achieving desired peel strength. The results show that peel strength is affected by welding parameters, with variations observed based on layer, width, and speed. Increasing speed reduces peel strength, while higher power and pressure force enhance peel strength up to a certain point. However, excessive power and pressure forces can cause material deformation and reduce peel strength. The study also found a strong correlation between power and peel strength, emphasizing the importance of energy input during welding. Power and speed are identified as significant determinants of peel strength, with their combined influence playing a crucial role. The optimal peel strength (34.86 N/12 mm) is achieved at a welding speed of 2.11 m/min, power of 118.18 W, and pressure force of 343.94 N for a three-layer weld seam with a 12 mm welding width. Nonlinear quadratic analytical models are developed to predict multi-layered peel strength, and their results align closely with the actual points. Overall, this research provides valuable insights into optimizing seam quality and peel strength for multi-layered hybrid textile materials, benefiting weather protection applications and advancing bonding techniques in ultrasonic welding.