Bonding Patterns


At Beckmann Converting Inc., we are specialists in continuous web, roll-to-roll, ultrasonic bonding technologies*. This technology uses ultrasonic energy to bond multiple webs of technical textiles by creating bonding links at the weld points across the entire web width, from 20" to 124", 2 to 7 layers, and ½ oz/yd2 – 12 oz/yd2 in weight.


How It Works:

We create inter-ply adhesion by ultrasonic energy being transmitted into the composite layers at the points where the vibrating sonotrode (Horn) is pressing the layers against the raised “pins” of one of our “anvil rolls” – (see the “Roll Pattern” tab on our website), causing them to “melt” and form weld windows.

Interested in using our ultrasonic bonding technology? In our initial discussion, we will discuss the following: 

  • What properties do you hope to achieve by creating a multi-layer composite?
  • What materials are your product design comprised of?
  • What specific properties will the finished, multi-layer composite need to have?

Responses to these questions help us choose a potential Anvil Roll pattern. The ultrasonic bonding pattern that we select must sync with the property requirements of the laminate, its total weight, and the final finished product.


Why is this so important?

If an anvil roll pattern is too dense, for example, a heavier package of layers will cause the ultrasonic energy to be absorbed across the full contact area. This often results in energy loss, poor or no inter-ply adhesion at the bonding points, and slow operating speed. Adversely, if the anvil roll pattern is too open, it may not result in sufficient inter-ply strength, and may not work for the next converting process.

To combat this potential problem, Beckmann Converting is capable of making hand-laminated samples on our full-width ultrasonic laminating equipment, allowing for a quick evaluation of the raw materials and anvil roll patterns. This process assures the highest probability of a successful transfer of a new product development from hand-samples to commercial manufacturing.

*Please note, this technology is not the same as ultrasonic plunge welding or ultrasonic seam stitching