Comprehensive Analysis of Ultrasonic Bond Characteristics in PVC-Coated Hybrid Textiles

Ultrasonic bonding offers a promising alternative to traditional sewing and other plastic bonding techniques, with several potential advantages. This paper comprehensively analyzes ultrasonic bond characteristics in PVC-coated hybrid textiles, prevalent in awnings and camping tents. Untreated samples were used as controls to compare the effects of ultrasonic bonding on various characteristics. Developed experimental designs were applied using a 12 mm welding width in a lapped seam, with carefully selected parametric levels to achieve higher bond strength based on preliminary test results. Mechanical properties (tensile, cyclic, and tear strength, including thickness reduction) were thoroughly examined to assess ultrasonic bond seam efficiency. The analysis covered thermal, chemical, morphological, and weight loss aspects before and after ultrasonic welding. Results showed that the weld seam tensile efficiency ranged from 68.27% to 96.13%, indicating enhanced durability. Cyclic efficiency exceeded 95%, tear efficiency surpassed 70%, and both treated and untreated samples showed strengths above standard thresholds. Thermal findings indicated a 3% increase in crystallinity after ultrasonic treatment, enhancing thermal stability with lower weight loss and causing shifts in glass transition and melting temperatures. FTIR spectra revealed that ultrasonic bonding had no significant impact on the material’s chemical properties. Morphological analysis identified pre-existing microvoids, with no significant increase in their number and/or size following ultrasonic treatment. Overall, the study demonstrates the efficacy of ultrasonic welding in improving the mechanical, chemical, and thermal properties of PVC-coated hybrid textiles, providing valuable insights for applications like awnings, camping tents, and roofing materials for short- and long-term use.