Sonobond Ultrasonics has announced that its SeamMaster High Profile Ultrasonic Sewing Machines are being used to help assemble children’s underwear used for bedwetting protection. Several dozen machines have been purchased by companies needing to produce fully-sealed seams that prevent leaks from occurring between the absorbent insert and the rest of the panty. 

“Our rotary sewing machines utilize ultrasonic technology to provide the waterproof seams needed in the panty’s inner pocket,” explained Sonobond Vice President Melissa Alleman. “Since both the horn and pattern wheel rotate during the fabric bonding process, the seams are also soft and smooth against the skin.”

“In addition to these bedwetting protection panties, our machines can be used to assemble other types of incontinence panties and personal hygiene products.”

Creating an ultrasonic bond

Sonobond’s SeamMaster Ultrasonic Sewing Machine was originally developed in 1991 to meet tough OSHA regulatory requirements for barrier seams in medical garments and disposable items.  Instead of needles, thread, glues or other adhesives, Sonobond’s equipment uses a patented rotary system, coupled with high-frequency vibrations, to bond 100% synthetic woven and nonwoven materials or blends containing up to 40% natural fibres. 

Resembling a traditional sewing machine, the Sonobond ultrasonic sewing machine channels the ultrasonic vibrations between a rotating horn and wheel, producing a localized heat build-up, which causes the synthetic fibres to soften and fuse. 

This creates a strong molecular bond that’s impervious to moisture. “The resulting barrier seams are sealed, secure, ultra-reliable and soft-to-the-touch without the leaking issues caused by stitch holes, glue gaps, fraying or unravelling,” said Alleman.

Technology to speed production

The SeamMaster Ultrasonic Sewing Machine seals, seams and trims in one step, making it up to four times faster than conventional sewing machines and 10 times faster than adhesive methods, according to the manufacturer. Since additional measures required by traditional assembly methods to ensure barrier seams are also eliminated, some manufacturers have been able to boost output by more than 25%.

In addition to incontinence and personal hygiene products, this sealing capability makes Sonobond’s ultrasonic sewing machines ideal for assembling medical protective apparel that meets AAMI standards for fluid protection. These include surgical gowns, facemasks, caps and booties, as well as disposable healthcare products, such as mattress covers and lint-free wound dressings.

Achieving life-saving specifications

Sonobond’s ultrasonic rotary sewing machines are also designed to help manufacturers of body armour achieve National Institute of Justice (NIJ) standards that have become increasingly stringent as law enforcement, military personnel, Secret Service and CIA agents, and emergency responders don protective gear to ensure their safety. 

“Bulletproof materials contained in ballistic vests lose their life-saving effectiveness when exposed to water, so it’s imperative that the seams in the outer nylon shell are perfectly fused,” explained Alleman.  “Once again, the ultrasonic technology utilized by Sonobond’s ultrasonic sewing machines reduces any risk of water or moisture damage to the interior contents, ensuring personal safety.”

www.sonobondultrasonics.com