Respiratory masks

Production with ultrasonic technology
Ultrasonic components for Machine builders
Cut-outs for masks

with ultrasonic cut'n'seal
Cut'n'Seal Sonotrodes
Cut'n'seal anvil

for nonwoven cut-outs

Ultrasonic technology for the production of breathing masks

Advantages at a glance

Economical and reliable production
Aesthetic and reliable edge sealing
Cutting and sealing in a single pass
High process repeat accuracy
Various sealing modes and multi-stage processes
Long tool life thanks to Cutting controller
Acoustic expertise even for complex contours
Extensive process control and statistical evaluation

Breathing masks assembled with ultrasonic welding

Breathing masks protect against fine dust, smoke or liquid mist (aerosol) and provide some protection against bacterial and viral droplet infections. Particle filtering folding or molded masks are divided into the protection classes FFP1, FFP2 and FFP3 (Filtering Face Piece). The protection class defines the structure of the filter materials.

Ultrasonic technology is the ideal and economical method for producing all types of protective masks. Depending on the mask type, different cutting and sealing applications are used. For example, multi-layer filter material can be made into finished masks using Telsonic's cut'n'seal technology. Ultrasonic technology can also be used to attach additional parts such as nose-shaped brackets, valves or carrying straps.

Different mask types

with ultrasound from Telsonic for every cutting and joining task

Surgical masks

with welding components from Telsonic

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Duckbill masks

with or without valve

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Molded masks

with or without valve

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Reusable masks

with replaceable particle filters

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Reusable masks

with replaceable filter cartridges

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medical applications

Cut'n'seal, cleaning and screening with ultrasonic technology

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Surgical masks with welding components from Telsonic

1 Requirements

Surgical or general nose-mouth protection masks are disposable masks and must be able to be manufactured cost-effectively in large quantities.

2 Connection tasks

Due to the high quantities, high-speed systems are used. Depending on the system configuration and output rate, one or more ultrasonic systems are integrated for the following joining tasks:

Edge sealing of the filter material to the edge band
Fixation of the nose bracket
Fixation of the carrying straps

3 Manufacturing methods

All sealing operations can be carried out fully automatically. For integration into automatic production lines, Telsonic offers a wide range of ultrasonic components such as converters, sonotrodes, feed units and controllers. Sonotrodes are individually designed for the respective joining task. The MAG ultrasonic generator enables the highest clock rates thanks to dynamic control.

Duckbill masks with or without valve

1 Requirements

Duckbill shaped masks are available in numerous designs and shapes, with vertical or horizontal embossing and with or without integrated breathing air valve.

2 Connection tasks

This type of filter mask provides effective breathing protection against fine dust particles in various industry branches. The diamond-shaped embossing in the front for increased dimensional stability is also applied with ultrasound.

Circumferential edge sealing of the filter layers with structured sonotrode
Diamond-shaped embossing in mask front
Fixation of the nose-shaped bracket
Installation and sealing of an optional valve
Trimming and sealing of the left and right corners
Fixation of the attachment loops for the carrying straps

3 Manufacturing methods

The various connection and cutting tasks can be carried out with individual workstations or automatically in special-purpose systems. The ultrasonic core components required for this—such as converters, sonotrodes, generators and process controllers—are identical. For trimming and simultaneous edge sealing, the proven Telsonic cut'n'seal process is used.

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Molded masks with or without valve

1 Requirements

Dimensionally stable masks are given their shape by stiffer filter layers on the one hand and by a vertical or horizontal shaping cut on the other. Optionally, this mask type can also be equipped with an air breathing valve. The carrying straps that are looped in must not tear the slots that have been inserted as a result of the strap force.

2 Connection tasks

With this mask type, subsequent manufacturing operations are carried out economically and safely with ultrasound. A large, FEM-optimized sonotrode is required for edge sealing.

Circumferential edge sealing
Inserting the feed-through slots for the carrying straps
Horizontal contour cut
Installation and sealing of an optional valve
Fixation of the nose bracket

3 Manufacturing methods

The reliable ultrasonic cut'n'seal process is used for the horizontal contour cut and the insertion of the four feed-through slots for the carrying straps. With this proven technology, the cut edges of the different filter layers can be sealed simultaneously. Both the sealing operations and the cut'n'seal tasks can be carried out with individual workstations or with ultrasonic components integrated in fully automatic machines. Our MAG ultrasonic generators are characterized by the highest clock rates thanks to dynamic control. The control can be analogue or via state-of-the-art, proven Fieldbus interfaces.

Reusable masks with replaceable particle filters

1 Requirements

The replaceable particle filters are ultrasonically formed into the desired shape from sheet material with the bayonet lock already fitted. It is crucial to have a tight, reliable seal and a fray-free edge zone.

2 Connection tasks

Circular blanks are separated from the multi-layer filter material in one cycle but with two operations (two-stage process):

Welding of all filter layers by means of an internal, circumferential sealing
Cutting out the sealed filter blanks with simultaneous edge sealing

3 Manufacturing methods

This demanding, combined sealing and punching task with simultaneous edge sealing can be performed semi or fully automatically. Telsonic's cut'n'seal process also allows for a multi-stage process, with which the particle filters can be manufactured economically, reliably and cleanly. The TCS5 process controller with the expandable and future-proof Telso®Flex software offers numerous options for implementing even complex joining tasks. The robust and rigid USP welding presses and feeders are ideal for these joining tasks.

Reusable masks with replaceable filter cartridges

1 Requirements

The lateral filter cartridges on this mask type can be replaced. Each cartridge contains application-specific pre-filters, which must be cleanly separated with a defined shape. The edge zone must be reliably sealed and must not fray.

2 Connection tasks

The individual pre-filters are intermittently punched out of roll material using ultrasound, and the edge zone is simultaneously sealed.

3 Manufacturing methods

Telsonic's ultrasonic cut'n'seal process can be applied in single workstations as well as in semi or fully automated production plants. The interaction of the tools, the correct choice of parameters and the control technology are always important. This guarantees long tool life and perfect cutting and sealing quality. The robust and rigid USP welding presses and feeds are perfect for the task.