A large auto interior manufacturing factory adopts sound insulation cotton to optimize vehicle NVH performance for finished vehicles. In daily assembly work, workers need to fix sound insulation cotton onto plastic substrates. In the past, the workshop used ordinary smooth ultrasonic welding tips for spot welding. Soft sound insulation cotton is prone to sliding under ultrasonic vibration. Only shallow and weak fusion points can be formed. Under long-term vehicle vibration, continuous road bumps and temperature changes inside the cabin, the welding spots easily fail, causing the sound insulation cotton to peel off. This creates large quantities of defective products, increases heavy rework workload, and negatively affects continuous stable assembly line production. Besides auto sound insulation cotton, the factory also processes cotton textile materials, masks and welding tape, which face identical welding slipping problems.

To completely solve slipping, virtual welding and peeling risks during sound insulation cotton processing, the factory replaced traditional smooth welding tips and officially adopted our 8mm textured spot ultrasonic welding head for all sound insulation cotton fixing operations.

This textured spot welding head is designed with an 8mm working end covered with dense anti-slip textured patterns. The special concave-convex surface locks soft fibrous materials effectively during vibration, concentrates ultrasonic energy accurately on the welding contact area and achieves reliable spot fusion between sound insulation cotton and base materials. It avoids material shifting, burning and perforation during welding. Made of high-hardness wear-resistant metal material, the welding head keeps consistent performance under long-duration continuous production. It is universally compatible with mainstream handheld ultrasonic welding guns. The physical fusion process requires no glue or auxiliary adhesives, meeting automotive interior environmental standards. Apart from automotive sound insulation cotton, it also fits cotton spinning fabrics, disposable masks and welding tape welding work.

After long-term mass production application, the factory’s defective rate caused by sound insulation cotton welding peeling decreased significantly. Rework volume was largely reduced. Product rejection and assembly line interruptions triggered by failed welding spots were effectively controlled. The stability of finished auto interior parts was greatly upgraded, improving overall workshop production efficiency.