Ultrasonic Welding Tool Profiles for Precise Conductor Joining
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Solution Overview
Problem
Existing ultrasonic welding methods and devices struggle with reproducibility and process reliability due to manufacturing tolerances and surface roughness, leading to inconsistent welding paths and positioning issues between conductors and connection parts.
Innovation Solution
The use of ultrasonic welding tools with mutually corresponding profiles on their contact surfaces, allowing for form-fitting engagement and increased effective contact area, which enhances process accuracy and reduces variance in welding paths, enabling reliable and reproducible welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If frictional engagement is used to fix the connecting part to the ultrasonic welding tool, then the device complexity is reduced, but the manufacturing precision deteriorates due to inability to compensate for manufacturing tolerances
Solution Approach 1:
The contact surface is segmented into multiple corresponding profiles (ridges and grooves) that interlock to provide precise positioning. This segmentation allows the connecting part to be fixed with high precision through the interlocking profiles while maintaining a relatively simple overall fixing mechanism without complex adjustment devices.
Solution Approach 2:
The contact surface is given a specific local quality through the corresponding profiles that provide form-fitting engagement. This local structural feature enables precise positioning at the critical contact interface, compensating for manufacturing tolerances without requiring the entire fixing mechanism to be complex.
2Reliability
If clamping devices are used to fix the connecting part, then the reliability of fixation is improved, but the device complexity increases and manufacturing precision deteriorates due to surface roughness and tolerances
Solution Approach 1:
The contact surface is divided into corresponding profiles that create multiple interlocking points. This segmentation provides reliable fixation through the interlocking mechanism while avoiding the need for complex clamping devices with multiple surfaces, thereby reducing device complexity.
Solution Approach 2:
Instead of using external clamping devices to force connection, the solution inverts the approach by designing the contact surfaces themselves to provide form-fitting engagement through corresponding profiles. The fixation reliability is achieved through the geometry of the contact surfaces rather than external clamping forces.
3Ease of manufacture
If flat contact surfaces are used, then the ease of manufacture is improved, but the manufacturing precision deteriorates due to manufacturing tolerances causing welding path deviations
Solution Approach 1:
The contact surface is given a specific local quality through corresponding profiles that provide form-fitting engagement. This local structural feature enables precise welding path positioning while the overall manufacturing process remains relatively simple, as the profiles can be integrated into the contact surface manufacturing without requiring separate complex operations.
Solution Approach 2:
The corresponding profiles on the contact surfaces provide a form of curvature or non-flat geometry that enables precise positioning. The interlocking profiles create a unique engagement geometry that compensates for manufacturing tolerances and ensures consistent welding paths, while still being manufacturable using standard techniques.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach improves the accuracy and reliability of the welding process by compensating for manufacturing tolerances and surface irregularities, ensuring consistent and robust connections between conductors and connection parts.
Implementation Method 1
an ultrasonic vibration is introduced into one of the components to be welded by a sonotrode
Implementation Method 2
This relative movement results in friction and ultimately in the welding of the surfaces of the two components
Implementation Method 3
ultrasonic welding breaks down the aluminum oxide layer at the contact surface between the components to be welded
Implementation Method 4
The sonotrode is excited by ultrasonic vibration via an ultrasonic converter and an optional booster. The ultrasonic vibration is introduced into the terminal part or conductor by means of the contact force of the sonotrode or anvil
Data Source
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AI summary
The invention relates to a welding device and to a welding method for producing an integrally bonded connection between a conductor (10) and a connection part (8), with at least one ultrasonic welding tool (4), wherein at least part of a contact face (18) of the connection part (8) contacts at least part of a contact face (16) of the ultrasonic welding tool (4).