Ultrasonic Welding Contact Profiling for Repeatable Conductor Joints
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Solution Overview
Problem
Ultrasonic welding of conductors and connecting parts is hindered by production-related manufacturing tolerances and surface roughnesses, leading to inconsistent positioning and welding path deviations, which compromise process reliability and repeatability.
Innovation Solution
The use of ultrasonic welding tools with profiled contact surfaces that correspond and engage in a form-fitting manner, allowing for precise positioning and increased contact area, thereby compensating for manufacturing tolerances and ensuring reliable welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If frictional connection is used to fix the connecting part on the ultrasonic welding tool, then the connecting part can be positioned on the tool, but production-related manufacturing tolerances cause inadequate repeatable positioning
Solution Approach 1:
The contact surface is segmented into multiple corresponding profilings (protrusions and recesses) that divide the contact interface into discrete engagement points, enabling precise positioning that compensates for manufacturing tolerances
Solution Approach 2:
The profilings feature asymmetric geometric shapes with specific protrusions and recesses that create a unique fit between the connecting part and tool, ensuring repeatable positioning regardless of manufacturing variations
2Reliability
If force fit with clamping is used to fix the connecting part, then the connecting part can be secured on the ultrasonic welding tool, but manufacturing tolerances and surface roughness further increase position deviation
Solution Approach 1:
The corresponding profilings are pre-formed on both the connecting part and tool contact surfaces, creating a predetermined form-fitting connection that establishes precise positioning before the welding process begins
Solution Approach 2:
The profilings feature curved or rounded geometric forms that facilitate form-fitting engagement, allowing the connecting part to settle into a precise position on the tool through the contoured surfaces
3Device complexity
If flat contact surfaces are used, then the welding process is simple, but manufacturing tolerances cause welding path deviations up to 0.3 mm
Solution Approach 1:
Instead of requiring the entire contact surface to be perfectly flat, only specific localized areas feature corresponding profilings that provide the necessary positioning precision, while other areas maintain simpler geometry
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
Enhances process accuracy and reliability by reducing welding path variance, enabling reproducible and robust connections between conductors and connecting parts.
Implementation Method 1
an ultrasonic vibration is introduced by a sonotrode into one of the components to be welded together
Implementation Method 2
This ultrasonic vibration causes the two components to be welded to move relative to each other at their contact surfaces. This relative movement results in friction and ultimately in welding of the surfaces
Implementation Method 3
Ultrasonic welding plasticizes at least one of the two components to be welded together at the contact surface, resulting in a material bond
Data Source
AI summary
The subject matter relates to a welding device as well as a welding method for producing a material bond connection between a conductor (10) and a connecting part (8), with at least one ultrasonic welding tool (4), wherein at least part of a contact surface (18) of the connecting part (8) contacts at least part of a contact surface (16) of the ultrasonic welding tool (4).