medical technology, and for use in the military and tele- communication fi elds.” As the percentage of wind- and solar-generated electricity climbs to the realm of 20–30% in the US, the need for bat- tery storage is expected to become critical. In fact, the Joint Center for Energy Storage Research notes that renewable electricity production in Hawaii has already exceeded one- third of its total power production, an achievement that’s also causing problems with the state’s electrical grid. Large-scale battery storage systems are seen as a “balancing resource” for the grid.
Redesigning Batteries Battery manufacturers are now designing rechargeable batteries for these stationary electrical energy storage ap- plications, offering a low-cost alternative to lead acid de- signs. Some battery systems are confi gured to scale from residential, to commercial, to grid use, offering solutions for power backup, as well as to handle fl uctuations in energy use. Ideally, such rechargeable battery systems will be afford- able and safe, and improve renewable power quality and reliability by ensuring an unin- terruptible power supply. “Clearly, we want to help these innovative manufacturers achieve their goals by providing the most reliable means of assembling their products,” said Devine. Sonobond’s ultrasonic metal spotwelders can join more layers, without tearing, than any of its competitors, enabling battery manufacturers to increase their production capacity. Plus, these welders are confi gured to be more conducive to custom tooling, making them adaptable to multiple applica- tions. Additionally, the welders are ideal for environmentally conscious manufacturers since they require no external heat, current, fl uxes or fi llers, and produce no arcs, sparks or
fumes. Instead, the welders employ the company’s unique, patented Wedge-Reed ultrasonic bonding system that produces durable joints with better conductivity than other methods and has good repeatability.
Welding with a Wedge-Reed System Patented in 1960, the Wedge-Reed system was spe-
Ultrasonic metal welding technology provides a cost- effective, environmentally friendly method for attaching multiple layers of foil to tabs and terminals used in lithium-ion and NiMH battery assembly. Up to 100 layers of copper and aluminum foils as thin as 7 μm can be welded without tearing, and in just one pulse.
cifi cally designed for high impedance metal welding. It combines low vibratory amplitude with high vibratory force directed in a shear mode parallel to the interface of the materials to be welded. The shear mode is essential for ultrasonic metal welding. The Wedge-Reed system uses a vertical, vibrating reed driven by a wedge-shaped coupler and transducer as- sembly that’s perpendicular to the reed. With the line of static clamping force directly above the parts to be welded, high clamp force can be achieved without bending stress or stalling. The result is precise, dependable, solid-state and highly conductive welds. In fact, this system is also the only ultrasonic assembly system that can reliably weld most oxidized and tinned met- als in just one pulse without pre-cleaning.
In contrast, other ultrasonic
welders use a lateral drive system that combines high vibra- tory amplitude and low vibratory force, suitable for weld- ing plastics, but is rotated 90o to achieve the shear motion necessary for metal welding. The welding tip is part of—or attached to—a longitudinally vibrating transducer-horn as- sembly driven parallel to the metals being welded. “Because of its cantilevered approach, clamping force in a lateral drive system is applied some distance from the weldment, resulting in a bending moment on the coupler that limits static force,” said Devine. While this lateral position-
25 — Energy Manufacturing 2016
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