batteries & storage
ing works for many applications, it does not produce acceptable welds for tinned or oxidized wire and terminals.
Ultrasonic Spot-Welding Equipment Sonobond offers two ultrasonic spotweld- ers that weld multiple layers of foils (typically aluminum or nickel-plated copper) to tabs, tabs to tabs, or wire to terminals and also ac- commodate battery pouch assembly and HV termination welding. The SonoWeld 1600 can weld foils as
thin as 7 μm without tearing, as well as mul- tiple layers of foils to tabs and terminals for lithium-ion and NiMH battery assembly. The unit puts out 1500–2500 W to join nonfer- rous similar or dissimilar metal assemblies, including copper to aluminum. The Dual Head Spotwelder features two ultrasonic welding heads, one on either side of the welding area for increased welding capacity. It is the fi rst ultrasonic welder that can join up to 100 layers of copper or aluminum foils without tearing and in just one pulse. Like the SonoWeld 1600, it can also weld foils as thin as 7 μm. Additionally, the Dual Head Spotwelder can attach wires to terminals; weld nonferrous sheetmetal, includ- ing aluminum, up to 3-mm thick; and accommodate lightly tinned or oxidized wires. The dual head unit uses Sonobond’s 3500-W power supply.
Both Sonobond ultrasonic welding units have built-in
microprocessor controlled systems that allow automatic frequency control, overload protection, and storage and recall of up to 250 protocols. Digital displays permit selec- tion of welding modes by time, energy or distance. The SonoWeld 1600 and Dual Head Spot Welders employ heat- treated tool steel Taper Lock Tips that can perform up to 30,000 welds before redressing is required and as many as 100,000 welds before being easily removed and replaced. As with all Sonobond equipment, the spotwelders require only minimal training.
Achieving New Electrical Grid Storage Capability “It’s estimated that the market for batteries provid- ing stationary energy storage will increase from about $1
In addition to assembling newly designed rechargeable batteries, the SonoWeld 1600 Digital Ultrasonic Spotwelder is well suited for manufacturing lithium-ion, NiMH rechargeable batteries and pouch cells.
billion today to approximately $6 billion by 2020,” said Devine. “For battery manufacturers, mechanical fastening is inconsistent, and resistance welding or soldering uses more energy and often produces inadequate bonding. Our ultrasonic method is less expensive; uses a fraction of the energy needed for resistance welding; ensures RoHS com- pliance, which is problematical with soldering; and speeds the production process.
“Sonobond fully expects to help battery manufacturers keep pace with the growing demand for batteries, which potentially promises to make our energy grid cleaner and more resilient.” To assist battery manufacturers in determining the ben-
efi ts of ultrasonic welding for their particular applications and requirements, Sonobond offers a free Ultrasonic Welding Viability Test. Using materials provided by the manufacturer, Sonobond produces no-cost, no-obligation sample welds. If Sonobond’s equipment is incorporated into the customer’s production process, service and technical support is pro- vided before, during and after installation.
Edited by Yearbook Editor James D. Sawyer from information provided by Sonobond.
26 — Energy Manufacturing 2016
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