May, 2016
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tech.com
Ultrasonic Welding Meets Needs of Complex Automotive Electronics
S By Melissa Alleman, Vice President, Sonobond Ultrasonics
onobond Ultrasonic's metal welding technolo- gy has been developing alongside the growing number of increasingly complex electronic
components, especially those in the automotive industry. The company offers wire-to-terminal welders
that produce single point ground terminals, and can also accommodate a variety of specialty appli- cations through custom tooling capabilities. Today's automotive circuity is particularly
susceptible to electrical noise caused by multiple ground connections. Sonobond's single-point ground welder is a microprocessor-controlled, spot- welding system that can ultrasonically weld as many as 18 wires onto a single terminal with one pulse. It then automatically folds over the terminal arms to provide stress relief for the joint. Ground loops that generate electrical noise are thereby eliminated.
Ultrasonic Welding and Wedge-Reed Bonding
The ultrasonic metal welding
technique, as employed by the single point ground welder and other Sono - bond equipment, uses a welding tip to direct high-frequency, ultrasonic vibra tory energy to the surface between the metals being welded. The vibrations disperse the oxides and surface films between the workpieces and create a true metallurgical bond. No materials are melted, and no heat, current, fluxes, or fillers are used, which makes the process energy-effi- cient and environmentally safe.
display allows welding modes to be selected by time or energy and provides automatic frequency control and overload protection. Automatic control monitoring can also detect variations from preset limits. Weld data can also be transferred to or from a computer through the unit's RS232 port.
Wire-to-Terminal and Wire-to-Wire
For other spot and wire-to-terminal welding
applications, Sono bond offers its SonoWeld® 1600 metal spot welder. The unit welds foils, foils to tabs for batteries and capacitors, and joins dissim- ilar metals, such as copper to aluminum. As with
SonoWeld 1600 metal spot welder. Continued on next page
Page 75
Dual-head ultrasonic spot welder.
The company's patented Wedge-
Reed bonding system takes ultrason- ic welding technology a step further to assure precise, ultra-reliable welds. Shear mode vibration parallel to the welding surface is essential for metal welding to occur. The system generates shear mode with high vibratory force and low amplitude while the line of force is directly over the parts to be welded. This creates maximum ultrasonic metal welding effectiveness without bending stress or stalling, and enables most oxidized and tinned metals to be welded.
Single Point Ground Welder In addition to welding up to 18
wires, the single point ground welder can also weld wire bundles up to 20mm2 (0.031in2) to a single terminal in one pulse. It uses heat-treated, tool-steel taper lock tips that are easy to remove and can be readily re - dressed. The tips are able to perform up to 100,000 welds before being dis- carded. The 2,500W unit includes a microprocessor that stores and recalls up to 250 protocols. A digital
See at NEPCON China, Booth 1L18 and SMT Hybrid Packaging, Booth 7A-425
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