E-MOBILITY
the food industry for may years. This process has demonstrated energy savings of up to 75% compared to conventional methods.
USING ENERGY ONLY WHERE IT IS NEEDED The key to achieving energy savings lies in ultrasonic sealing. Unlike traditional methods, this technology does not rely on an external heat source. Instead, heat is generated internally within the materials through friction during the brief welding process, lasting only 100 to 200 milliseconds. This targeted approach ensures that energy is utilised only where necessary, eliminating any wastage between the welding tool and the application. Another benefit is that the welding
tools remain cool and ready for immediate use, eliminating the need for preheating, saving additional energy. Preliminary tests conducted in both the ultrasonic laboratory and production settings have confirmed that the experience gained from sealing pouch packaging can be effectively applied to
the sealing of pouch cells. Given rising energy prices and rapidly growing demand for energy, savings become a major advantage for companies both ecologically and economically. Alongside energy savings,
reducing resource consumption plays a crucial role in enhancing the sustainability and cost-effectiveness of EV production. Ultrasonic welding facilitates a substantial reduction in resource consumption in two ways: the reduction of scrap rates, and the elimination of additional adhesives.
CONSISTENTLY LOW SCRAP RATES As one of the most cost-intensive components of an EV, the battery is a particular focus when making production safer and more sustainable. With dwindling availability of rare earth materials and the costly recycling of used batteries, responsible handling of raw materials is critical. Ultrasonic welding significantly
reduces the scrap rate during battery production. The generator can gather valuable data during the process
Through direct contact between the Sonotrode and the application, the generator can collect valuable data which can be used to optimise the welding process
through direct contact between the welding tools and materials. This data enables the visualisation and optimisation of welding parameters such as force, energy, and amplitude. By recording up to 150 parameters per weld, it becomes possible to minimise industry-standard scrap rates from up to 20%, to a single-digit percentage.
NO NEED FOR ADDITIVES Many plastic applications in EVs still rely on adhesives due to the relatively low investment costs of the technology. However, the chemicals present in adhesives can have adverse environmental effects during production and disposal. Adhesives often demand increased energy input, such as heating or drying, to ensure their efficacy. The utilisation of these chemicals not only effects the sustainability aspect but also contributes to ongoing cost factors. In recent years, the prices of raw materials have escalated, leading to a significant rise in costs associated with adhesive usage. Consequently,
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