Innovative battery manufacturers are responding to the growing need for affordable and efficient solutions for renewable energy storage. To accommodate the demand, they are using reliable, cost-effective and environmentally friendly ultrasonic technology to assemble their products.
“Currently, wind and solar account for only about 6 percent of the United States’ electrical power generation. But, as reliance on alternative sources of energy increases, storage batteries will become essential as backup, providing power when there is no wind or sun,” said Sonobond President Janet Devine. “In fact, some battery manufacturers are already developing new formats for home and utility-sized energy storage systems that could eventually make wind and solar more consistent power resources.
“Some battery manufacturers hoping to commercialize new types of rechargeable batteries – that may eventually provide backup power, as well as grid-scale distributive storage to maintain peak power – are already employing Sonobond’s ultrasonic assembly technology,” notes Devine. “Additionally, we continue to supply welding units to manufacturers seeking environmentally friendly methods for assembling existing lithium-ion and NiMH rechargeable batteries used in applications such as all-electric and hybrid automobiles, medical technology, and military and telecommunication fields.”
Sonobond’s ultrasonic metal spot welders require no external heat, current, fluxes or fillers and produce no arcs, sparks or fumes. Instead, the welders create durable bonds by employing the company’s unique, patented Wedge-Reed ultrasonic bonding system that combines high vibratory force and low amplitude coupling. Using shear mode vibration parallel to the welding surface, while the line of force is directly over the parts to be welded, achieves precise, dependable, solid-state and highly conductive welds. Sonobond’s is also the only ultrasonic assembly system that can weld most oxidized and tinned metals in one pulse without pre-cleaning.
Sonobond offers two ultrasonic spot welder models that weld multiple layers of foils to tabs or terminals, accommodate battery pouch assembly and HV termination welding. The SonoWeld 1600 and Dual Head Spot (DHS) Welders weld foils as thin as seven microns. Also, the Dual Head Spot Welder is the first ultrasonic welder that can join up to 100 layers of copper or aluminum foil without tearing, and in just one pulse. The units use outputs of 1,500, 2,500 or 3,500 watts. Both models have digital displays that allow weld control to be selected by time, energy, or distance. Each unit has a power supply with a built-in microprocessor featuring automatic frequency control, overload protection, and storage and recall of up to 250 protocols.
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 spot welders require only minimal training.
To assist battery manufacturers in determining the benefits 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 provided before, during and after installation.