The present and future of ultrasonic welding technology


The present and future of ultrasonic welding technology

Welding of plastics using ultrasonics

Ultrasonic welding of plastic materials creates a molecular bond within the weld seam. Longitudinal vibrations in frequencies of 20 kHz, 30 kHz, and 35 kHz with tool amplitudes between 5 µm and 50 µm are introduced into the plastic materials under the action of force. Ultrasonic vibrations are focused by means of special design of the components or tools. This specific geometry within a component is referred to as energy director. The contact points in the joining area are actively molded by means of energy input to achieve elastic deformation. Friction occurring between the contact surfaces and within the molecule chains generates heat that causes the material to melt.

Ultrasound Activates Plastic Molecules - Frictional Heat Generation

Metal welding is suitable for applications such as:

  Wire - Terminal
  battery cell

Metal welding is a diffusion phenomenon of contact surfaces, and heat is generated by friction between contact surfaces, but heat generation is significantly less than other joining methods. [Laser or resistance welding raises the temperature to the melting point of the metal]

Welding principle by application

One Principle, Infinite Possibilities


You will do a lot of foil welding, mainly in battery cells. Foils typically have a thickness between 6 µm and 0.3 mm. 2 to 160 foils can be welded at the same time. It is often used in prismatic cells, pouches and cylindrical cells.

Terminal - Terminal

Application for welding metal terminals up to 3mm thick. The pressure and amplitude are much higher than for foil welding. It is often used in battery management systems or high-power contacts.

Cable - Terminal

In modern automobiles, ultrasonically bonded cables and connectors have become indispensable. The cross-sectional area of ​​the cable ranges from 6 to 85 mm², and the main materials are copper and aluminum. It is widely used in cable harnesses and high-power transmission devices for electric vehicles.