Ultrasonic Welding is a joining technique that lowers energy use and increases safety. USW is environmentally clean, while conventional welding can result in gassing because materials are heated to very high temperatures. Manufacturers are turning to USW in lieu of other welding techniques.

(Madison, NJ)- Ultrasonic Welding (USW) is a joining technique that lowers energy use and increases safety. USW is also environmentally clean, while conventional welding can result in gassing because materials are heated to very high temperatures. USW

uses high-frequency ultrasonic acoustic vibrations to create solid-state welds. Manufacturers are turning to USW in lieu of other welding techniques which apply too much heat to lithium-ion (Li-ion) and Ni-metal hydride (Ni-MH) battery components. Materials being ultrasonically welded are heated to ~200 °F versus over 1,000 °F for conventional welding.

Although USW is a relatively simple process, care needs to be taken during the setup of the ultrasonic bonder. The horn and anvil need to be precisely aligned so that the horn exerts uniform pressure across the entire weld area. However, no instrumentation is built in to the equipment that ensures uniformity of pressure at the interface of the horn and anvil. The use of Pressurex® pressure indicating sensor film to adjust the horn and anvil is an economical and precise process that helps ensure this outcome. It will also result in less scrap from rejected product.

Pressurex® is an easy-to-use tool that reveals the distribution and magnitude of pressure between any two contacting surfaces. When placed between the horn and the anvil of the ultrasonic bonder, the film instantaneously and permanently changes color directly proportional to the actual pressure applied. The precise pressure magnitude is then easily determined by comparing color variation results to a color correlation chart (conceptually similar to interpreting Litmus paper). Pressurex® measures surface pressures between (2 - 43,200 psi (0.14 - 3,000kg/cm2).

Shown at left, below, are aluminum and copper ultrasonic welds in a Li-ion battery. Next to that are pressure maps that show pressure variations across the weld zone which can result in less than optimal weld strength. Testing with the sensor film and adjusting the horn and anvil until uniform contact is achieved optimizes the weld and prevents weld defects. While most testing is done exclusively with the sensor film, imaging analysis is also available.

M O R E

Aluminum and Copper Ultrasonic Welds in a Li-ion Battery Horn's Pattern on Pressurex Reveals Contact Flaws Pressurex Pressure Profile after Image Analysis


For further information and to obtain a sample of Pressurex® in your pressure range, contact Sensor Products Inc. at 1.973.884.1755 (USA), email info@sensorprod.com or visit www.sensorprod.com/sample

About Sensor Products Inc. (USA)
Headquartered in New Jersey and established in 1990, Sensor Products Inc. is a world leader in the manufacture and distribution of tactile pressure sensing solutions. Their customized and off-the-shelf products are installed within all of the Fortune 500 industrial companies as well as thousands of smaller manufacturing firms. Their sensors are used in applications as diverse as tire testing to semiconductor manufacturing and from R&D labs to space missions. Additionally, Sensor Products provides in-house and on-site stress and pressure mapping analysis, as well as a variety of regional technical seminars.