What Should Be Noted When Installing Products Into Batteries And Then Ultrasonic Welding？

1. Step out of the misconception of ultrasonic welding: The frequency of oscillation, output power, amplitude range, etc. to be used should be determined based on factors such as the welding wire area, material, whether the workpiece is airtight with electrons, and whether it is a component. The misconception that higher power is better is a misconception. If you are not familiar with ultrasound. It is best to consult relevant engineering and technical personnel.
2. Welding die structure requires strict inspection: Regular ultrasonic die production has a strict inspection program for incoming materials, and the processing dimensions are all processed through computer software simulation and verification. Quality is the guarantee. These processes are generally not achievable in workshops. If the mold is not designed properly, the reaction problem may not be obvious when welding small workpieces. When the power is high, various drawbacks may occur, and in severe cases, the power components may be directly damaged.

3. When welding, the thermal resistance should reach the melting point of the workpiece: After the ultrasonic transducer converts electrical energy into mechanical energy, it is transmitted through the material molecules of the workpiece. The acoustic resistance of ultrasonic sound waves in solid is much lower than that in air. When the sound wave passes through the seam of the workpiece, the acoustic resistance in the gap is large, and the generated heat energy is considerable. The temperature reaches the melting point of the workpiece, and a certain amount of pressure is applied to fuse the joint. However, other parts of the workpiece will not be fused due to low thermal resistance and low temperature.
4. Weldability of two types of workpieces during welding: some can be better fused between different materials, some can be basically fused, and some cannot be fused. The melting point between the same material is the same, and theoretically it can be welded. However, when the melting point of the workpiece to be welded is greater than 350 ℃, ultrasonic welding is no longer suitable. Because ultrasound instantly causes the molecules of the workpiece to dissolve, it is judged that it is within 3 seconds and cannot be well fused, so other welding processes need to be selected. Generally speaking, ABS material is the easiest to weld, while nylon or PP material is generally weldable.
5. There are certain requirements for welding area: when ultrasonic instantaneous energy is generated, the larger the welding area, the greater the energy dispersion, and the worse the welding effect, which may prevent welding. In addition, ultrasonic waves propagate longitudinally, and energy loss is proportional to distance. Long distance welding should be controlled within 6 centimeters. The welding wire should be controlled between 30 and 80 wires, and the arm thickness of the workpiece should not be less than 2 millimeters, otherwise it cannot be well fused, especially for products that require airtightness.
6. The output power of ultrasonic welding needs to be balanced: the size of mechanical output power is determined by the thickness and diameter of piezoelectric ceramic sheets, design process, material, etc. When the ultrasonic transducer is fixed, the maximum power is also fixed. Measuring the size of output energy is a complex process, and it is not that the larger the ultrasonic transducer, the greater the output energy used in the circuit. The more ultrasonic power tubes there are, the more complex amplitude measuring instruments are required, Only then can its amplitude be accurately measured.