Lithium-Ion Batteries
Ultrasonic Welding:
- Joining battery tabs to electrodes
- Connecting multiple cells in battery packs
- Sealing pouch cell casings
Heat Staking:
- Securing battery management systems (BMS) to packs
- Attaching cooling components to battery modules
- Fastening protective covers to battery assemblies
Electric Vehicle Batteries
Ultrasonic Welding:
- Bonding copper and aluminum foils in cell construction
- Joining bus bars for high-current connections
- Assembling cylindrical cells into modules
Heat Staking:
- Attaching sensors to battery packs
- Securing insulation components within modules
- Fastening terminal connections to battery housings
Consumer Electronics Batteries
Ultrasonic Welding:
- Joining thin foils in small-format cells
- Connecting battery tabs in smartphones and laptops
- Sealing polymer battery casings
Heat Staking:
- Attaching protection circuits to battery packs
- Securing battery contacts in wearable devices
- Fastening battery compartments in consumer gadgets
Energy Storage Systems
Ultrasonic Welding:
- Joining large-format cells for grid storage
- Connecting modular battery units
- Assembling battery stack components
Heat Staking:
- Attaching thermal management components
- Securing monitoring systems to battery enclosures
- Fastening protective covers on storage units
Medical Device Batteries
Ultrasonic Welding:
- Joining components in implantable batteries
- Sealing battery casings for medical equipment
- Connecting cells in portable medical devices
Heat Staking:
- Attaching battery contacts in hearing aids
- Securing battery holders in diagnostic equipment
- Fastening battery packs in wearable health monitors
Next-Generation Battery Technologies
Ultrasonic Welding:
- Joining components in solid-state batteries
- Assembling flexible and printed batteries
- Connecting elements in flow batteries
Heat Staking:
- Attaching novel electrode materials
- Securing components in structural batteries
- Fastening advanced current collectors
Key Advantages in Battery Manufacturing
- Fast, efficient joining process suitable for high-volume production
- Ability to weld thin, delicate materials without damage
- Creation of high-strength, low-resistance electrical connections
- Minimal heat-affected zone, preserving battery material integrity
- Clean process with no added materials, ensuring battery purity
- Compatibility with automation for consistent, repeatable results
- Ability to join dissimilar metals common in battery construction
- Reduced energy consumption compared to resistance welding
- Suitable for joining next-generation battery materials
- Improved battery pack reliability and performance
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