Welding device and welding method for producing a material bond connection between a conductor and a connecting part

Patent metadata

Field	Value
Publication number	US-12551969-B2
Application number	US-202017785726-A
Country	US
Kind code	B2
Filing date	Nov 2, 2020
Priority date	Dec 17, 2019
Publication date	Feb 17, 2026
Grant date	Feb 17, 2026

Abstract

The subject matter relates to a welding device as well as a welding method for producing a material bond connection between a conductor ( 10 ) and a connecting part ( 8 ), with at least one ultrasonic welding tool ( 4 ), wherein at least part of a contact surface ( 18 ) of the connecting part ( 8 ) contacts at least part of a contact surface ( 16 ) of the ultrasonic welding tool ( 4 ).

First claim

What is claimed is:

1 . A system comprising:
a combination including an ultrasonic welding tool, a conductor and at least one connecting part; the ultrasonic welding tool having a sonotrode and an anvil, wherein a contact surface of the connecting part contacts a contact surface of the sonotrode or the anvil of the ultrasonic welding tool, wherein the connecting part is formed from a conductive material comprising aluminum and/or copper, wherein the contact surface of the connecting part and the contact surface of the sonotrode or the anvil of the ultrasonic welding tool have profiles corresponding at least in parts to one another, wherein the profiles are formed by substantially mutually corresponding corrugated profiles of at least part of the contact surface of the connecting part and of at least part of the contact surface of the sonotrode or the anvil of the ultrasonic welding tool, wherein the connecting part, the sonotrode and the anvil are arranged to receive the connecting part in between the sonotrode and the anvil and arranged to receive the conductor against the connecting part so that during ultrasonic welding the connecting part and the conductor are pressed at each other in between the sonotrode and the anvil for welding the connecting part and the conductor together; and a pressing tool is arranged to contact the connecting part and the pressing tool positions and fixes the connecting part on the ultrasonic welding tool between the sonotrode and the anvil.

2 . The system according to claim 1 , wherein
the profiles are formed by substantially mutually corresponding wave-shaped profiles of at least part of the contact surfaces of the connecting part and of the sonotrode or the anvil of the ultrasonic welding tool.

3 . The system according to claim 1 , wherein
the conductor is a flat conductor or a bus bar and/or the connecting part is a flat part.

4 . The system according to claim 1 , with at least one conductor, wherein
a further contact surface of the sonotrode or the anvil which is not in contact with the connecting part, is in contact with at least part of a contact surface of the conductor, and at least one part of the further contact surface and the contact surface of the conductor have a further profiles.

5 . The system according to claim 4 , wherein
the further profiles are formed by wave-shaped profiles, by serrated profiles or by fluted profiles.

6 . Welding method for producing a material bond connection between a conductor and a connecting part, comprising:
arranging the connecting part and the conductor on an ultrasonic welding tool between a sonotrode and an anvil of the ultrasonic welding tool, wherein the connecting part is formed from a conductive material comprising aluminum and/or copper, wherein a contact surface of the sonotrode or the anvil of the ultrasonic welding tool and a contact surface of the connecting part are in contact with each other, wherein the contact surface of the connecting part and the contact surface of the sonotrode or the anvil of the ultrasonic welding tool have profiles corresponding at least in parts to one another, wherein the profiles are formed by substantially mutually corresponding corrugated profiles of at least part of the contact surface of the connecting part and at least part of the contact surface of the sonotrode or the anvil of the ultrasonic welding tool, the connecting part and the conductor are pressed at each other in between the sonotrode and the anvil and welded together by ultrasonic welding, wherein the at least one part of the contact surface of the connecting part and the at least one part of the contact surface of the ultrasonic welding tool at least partially interlock along the corrugated profiles and the connecting part is in contact with a pressing tool and the pressing tool positions and fixes the connecting part on the ultrasonic welding tool between the sonotrode and the anvil.

Assignees

• Auto Kabel Man Gmbh

Inventors

• Sebetlela Kabelo

Classifications

• B23K2101/38

  Conductors · CPC title

• B23K2103/12

  Copper or alloys thereof · CPC title

• B23K2103/10

  Aluminium or alloys thereof · CPC title

• B23K20/2336

  both layers being aluminium · CPC title

• B23K20/10 Primary

  making use of vibrations, e.g. ultrasonic welding · CPC title