Ultrasonic tab welding

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Ultrasonic tab welding

Postby Inwo » Thu Oct 12, 2017 5:46 pm

Thinking of acquiring a welder for aluminum lto pouch tabs.
Anyone have information or sources.

Found one for $3500 from China. Fits my budget if it works. I don't know what to look for.
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Re: Ultrasonic tab welding

Postby PaulD » Thu Oct 12, 2017 6:14 pm

I would recommend asking the welder vendor what materials and thicknesses the machine can weld. The little ones for welding current collector foils likely don't have the power to do thick tabs. Just as a reference point, I nearly maxed out a 1.5kw welder doing 3X 0.2mm copper tabs to 1.6mm copper busbar with large pads (maybe a 0.5in2 area) on the horn. Aluminum to copper required about 75% of the power.
If you are just doing aluminum to aluminum, less power is needed. The vendor should be able to tell you.
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Re: Ultrasonic tab welding

Postby 999zip999 » Thu Oct 12, 2017 6:35 pm

What battery cells we talking about.?
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Re: Ultrasonic tab welding

Postby Inwo » Thu Oct 12, 2017 7:28 pm

PaulD wrote:I would recommend asking the welder vendor what materials and thicknesses the machine can weld. The little ones for welding current collector foils likely don't have the power to do thick tabs. Just as a reference point, I nearly maxed out a 1.5kw welder doing 3X 0.2mm copper tabs to 1.6mm copper busbar with large pads (maybe a 0.5in2 area) on the horn. Aluminum to copper required about 75% of the power.
If you are just doing aluminum to aluminum, less power is needed. The vendor should be able to tell you.


You have experience with ultrasonic welding? I'm starting from zero.
I'll get the specs. Means nothing to me!
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Re: Ultrasonic tab welding

Postby Inwo » Thu Oct 12, 2017 7:37 pm

999zip999 wrote:What battery cells we talking about.?


11ah and 50ah titanate pouches. LTO
These were made for Altairnano by Kokam. 9 years old, but hey, LTO are forever!

ltopics4.gif
ltopics4.gif (138.34 KiB) Viewed 205 times


Foil to foil only, but maybe several layers.
Only have a thousand or so 50ah, so will need to parallel the 11s for my uses. >100ah
Tabs may only reach to about 4p without bus bar of some kind.
Maybe I will need tab to cu welds.
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Re: Ultrasonic tab welding

Postby Inwo » Thu Oct 12, 2017 7:38 pm

Maybe I need a partner with a welder?
:wink:
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Re: Ultrasonic tab welding

Postby Inwo » Thu Oct 12, 2017 7:48 pm

Quick Details

Type: Other

Voltage: AC 110V or 220V +/-10%, 50/60Hz
Current: Request
Rated Capacity: 2000W
Rated Duty Cycle: Request
Dimensions: 360mm(L) x 480mm(W) x 200mm(H)
Weight: 60kg
Usage: Welding Machine
Certification: CE Certificate
After-sales Service Provided: Engineers available to service machinery overseas
Color: Request
Warranty: 1 Year, One Year limited warranty with lifetime support
Features: Preset welding programs selectable for Al and Cu
Welding Area: 4mm(L) x 4mm(W)
Welding Head: The welding heads and welding bases are included
Controller: 360mm(L) x 480mm(W) x 200mm(H)
Welder: 200mm(L) x 460mm(W) x 270mm(H)
Material: Steel
Ultrasonic Frequency: 40K Hz
Max. Welding Thickness: Max. 20 layers


tmaxwelder.gif
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tmaxwelder1.gif
tmaxwelder1.gif (86.06 KiB) Viewed 203 times
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Re: Ultrasonic tab welding

Postby PaulD » Fri Oct 13, 2017 12:21 pm

Cool. Looks like that might work. The machine I was referring to is $40K and doens't belong to me!
At 2000W, not sure how it could run off of 110V.

Inwo wrote:Quick Details

Type: Other

Voltage: AC 110V or 220V +/-10%, 50/60Hz
Current: Request
Rated Capacity: 2000W
Rated Duty Cycle: Request
Dimensions: 360mm(L) x 480mm(W) x 200mm(H)
Weight: 60kg
Usage: Welding Machine
Certification: CE Certificate
After-sales Service Provided: Engineers available to service machinery overseas
Color: Request
Warranty: 1 Year, One Year limited warranty with lifetime support
Features: Preset welding programs selectable for Al and Cu
Welding Area: 4mm(L) x 4mm(W)
Welding Head: The welding heads and welding bases are included
Controller: 360mm(L) x 480mm(W) x 200mm(H)
Welder: 200mm(L) x 460mm(W) x 270mm(H)
Material: Steel
Ultrasonic Frequency: 40K Hz
Max. Welding Thickness: Max. 20 layers
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Re: Ultrasonic tab welding

Postby Inwo » Fri Oct 13, 2017 11:44 pm

Tnx, tempted to spend my battery money on it. Easy come easy go.
If it works, I could maybe get 1/2 price when I'm through with it.

Hate renting. Then I'd have to hustle. Like having a real job.
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Re: Ultrasonic tab welding

Postby 999zip999 » Sat Oct 14, 2017 12:33 am

I guess 2,000 watts is 220v. Now the big question is how much ? Be nice to talk to someone who has one.
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Re: Ultrasonic tab welding

Postby Inwo » Sat Oct 14, 2017 9:00 am

Exactly, I have know idea what I'd be getting into.
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Re: Ultrasonic tab welding

Postby Inwo » Tue Oct 17, 2017 12:25 am

Found a $1500 handheld welder.
Last edited by Inwo on Tue Oct 17, 2017 9:58 pm, edited 2 times in total. View post history.
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Re: Ultrasonic tab welding

Postby Inwo » Tue Oct 17, 2017 9:57 pm

PaulD wrote:I would recommend asking the welder vendor what materials and thicknesses the machine can weld. The little ones for welding current collector foils likely don't have the power to do thick tabs. Just as a reference point, I nearly maxed out a 1.5kw welder doing 3X 0.2mm copper tabs to 1.6mm copper busbar with large pads (maybe a 0.5in2 area) on the horn. Aluminum to copper required about 75% of the power.
If you are just doing aluminum to aluminum, less power is needed. The vendor should be able to tell you.



Cheap way out for 800 watt handheld welder. Should be ok aluminum only. If it won't weld to cu bus, I'll bolt terminations.
Weld series connections only. I'd rather risk $1500 than $5000.
Think I could resell it if I want a bigger one later.
This will be my tuition payment.
Been there done that! :D
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