Haven't been on here in a while and in the interim got into semiconductor fab which involves this cool tech called wire bonding! Usually the wires involved are very small but they can be bigger, big enough to carry current for high power ebikes. Wire bonding has been used in industry for decades. The process is simple. So wire bonding can't be that hard. We need just a few ingredients:
1) Right frequency: some dozens of kHz, lower with thicker wire
2) Pressure ???
3) Interface: some tip on our ultrasonic emitter to transfer the work to the wire and bonding surface
Wire bonding is better than spot welding or soldering because there is less heat. It's also ideal for attaching small gage wires which can serve as fuses.
We already have handheld spotwelders which are totally laborious to use. Ultrasonic emitters don't seem to be very expensive at all in principle.
Why are enthusiasts not wire bonding batteries in 2022? What is the holdup?
1) Right frequency: some dozens of kHz, lower with thicker wire
2) Pressure ???
3) Interface: some tip on our ultrasonic emitter to transfer the work to the wire and bonding surface
Wire bonding is better than spot welding or soldering because there is less heat. It's also ideal for attaching small gage wires which can serve as fuses.
We already have handheld spotwelders which are totally laborious to use. Ultrasonic emitters don't seem to be very expensive at all in principle.
Why are enthusiasts not wire bonding batteries in 2022? What is the holdup?
