Ultrasonics and electromobility
eMobility and Ultrasonics

Metal & Plastic Welding
Battery powder sieved with ultrasound
Thin-walled bumper

supported by SONIQTWIST® torsional welding technology

Metal and Plastic Welding Check-out the application possibilities:

Powerful Reliable contacting of high-voltage conductors, battery films and high-performance electronics

A typical example of use is the secure, positive-welded connection of copper, aluminum and a combination thereof, e.g. for high-voltage connections in a vehicle. Charging cables with plugs, from the charging station to the high-voltage battery, enable rapid charging even under difficult conditions. A reliable connection with low contact resistance is important here. The contacts between the individual aluminum and copper films of the pouch cells on a high-voltage battery, as well as the arresters for the external connections, are welded quickly, reliably and with high quality using ultrasonics.

A central electronic component for converters of electrical drives and battery charging systems are IGBT power semiconductors, which are capable of switching electrical currents quickly and with minimal losses. The unique torsional welding technique SONIQTWIST®, which uses slim sonotrodes that approach from above, is particularly suitable for the sensitive ceramic substrates of the IGBTs, onto which the contacts are welded on the conductor paths, especially when space is limited.

Ultrasonic welding for safe electrical connection at Ferrari Purosangue

Understanding PowerWheel® for EV Cable Terminations

Eco-friendly Joining technology for lightweight construction

Ultrasonic technology plays a key role in lightweight automotive construction. New materials and thin-wall technology are used here, for which the SONIQTWIST® ultrasonic welding technology is ideally suited. This patented and gentle welding process makes it possible, for example, to significantly reduce the wall thickness of vehicle bumpers to approx. 2 mm without leaving visible marks on Class A surfaces of vehicle parts that are already painted.

Ultrasonic technology thereby makes a significant contribution to reducing the weight of the vehicle, as it enables the use of such a thin material thickness in the first place. The fact that no adhesives or other consumables are required in comparison to other technologies is another analogy to electromobility: electric vehicles do not burn finite fuel and can be operated with renewable energy. They are thus eco-friendly.

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Efficient Ultrasonic sieving in battery production

Thanks to its extensive experience in sieving, Telsonic is involved in the key process of battery production right from the very beginning: Sieves stimulated with ultrasonics reduce friction during the separation of powdered battery materials. This reliable and energy-efficient process technology enables higher selectivity and thus a homogeneous powder consistency for the manufacture of electrodes for vehicle batteries. Ultrasonically stimulated double-decker sieves with precisely defined mesh sizes are often used in practice. This allows the carbon for the anode and the lithium metal oxide for the cathode to be separated with a high degree of selectivity, and outsize grains are reliably removed. These quality characteristics are essential for subsequent processes, in which the powder is mixed into a paste with water and solvent and must be applied to the electrode carrier films in an extremely homogeneous way.