Advantages of aluminum ultrasonic wire bonding?

Wire bonding has been widely used in the field of microelectronics and power electronics since 1970. Now Wire bonding technology has a new field of application, namely the growing field of electric vehicles, especially for battery connections. Wire bonding is used in the production of some electric vehicles for the connection between battery packs.

Since the widespread use of wire bonding in microelectronics in 1970, some electric vehicle manufacturers have been using wire bonding for battery connection.

In 2006, TESLA pioneered the use of wire bonding as a model for connecting cells into a large battery pack. In TESLA's view, the traditional soldering process was time consuming and prone to failure. It is also difficult to test the connections between cells and conductors for problems. In addition to simple connections, TESLA has also designed a way to use Aluminum wire bonding, a fusible connection technology. TESLA engineers believe that other bonding techniques create electrical protection problems, and that without fuse protection, a single cell can become internally short-circuited after a failure or damage, rendering all other cells connected in parallel with it unusable.

Advantages

Traditional brazing and fusion welding techniques have been used for many years and have some disadvantages. For example, the generation of thermal stresses, post-weld cleaning problems, lack of flexibility and difficulty in quality control, etc. Wire bonder's wire and tape welding performs much better than conventional welding in this respect and allows good control of each weld without any adverse effects on the production process.

• When aluminum wire welding or aluminum strip welding is used, it can be carried out at room temperature. No external temperature is required, and the temperature of the welding zone will not rise during ultrasonic friction welding. Other traditional welding methods require heating to melt the metal.
• Wire bonding is a clean welding technology and does not require any cleaning after welding. After the traditional welding technology, there will be some flux residues or molten metal explosives that need to be removed to avoid reliability problems. Wire bonding requires cleaning only when there are some pollutants or stubborn oxides on the surface.
• Wire bonding has good flexibility and strong compatibility, including low wire height, multi-pin selection, large working range, ribbon or circular wire selection.
• The wire can have good flexibility in direction and can control the mismatch between various thermal expansion parameters.
• Lead wire connection process, bonding wire can be directly used as fuse process, without resistance welding of nickel sheet in use, simplifying production process and reducing equipment investment.
• Ultrasonic automatic wire bonder adopts digital automatic frequency tracking ultrasonic system, digital control pressure regulation function, first-class image recognition equipment and full closed-loop motion control circuit, and is widely used in the connection of battery, cell and bus aluminum wire in the new energy automobile industry.

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