US 12,451,621 B2
Multistage welding of splices by means of an ultrasonic welding device
Dennis Tobias Kaemmerer, Wettenberg (DE); Andreas Schary, Hohenahr (DE); and Björn Kleespiess, Solms (DE)
Assigned to Schunk Sonosystems GmbH
Appl. No. 18/017,213
Filed by Schunk Sonosystems GmbH, Wettenberg (DE)
PCT Filed Jul. 30, 2020, PCT No. PCT/EP2020/071582
§ 371(c)(1), (2) Date Jan. 20, 2023,
PCT Pub. No. WO2022/022833, PCT Pub. Date Feb. 3, 2022.
Prior Publication US 2023/0275364 A1, Aug. 31, 2023
Int. Cl. B23K 20/00 (2006.01); B23K 20/10 (2006.01); H01R 4/02 (2006.01); H01R 43/02 (2006.01); B23K 101/38 (2006.01)
CPC H01R 4/021 (2013.01) [B23K 20/004 (2013.01); B23K 20/106 (2013.01); H01R 43/0207 (2013.01); B23K 2101/38 (2018.08)] 14 Claims
OG exemplary drawing
 
1. A method for welding a splice by way of an ultrasonic welding device, wherein the ultrasonic welding device has a sonotrode for generating ultrasonic vibrations, an anvil, a first lateral element, a second lateral element and a compaction chamber, the height of which is adjustable by varying a distance between the sonotrode and the anvil and the width of which is adjustable by varying a distance between the first lateral element and the second lateral element, wherein the method comprises:
arranging first conductor portions to be welded of at least two electrical conductors in the compaction chamber;
adjusting the width of the compaction chamber to a predetermined value for a first welding operation;
performing the first welding operation by activating the sonotrode and compressing the first conductor portions between the sonotrode and the anvil, wherein the first conductor portions are welded together to form a first splice;
arranging a second conductor portion to be welded of at least one further electrical conductor and the first splice in the compaction chamber, wherein the second conductor portion is arranged between the first splice and the sonotrode;
adjusting the width of the compaction chamber to a predetermined value for a second welding operation, wherein the width of the compaction chamber for the second welding operation is greater by a predetermined tolerance value than the width of the compaction chamber for the first welding operation, so that the first splice has a slight clearance between the first lateral element and the second lateral element after adjusting the width of the compaction chamber; and
performing the second welding operation by reactivating the sonotrode and compressing the first splice and the second conductor portion between the sonotrode and the anvil, wherein the first splice and the second conductor portion are welded together to form a second splice.