Eiichi Sugimoto

Welding characteristics of aluminum, copper, nickel and aluminum alloy with alumina coating using ultrasonic complex vibration welding equipments

Welding of aluminum-copper, aluminum nickel plate specimens and aluminum alloy is essential for fuel cell, battery or EDLC electrodes for electric or hybrid automobile and other various industry fields. Welding characteristics and welded structures are studied on same and different metal specimens using various complex vibration welding systems.

Welding of flat copper braid wire specimens using ultrasonic complex vibration - Direct machining of terminal parts on flat braided wires -

Braid wires are flexible and vibration-proof, and used widely for connecting various electrical equipments including battery earth wire and various electrical equipments. Braid wire end is usually connected using a solder or solderless terminal, and connected to the equipment by fixing bolts. Direct machining of terminal part of flat braided wire using a 20 kHz ultrasonic complex vibration is studied and rigid terminals are obtained. Using conventional linear vibration system, rigid terminals could not obtained.

Ultrasonic welding of electronic parts and devices using a long and thin complex vibration welding tip

Ultrasonic complex vibration welding was applied for deep and narrow area of electronic parts positioned at long distance from the vibration system. Usually, electric resistance welding was used to weld such part, but there are possible defect caused by sparked metal particles radiated from welding position. To overcome the defect and make possible to join such deep area, 20 kHz and 27 kHz ultrasonic complex vibration systems using 2.0- and 3.0-mm-diameter, 70- to 100-mm-long hard metal and tungsten welding tips were developed. Using the ultrasonic complex vibration systems, various metal specimens including copper, nickel clad copper terminal and steel or nickel coated steel cases were successfully welded with weld strength almost equal to these material strength.

Compacting of various metal, alloy and ceramic powder using 20 kHz ultrasonic vibration compacting equipments with upper and lower vibration punches

−20 kHz ultrasonic vibration compacting system with 15-mm-diameter upper and lower vibration punches and a radial vibration die, and 20 kHz vibration compacting system using 5-mm-diameter upper and lower vibration punches are studied. Compacting of metal, alloy and ceramics powder is important process for powder metallurgy which is used for producing small and precise mechanical parts and required for various industry fields including electronics. Some complex metal alloy, amorphous alloy and fine ceramic powder such as zirconium are impossible to compact using only static pressure. Various powder are compacted with larger density and more uniform distribution compared that without vibration.

Ultrasonic welding using a long and thin complex transverse vibration welding tip with vibration detector and static pressure controller

Ultrasonic welding could not been applied for deep and narrow parts positioned at long distance from the vibration system. Usually, electric resistance or laser welding was used to weld such part, but there are possible fatal defect caused by sparked metal particles. To join such deep area, ultrasonic complex vibration systems using a long welding tip of 2.0- and 3.0-mm-diameter vibrating in circular to elliptical locus were developed. To improve welding characteristics furthermore, complex vibration velocity detector of welding tip and static pressure control system were developed.

Ultrasonic complex vibration welding of many metal foils and terminals of Li-ion battery and capacitor

Ultrasonic complex vibration welding using twodimensional vibration stress has significantly superior welding characteristics compared with conventional welding with linear vibration. Welding of same and different metal parts and foils such as aluminum and copper electrode foils and terminals is important for electronic devices, Li-ion battery or EDLC electrodes and other various industry fields. For welding of various welding specimens, various welding tips were developed and studied on their vibration and welding characteristics.

Ultrasonic plastic continuous welding system for wide plastic nets and sheets using two 20 kHz long longitudinal vibration cylinders

Ultrasonic welding method for wide and long plastic net and sheet was developed using two 20 kHz rotating 3 to 13.5 wavelength longitudinal vibration cylinders. Specimens of 1 m to 3 m width and several km length are required for such as agriculture and gardening and also various gas filters. Intersections of the net element wires must be fixed. Two-vibration-system welding method has superior welding characteristics.

Welding characteristics of same and different metal specimens using ultrasonic complex vibration welding equipments

Welding characteristics of ultrasonic complex vibration of same and different metal specimens are studied using newly designed ultrasonic complex vibration welding systems. Using complex vibration which induces two-dimensional vibration stress to the welding area, the required vibration velocity and specimens damages by vibration fatigue decrease significantly compared with a conventional welding system using linear vibration locus.

Welding characteristics of bi-metal, braided wires, aluminum and copper foils using 20 kHz ultrasonic complex vibration welding equipments

Welding characteristics of copper, bimetalic strip, braided flexible copper and tin coated copper wires consisted of thin wire elements, and large number of aluminum and copper thin foils are studied. Welding of copper, bimetal and braided wires and different metal foils are required for various electronic devices and multi-layer fuel cell, battery or EDLC electrodes for electric or hybrid automobile and various industry fields. These specimens are welded successfully using complex vibration welding.

Plunging of metal pins using a 20 kHz ultrasonic vibration system

Plunging of metal pin or shaft into small hole inducing longitudinal vibration on static plunging force is studied. When inserting pin or shaft using only static force, the material with holes happen to broken by plunging pin by large static force and also the motor shaft plunged into the rotor center has inevitably eccentricity and must to adjust the eccentricity by manual or some machines. Using ultrasonic vibration, static force and eccentricity can be decreased due to decreasing frictional force by vibration.