The document discusses ultrasonic metal welding systems and their applications in solar panel assembly. It describes universal welding systems for solar panel assembly, seam welding of solar collectors, and welding of components like thermal fins and absorbers. The systems can weld materials like aluminum, copper and gold. The document also discusses the welding of substrates, coatings, and busbars for photovoltaic applications. It provides information on the physical and mechanical properties of ultrasonic welds. The final pages cover the software, control systems, and advantages of ultrasonic metal welding.

1. Stapla Ultrasonics
Schunk Sonosystems
Perfection in connection
Ultrasonic Metal Welding
Page: 1
Ultrasonic Metal Welding

2. Stapla Ultrasonics
Schunk Sonosystems
Universal Welding Systems
For Solar Panel Assembly
Page: 2
Ultrasonic Metal Welding

3. Stapla Ultrasonics
Schunk Sonosystems
Seam Welding
Solar Collector
Page: 3
Ultrasonic Metal Welding

4. Stapla Ultrasonics
Stapla Ultrasonics
Schunk Sonosystems
Welding Solar Thermal and Thin Film
Thermal Fins
Thermal Absorbers
Thin Film Panels
Page: 4
Ultrasonic Metal Welding

5. Stapla Ultrasonics
Schunk Sonosystems
Stapla Ultrasonics
Welding Solar Thermal and Thin Film
Thermal Fins
Stapla RSK
Stapla Solstar-3
Thermal Absorbers
Stapla RM-20
used in all seam welders
Stapla SWR-20
Thin Film Panels
Schunk SWR-20-AFC
Page: 5
Ultrasonic Metal Welding

6. Schunk Sonosystems
Stapla Ultrasonics
Photovoltaic Industry
Physical Properties of the Connection
Electrical resistance:
Transition resistance:
30 – 40 mΩ
(~ 2 – 3 mΩ/mm²)
Mechanical strength:
Peel strength:
15 N
Geometry of joint zone:
3 mm x 5 mm
Page: 6
Ultrasonic Metal Welding

7. Stapla Ultrasonics
Schunk Sonosystems
Photovoltaic Industry
Applied Busbars
Materials:
Aluminum,
Copper,
Gold,
Page: 7
Ultrasonic Metal Welding

8. Schunk Sonosystems
Stapla Ultrasonics
Photovoltaic Industry
Substrates and Coatings
Al
Types of substrates:
Glass,
Stainless steel foils,
Copper foils,
Mo
Cr
Types of coatings:
Aluminum,
Chromium,
Molybdenum,
Zinc oxide,
Tin oxide,
Page: 8
3 mm
2 mm
1 mm
Ultrasonic Metal Welding

9. Schunk Sonosystems
Stapla Ultrasonics
Photovoltaic Industry
Applied Busbars
Materials:
Aluminum,
Copper,
Gold,
…
Glass
Mo
Al
Cu *
Au
Page: 9
Ultrasonic Metal Welding

10. Stapla Ultrasonics
Schunk Sonosystems
Software and Control Systems
• Key locked operation (production) mode providing welding with process
control system
• Statistic module with trending functions
• Logbook recording all welds with the respective welding parameters
• Maintenance clock monitoring the status of the welding module
• SPC Capabilities
• Automatic continuous checking of machine functions
• Network set-up
• Software compatibility of upgraded software versions
• Display of customized pictures and graphics
• Input of application data via barcode reader (ser./par.) or keyboard
Page: 10
Ultrasonic Metal Welding

11. Schunk Sonosystems
Stapla Ultrasonics
Ultrasonic Metal Welding Advantages:
•
low heat, no melting
•
no consumable materials
easy to automate
•
•
low resistance
•
•
longer tool life
•
•
fast cycle time
•
•
operator safety
•
•
environmentally friendly
•
•
requires minimal training for
operators.
•
•
•
statistical process control
low energy requirement
high weld strength
weld dissimilar materials
full quality control
pure metallurgical bond
modular machine design
easy to setup and operate
Page: 11
Ultrasonic Metal Welding

12. Stapla Ultrasonics
Schunk Sonosystems
For more information please contact:
Stapla Ultrasonics Corporation
E-Mail: info@staplausa.com
Website: www.staplaultrasonics.com
Page: 12
Ultrasonic Metal Welding