With the accelerated development of Jiujiang's electronic information industry cluster, the field of electronic component packaging and welding is facing the need for technological upgrading. This article will deeply analyze the production pain points of local enterprises, interpret the innovative value of ultrasonic welding technology, and explore the practical path of this process in industrial upgrading.
Welding technology bottleneck in Jiujiang electronic manufacturing industry
In Jiujiang Economic and Technological Development Zone, many electronic companies reported that traditional welding processes face three major challenges: first, miniaturized components are highly thermally sensitive, and manual welding is prone to thermal damage; second, the demand for packaging of multi-layer composite materials has increased, and traditional processes are difficult to ensure the quality of interface fusion; third, emerging fields such as new energy vehicle electronic components require welding strength to be increased to more than 3.5N/mm². Data from a circuit board manufacturer showed that the product defect rate caused by traditional welding is as high as 2.3%, with annual losses exceeding one million yuan.
Breakthrough application of ultrasonic welding technology
Micro sensor packaging: 20kHz high-frequency vibration is used to achieve non-destructive welding of 0.1mm enameled wire, and the heat-affected zone is controlled within 50μm
Lithium battery tab welding: Achieve metallurgical bonding of copper and aluminum dissimilar metals through adjustable amplitude technology, reducing resistance by 40%
Smart wearable device assembly: non-contact welding avoids damage to precision electronic components, and the yield rate is increased to 99.6%
Automotive electronic module packaging: welding strength meets ISO 5183 standards and has no attenuation after 2000 hours of aging test
Production changes brought about by technological innovation
Compared with traditional processes, ultrasonic welding machines have unique advantages:
Energy saving: single-point welding energy consumption is 50W, which is 80% lower than laser welding.
Improved efficiency: 0.3 seconds per soldering point increases production line efficiency by 3 times
Material compatibility: Can process 8 types of engineering plastics such as PET, nylon, PC, etc.
Intelligent control: equipped with pressure feedback system, welding depth accuracy up to 0.02mm
Apsonic localization solution practice
In the context of Jiujiang's industrial upgrading, Apsonic, which has been deeply involved in the ultrasonic field for 15 years, launched a servo series welding equipment. This model adopts a modular design and supports a fast energy conversion system, which is adapted to the multi-variety and small-batch production characteristics of Jiujiang enterprises. According to actual tests by a relay manufacturer in Jiujiang, the automatic amplitude compensation function configured in the equipment has increased the welding stability of different batches of materials by 35%, and the independently developed acoustic system has extended the life of the transducer to more than 6 million times. The person in charge of corporate procurement gave feedback: "The localized service team of the equipment can respond to technical needs within 4 hours, and the annual maintenance cost is reduced by 60%."
