Revolutionary screw solution for silver-plated aluminum busbars: a case study

Sponsored by Telsonic.

Telsonic’s advanced torsional SONIQTWIST^® welding technology has been successfully applied in a groundbreaking solution for fixing silver-plated aluminum busbars using screws. This innovation, developed in collaboration with the KERN-LIEBERS Group, a producer of precision stamped parts, promises to set new standards for reliability and conductivity in electrical connections for industrial applications. 

The Challenge: Securing Silver-Plated Aluminum Busbars 

The KERN-LIEBERS Group has pioneered a technique to coat aluminum busbars inline with silver. This silver coating enhances the busbars’ conductivity but poses a challenge for secure attachment using screws, due to the relaxation properties of aluminum. The solution requires the integration of a copper sleeve into the busbar, providing a durable and electrically conductive connection that allows for screw fixation.

The Solution: Integrating Copper Sleeves with Ultrasonic Welding 

To implement this solution, a copper sleeve is placed into a pre-punched hole in the busbar. The sleeve is designed with an oversized collar to facilitate the transmission of torsional ultrasonic vibrations through a sonotrode. This process welds the copper sleeve to the silver layer, ensuring the integrity of the silver coating is maintained. 

Telsonic’s torsional SONIQTWIST® technology – the torsional welding system TSP3000.

Configuration Advantages

The integration of silver coating expands the compatibility of ultrasonic welding to new aluminum alloys. Ultrasonic welding offers a process-secure and long-term stable connection between dissimilar metals with minimal electrical resistance. The production of busbars with punched holes is cost-efficient, and integrating the silver coating into the production process eliminates additional transport costs for external coating.

Successful Implementation: Torsional SONIQTWIST® Technology 

This application was successfully executed using Telsonic’s torsional SONIQTWIST® technology. The torsional welding system TSP3000, depicted above, demonstrates Telsonic’s capability to meet the demanding requirements of industrial applications, ensuring reliable and conductive connections.