Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Industry and research join forces to improve bonding processes in the automotive industry

09.12.2013
In power electronics systems bonded connections create the central electrical connections between adjoining surfaces.

The quality of these bonded connections is one of the main factors that determines the reliability and availability of drive systems in electric vehicles, and hence constitutes a major design challenge for German auto manufacturers aiming to electrify their vehicles.


Laser-guided bonding head
Source: Fraunhofer ILT, Aachen, Germany


Laser-welded copper ribbon bond.
Source: Fraunhofer ILT, Aachen, Germany

Now the partners participating in the RoBE (Robust Bonds in Electric Vehicles) collaborative research project have developed a reliable means of predicting the service life of these bonded connections, and also developed an alternative bonding technique based on laser micro welding that is ready for industrial implementation.

The new technique opens up a wider range of options for the use of wire bonding, especially in applications requiring the joining of copper. Here, modern laser sources with a very high beam quality ensure precise, reproducible weld joints in copper and aluminum. Through the additional use of oscillation welding in combination with adapted design of the wire and ribbon joining zones, the strength of the joint can be improved still further. By comparison with conventional wire bonding, this process offers a higher surface quality and requires less cleaning. Moreover, the process is less dependent on the nature of the underlying surface or the vibration characteristics of the workpiece.

A standard bonding machine was adapted to allow the laser bonding process to be combined with traditional bonding technologies. The new machine now allows the use of a laser in the bonding process. The main applications of this system include ribbon bonding on DCB substrates and copper terminals in the packaging of power electronics assemblies.

Advances in the field of wire bonding technologies that extend the range of design opportunities while at the same time reducing costs are a vital factor in Germany’s future as a leading provider of electromobility solutions. For this reason, since August 1, 2011 the German Federal Ministry of Education and Research (BMBF) has set aside €4.96 million in funding to support this collaborative project as part of its ICT 2020 initiative in the category “Key technologies for electromobility” (STROM).

Contacts

Dr. Alexander Olowinsky
Head of the Micro Joining Group
Phone +49 241 8906-491
alexander.olowinsky@ilt.fraunhofer.de
Dipl.-Ing. Benjamin Mehlmann
Micro Joining Group
Phone +49 241 8906-613
benjamin.mehlmann@ilt.fraunhofer.de
Fraunhofer Institute for Laser Technology ILT
Steinbachstraße 15
52074 Aachen, Germany

Petra Nolis | Fraunhofer-Institut
Further information:
http://www.ilt.fraunhofer.de

More articles from Automotive Engineering:

nachricht When your car knows how you feel
20.12.2017 | FZI Forschungszentrum Informatik am Karlsruher Institut für Technologie

nachricht Did you know how many parts of your car require infrared heat?
23.10.2017 | Heraeus Noblelight GmbH

All articles from Automotive Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Developing reliable quantum computers

International research team makes important step on the path to solving certification problems

Quantum computers may one day solve algorithmic problems which even the biggest supercomputers today can’t manage. But how do you test a quantum computer to...

Im Focus: In best circles: First integrated circuit from self-assembled polymer

For the first time, a team of researchers at the Max-Planck Institute (MPI) for Polymer Research in Mainz, Germany, has succeeded in making an integrated circuit (IC) from just a monolayer of a semiconducting polymer via a bottom-up, self-assembly approach.

In the self-assembly process, the semiconducting polymer arranges itself into an ordered monolayer in a transistor. The transistors are binary switches used...

Im Focus: Demonstration of a single molecule piezoelectric effect

Breakthrough provides a new concept of the design of molecular motors, sensors and electricity generators at nanoscale

Researchers from the Institute of Organic Chemistry and Biochemistry of the CAS (IOCB Prague), Institute of Physics of the CAS (IP CAS) and Palacký University...

Im Focus: Hybrid optics bring color imaging using ultrathin metalenses into focus

For photographers and scientists, lenses are lifesavers. They reflect and refract light, making possible the imaging systems that drive discovery through the microscope and preserve history through cameras.

But today's glass-based lenses are bulky and resist miniaturization. Next-generation technologies, such as ultrathin cameras or tiny microscopes, require...

Im Focus: Stem cell divisions in the adult brain seen for the first time

Scientists from the University of Zurich have succeeded for the first time in tracking individual stem cells and their neuronal progeny over months within the intact adult brain. This study sheds light on how new neurons are produced throughout life.

The generation of new nerve cells was once thought to taper off at the end of embryonic development. However, recent research has shown that the adult brain...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

VideoLinks
Industry & Economy
Event News

2nd International Conference on High Temperature Shape Memory Alloys (HTSMAs)

15.02.2018 | Event News

Aachen DC Grid Summit 2018

13.02.2018 | Event News

How Global Climate Policy Can Learn from the Energy Transition

12.02.2018 | Event News

 
Latest News

Stiffness matters

22.02.2018 | Life Sciences

Magnetic field traces gas and dust swirling around supermassive black hole

22.02.2018 | Physics and Astronomy

First evidence of surprising ocean warming around Galápagos corals

22.02.2018 | Earth Sciences

VideoLinks
Science & Research
Overview of more VideoLinks >>>