The cooling pump heats up during operation, which can lead to condensation. The occurrence of moisture can have a detrimental effect on the lifetime of the electronic circuitry and consequently of the whole pump. This is prevented by ultrasonically welding the ePTFE membrane to the electrical connector. In the first part of the experimental set-up, a flat bottom horn was welded with different controlling methods. In the second part, a new horn with an energy director was constructed based on the findings. The quality of the weld joints was evaluated in terms of their visual quality and leakage pressure. Weld edge height measurements were also carried out. We found that the horn with an energy director in combination with flat weld edge is the best in terms of repeatability and material consumption. Ultrasonic welding with a flat bottomed horn and an energy director on the weld spot is more sustainable since it uses 50 J or 11x less energy than a horn with an energy director, making it more sustainable.
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