A welding device for battery tabs and non-lead metal strips

Abstract

This invention relates to a welding device for battery tabs and lead-free metal strips, comprising a battery positioning mechanism and a lead-free metal strip heating mechanism. The lead-free metal strip has a solder filler metal, and its melting point is higher than that of the tabs. The lead-free metal strip heating mechanism includes a heating element assembly for heating the lead-free metal strip. The heating mechanism and the battery positioning mechanism are brought close together, allowing the battery tabs to be welded to the heated lead-free metal strip. This invention controls the positions of the lead-free metal strip heating mechanism and the battery positioning mechanism, ensuring that the lead-free metal strip contacts and welds to the battery tabs after heating. It uses a lead-free metal strip instead of lead strips formed using molds and molten lead, making it more environmentally friendly and reducing energy consumption. Furthermore, using a heating element assembly to heat the pre-fabricated lead-free metal strip avoids the safety hazards of directly heating the lead-free metal strip and the welding quality problems caused by uneven heating.

Description

Technical Field

[0001] This invention belongs to the technical field of lead-acid battery manufacturing equipment, and particularly relates to a welding device for battery tabs and non-lead metal strips. Background Technology

[0002] Traditional lead-acid battery busbars were initially manufactured by welding (fusion-welding) the positive and negative electrode tabs together with lead and lead alloys using an oxygen-acetylene thermal fusion method, forming a cluster, and the resulting current collector was the busbar. After 2010, production gradually switched to machine casting and welding.

[0003] Patent document CN102891278A discloses a method for casting and welding lead-acid battery busbars. The method involves placing battery plates perpendicular to the ground along their width, and sequentially inserting tabs located on the same side into the toothed grooves of a busbar fixture. Molten lead from a lead-melting pot is injected into the busbar fixture by a lead-supply pump and kept at a constant temperature. Then, heating rods are used to sequentially fuse and weld the tabs together. While this invention replaces manual flame welding, it still involves melting lead in a high-temperature furnace and heating the mold to weld the tabs. This high-temperature furnace needs to operate continuously for 24 hours, resulting in high energy consumption. Furthermore, the production process cannot solve the environmental pollution from lead fumes and dust, or the generation of lead slag. The generation of lead slag not only increases material waste but also places high demands on subsequent lead slag treatment. If the lead slag is not properly treated, it affects the welding quality of the subsequent battery busbars, ultimately causing quality problems for the entire battery.

[0004] Patent document CN120033347A discloses a rapid welding structure and manufacturing process for a battery busbar. It proposes using non-lead metal strips made of a metal or alloy with higher conductivity than lead, along with non-lead metal positive and negative terminals. The non-lead metal strips are rapidly heated by electricity while being welded to the battery tabs and the non-lead metal positive and negative terminals. After a strong weld, the busbar is formed by cutting and sealed with glue. This solution improves the specific energy of lead-acid batteries, reduces material costs, increases production efficiency, reduces energy consumption, and reduces pollution. However, this patent document does not disclose the specific processing equipment structure. Furthermore, in actual production, directly heating the non-lead metal strips by electricity has several drawbacks. First, directly heating the non-lead metal strips results in high surface temperatures and high current, posing a significant safety hazard. Second, due to differences in internal resistance across the non-lead metal strip, the temperature varies, leading to uneven heating and potentially causing incomplete soldering of individual tabs, affecting the overall welding quality. Summary of the Invention

[0005] To address the aforementioned technical problems, the present invention aims to provide a welding device for battery tabs and non-lead metal strips, which offers high safety and better welding quality between the tabs and non-lead metal strips.

[0006] To achieve the above-mentioned objectives, the present invention adopts the following technical solution: A welding device for battery tabs and a non-lead metal strip includes a battery positioning mechanism and a non-lead metal strip heating mechanism. The non-lead metal strip is provided with brazing filler metal, and the melting point of the non-lead metal strip is higher than that of the tab. The non-lead metal strip heating mechanism includes a heating element assembly for heating the non-lead metal strip. The non-lead metal strip heating mechanism and the battery positioning mechanism are brought close together, so that the battery tabs are welded to the heated non-lead metal strip through the brazing filler metal on the non-lead metal strip.

[0007] The device of this invention uses a prefabricated non-lead metal strip to replace traditional liquid lead for welding to the electrode tab, and a low-melting-point brazing filler metal is placed on the non-lead metal strip. The brazing filler metal is close to the melting point of the electrode tab and lower than the melting point of the non-lead metal strip. By using the brazing filler metal as a medium, a reliable connection between the non-lead metal strip and the lead electrode tab is achieved at a temperature lower than the melting point of the non-lead metal strip. This avoids the environmental pollution caused by lead fumes and dust that would occur when using liquid lead of the same material as the electrode tab for welding, and also avoids the compatibility problem of direct welding of dissimilar metals.

[0008] The device of this invention enables the non-lead metal strip to be heated more evenly through the heating element assembly. The uniform heating of the non-lead metal strip allows the brazing filler metal on the non-lead metal strip to be completely melted and then fully contacted and fused with the electrode tabs. This ensures that each electrode tab can be firmly welded to the non-lead metal strip, avoids the occurrence of incomplete welds, and improves the welding quality.

[0009] As a preferred embodiment, the lead-free metal strip heating mechanism and / or battery positioning mechanism are brought together by a translational sliding mechanism, a flipping mechanism, or a lifting mechanism. These three structural methods enable more accurate positioning of the lead-free metal strip heating mechanism and battery positioning mechanism during welding, improving welding quality. In addition to the above three methods, the lead-free metal strip heating mechanism and battery positioning mechanism can also be gripped by robotic arms, and precise positioning welding can be achieved through the movement of the robotic arms.

[0010] As a preferred embodiment, the lead-free metal strip heating mechanism further includes a support frame, with both ends of the lead-free metal strip resting on either end of the support frame. The heating element assembly is mounted on the support frame and positioned below the lead-free metal strip, with its top surface in contact with the lead-free metal strip. This structure uses a support frame to support the lead-free metal strip, allowing for surface-contact heat transfer between the heating element assembly and the lead-free metal strip. This results in more uniform heating of the lead-free metal strip and prevents situations where the lead-free metal strip cannot be properly welded to the electrode tabs, or where the weld is weak, thus improving welding quality.

[0011] As a preferred embodiment, the non-lead metal strip heating mechanism further includes a support frame, with both ends of the non-lead metal strip resting on either end of the support frame. The heating element assembly is mounted on the support frame and positioned below the non-lead metal strip. The distance between the heating element assembly and the non-lead metal strip is adjusted by a lifting drive component, thereby heating the non-lead metal strip. In the above structure, the heating element assembly and the non-lead metal strip are connected through proximity or contact heat transfer, which allows for more uniform heating of the non-lead metal strip and prevents situations where the non-lead metal strip cannot be welded to the electrode tabs or the weld is weak, thus improving the welding quality.

[0012] As a preferred embodiment, the non-lead metal strip heating mechanism further includes a support frame, with the two ends of the non-lead metal strip resting on the two ends of the support frame, and the heating element assembly is a high-frequency induction heating assembly, which is arranged around the non-lead metal strip.

[0013] The device of the present invention utilizes a heating element assembly to heat a non-lead metal strip. The heating element assembly can be a heating method of heat conduction, heat convection, or heat radiation. Compared with the prior art heating method of directly energizing the non-lead metal strip, there is no need to consider the differences in internal resistance values ​​at various points on the non-lead metal strip, and the non-lead metal strip can achieve more uniform overall heating. Moreover, the above heating method does not generate current on the non-lead metal strip, thus improving overall safety.

[0014] As a preferred embodiment, the support frame has notches at both ends for placing non-lead metal strips, and the number of notches, the number of non-lead metal strips, and the number of rows of tabs in the battery are all the same; the positions of the notches, the positions of the non-lead metal strips, and the positions of the tabs in the battery also correspond. This structure positions the non-lead metal strips through the notches, and the positions are aligned with the tabs, which improves welding quality.

[0015] As a preferred embodiment, the support frame includes a first mounting plate and two side support plates, with the two side support plates respectively fixed to both ends of the first mounting plate. Each side support plate also has a notch at its upper end, and the end of the non-lead metal strip is located within the notch. This structure provides simultaneous and uniform support to both ends of the non-lead metal strip, preventing deformation due to heat. Furthermore, the side support plates can be replaced individually, reducing maintenance costs associated with wear and tear on the notches.

[0016] As a preferred embodiment, the heating element assembly includes a heating block, which is a metal block with heating elements inserted inside. The entire heating block is heated by energizing the heating elements.

[0017] As a preferred embodiment, the heating element assembly further includes an insulating shell that covers the heating block's sides and bottom, leaving only the top surface of the heating block in contact with the lead-free metal strip, thereby allowing the lead-free metal strip to be heated. This structure reduces heat loss during operation of the heating element assembly, lowers energy consumption, and avoids raising the temperature of other components in the device, thus preventing any impact on their lifespan and improving safety.

[0018] As a preferred embodiment, the width of the heating element assembly is z, the width of each non-lead metal strip is x, and the total spacing between multiple non-lead metal strips is y, where z ≥ x + y. This structure ensures that the heating element assembly can fully cover and heat the non-lead metal strips, resulting in a more uniform heat field and preventing insufficient temperature on the edge non-lead metal strips; furthermore, heating multiple non-lead metal strips at a time significantly improves efficiency.

[0019] As a preferred embodiment, the lifting drive assembly is fixed to the bottom of the support frame, and the lifting rod of the lifting drive assembly passes through the support frame and is connected to the heating element assembly, thereby driving the heating element assembly to lift and lower.

[0020] As a preferred embodiment, the system also includes an installation platform with through holes. When the battery tabs are welded to the lead-free metal strip, the lead-free metal strip heating mechanism and the battery positioning mechanism are located above and below the installation platform, respectively. The battery tabs are welded to the lead-free metal strip after passing through the through holes, or the lead-free metal strip is welded to the battery tabs after passing through the through holes, or the battery tabs are welded to the lead-free metal strip at the through holes. The installation platform ensures that the battery positioning mechanism and the lead-free metal strip heating mechanism are securely installed and in a more stable position, facilitating subsequent positioning and welding.

[0021] As a preferred embodiment, the non-lead metal strip heating mechanism further includes a lifting assembly. The lifting assembly is fixed to the lower part of the mounting platform via a mounting bracket. The support frame is slidably mounted on the mounting bracket and is driven to slide up and down by the lifting assembly. The lifting assembly moves the non-lead metal strip up and down, meeting the requirement for contact welding between the non-lead metal strip and the electrode tab.

[0022] As a preferred embodiment, the bottom of the support frame is fixed with a third mounting plate by a column, the lifting drive assembly is fixed to the bottom of the third mounting plate, and the lifting rod of the lifting drive assembly passes through the third mounting plate and the support frame and is connected to the heating element assembly to drive the heating element assembly to move up and down.

[0023] The lifting drive component moves the heating element up and down. After the non-lead metal strip and the tab melt, it can promptly detach from the non-lead metal strip and stop heating the non-lead metal strip, thus meeting the need for rapid cooling after the non-lead metal strip and the tab melt and improving efficiency.

[0024] As a preferred embodiment, the non-lead metal strip heating mechanism further includes a lifting assembly, which is fixed to the lower part of the mounting platform by a mounting bracket. The third mounting plate is slidably mounted on the mounting bracket and is driven to slide up and down by the lifting assembly.

[0025] As a preferred embodiment, guide posts are fixed at both ends of the bottom of the heating element assembly, and guide sleeves are fixed on the support frame. The heating element assembly is slidably connected to the support frame through the cooperation of the guide posts and guide sleeves.

[0026] The guide post structure at both ends of the heating element assembly ensures that the heating element assembly moves up and down in a horizontal state, preventing the non-lead metal strip from being unable to contact the heating element assembly due to horizontal tilt, which would lead to uneven heating of the non-lead metal strip and affect the subsequent welding quality.

[0027] As a preferred embodiment, the battery positioning mechanism is slidably mounted on the mounting platform and is driven by an electric cylinder, hydraulic cylinder, air cylinder, or gear and rack structure.

[0028] As a preferred embodiment, the battery positioning mechanism is provided with positioning holes that allow the battery to be inverted and expose the tabs, and the battery positioning mechanism also has a clamping mechanism for clamping and fixing the battery. The clamping mechanism ensures that the battery remains in a fixed position during processes such as moving and welding, ensuring accurate positioning and improving welding quality.

[0029] As a preferred embodiment, the battery positioning mechanism includes a sliding plate with positioning holes. A support strip is provided at the bottom of the positioning holes. The two sides of the battery casing rest on the support strip, and the battery tabs protrude from the positioning holes.

[0030] As a preferred embodiment, the lower end face of the skateboard is also fixed with a bottom support plate, and the bottom support plate is also provided with positioning holes. The width of the positioning holes on the bottom support plate is slightly smaller than the width of the positioning holes on the skateboard, so that the bottom support plate forms a support strip in the width direction of the positioning holes on the skateboard.

[0031] As a preferred embodiment, the clamping mechanism includes clamping strips slidably mounted on a sliding plate and located on either side or at both ends of the battery. A clamping strip driving assembly is also fixed to the sliding plate, which drives the clamping strips to clamp and secure the battery. Clamping strips are provided on both sides of the battery. Driven by the clamping strip driving assembly, the clamping strips simultaneously move towards and clamp the battery, keeping it centered. The large contact area between the clamping strips and the battery ensures that the clamping mechanism can firmly secure the battery.

[0032] As a preferred embodiment, the positioning hole is larger at the top and smaller at the bottom, with beveled sides, and its length is greater than the length of the battery. The shape of the positioning hole guides the placement of the battery, facilitating quick positioning; the greater length of the positioning hole ensures that the lead-free metal strip and its heating mechanism will not interfere with the positioning hole during welding of the tabs to the lead-free metal strip; after welding, the battery can also be removed more easily and quickly.

[0033] This invention proposes a novel dynamic contact welding device. By controlling the positions of the lead-free metal strip heating mechanism and the battery positioning mechanism, the lead-free metal strip is brought into contact with the battery tabs for welding after heating. The use of lead-free metal strips replaces the lead strips formed by molds and molten lead in the traditional process, making it more environmentally friendly and reducing energy consumption. At the same time, the use of a heating element assembly to heat the pre-fabricated lead-free metal strip avoids the safety hazards caused by directly heating the lead-free metal strip and the welding quality problems caused by uneven heating of the lead-free metal strip. Attached Figure Description

[0034] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments of this application and their descriptions are used to explain this application and do not constitute a limitation thereof.

[0035] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 and Figure 3 These are schematic diagrams of the non-lead metal strip heating mechanism of the present invention from two different angles; Figure 4 This is a schematic diagram of the structure of the first mounting plate, side support plate, heating element assembly, and lead-free metal strip of the present invention. Figure 5 This is an exploded structural diagram of the first mounting plate, side support plate, heating element assembly, and non-lead metal strip of the present invention. Figure 6 This is a schematic diagram of the overall structure of the battery positioning mechanism of the present invention; Figure 7 This is an exploded structural diagram of the battery positioning mechanism of the present invention; Figure 8 This is a structural schematic diagram of the components of the present invention: the sliding plate, the clamping bar, the slider B, the guide rail B, and the cylinder B.

[0036] The attached figures are labeled as follows: 1. Non-lead metal strip heating mechanism; 10. Non-lead metal strip; 11. First mounting plate; 12. Side support plate; 121. Notch; 122. Through hole; 13. Heating body assembly; 131. Insulation shell; 132. Heating block; 133. Power cord; 141. Second mounting plate; 142. Connecting post; 15. Third mounting plate; 151. Guide sleeve; 152. Guide post; 16. Cylinder A; 17. 18. Servo motor; 19. Connecting plate; 20. Lifting rod; 21. Battery positioning mechanism; 22. Slide plate; 23. Positioning hole; 24. Support bar; 25. Upper cover; 26. Bottom support plate; 27. Clamping bar; 28. Cylinder B; 29. ​​Slider B; 20. Guide rail B; 21. Limit block assembly; 22. Mounting platform; 33. Battery; 44. Electrode; 5. Translation screw; 6. Guide rail A; 7. Slider A; 8. Connecting block. Detailed Implementation

[0037] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0038] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0039] Furthermore, in the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0040] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more, unless explicitly defined otherwise.

[0041] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0042] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0043] The present invention will be further described below with reference to the accompanying drawings and embodiments: A welding device for battery tabs and non-lead metal strips includes a battery positioning support mechanism A and a non-lead metal strip positioning support mechanism B. The positioning support mechanism B is further equipped with a heating element assembly. After the heating element assembly heats the non-lead metal strip, the battery tabs are brought together by bringing the positioning support mechanisms A and B close, causing them to contact, melt, and cool before being welded together. In this embodiment, the battery refers to a battery in which the electrode assembly is installed in a groove in the battery casing, and the electrode tabs of the electrode assembly are shaped and flattened. In this embodiment, the non-lead metal strip is made of one of copper, aluminum, iron, silver, calcium, beryllium, magnesium, zinc, nickel, or tin, or an alloy thereof. The solder on the surface of the non-lead metal strip is tin or silver, attached to the surface of the non-lead metal strip by electroplating or other methods. In particular, using a non-lead metal strip with a higher conductivity than lead allows for a thinner and lighter battery busbar, reducing the material cost of lead-acid batteries.

[0044] The positioning support mechanism A and positioning support mechanism B can be brought closer together by one or more of the following methods: translation and sliding, flipping, lifting and lowering, or gripping and bringing together by a robotic arm. In this embodiment, the positioning support mechanism A of the battery is moved to the positioning support mechanism B of the non-lead metal strip, so that the battery tabs are aligned with the non-lead metal strip. Then, the heated non-lead metal strip is raised to make the battery tabs contact and melt with the heated non-lead metal strip. After both are cooled, the positioning support mechanism B is lowered to complete the welding.

[0045] The specific structure of the welding device for the battery tabs and the non-lead metal strip in this embodiment is as follows: Figure 1 As shown, the device includes a non-lead metal strip heating mechanism 1, a battery positioning mechanism 2, and an installation platform 3. Two parallel guide rails A6 are fixed on the installation platform 3. The bottom sides of the battery positioning mechanism 2 are slidably connected to the two guide rails A6 via sliders A7. The battery positioning mechanism 2 is driven by various methods such as electric cylinders, hydraulic cylinders, air cylinders, or gear racks. The battery positioning mechanism 2 is provided with positioning holes 201 that allow the battery 4 to be inverted and expose the tabs 41. The non-lead metal strip heating mechanism 1 is fixed to the bottom of the installation platform 3, and the installation platform 3 has through holes. After the battery positioning mechanism 2 slides the battery 4 into place, the non-lead metal strip heating mechanism 1 can lift the heated non-lead metal strip 10, pass through the through holes, and contact the tabs 41 of the battery 4.

[0046] like Figures 2 to 5 As shown, the non-lead metal strip heating mechanism 1 includes a support frame and a heating element assembly 13. The support frame includes a first mounting plate 11 and two side support plates 12. The two side support plates 12 are respectively fixed to both ends of the first mounting plate 11. Each side support plate 12 also has a notch 121 at its upper end. The end of the non-lead metal strip 10 is located in the notch 121. The two side support plates 12 support the end of the non-lead metal strip 10, making the non-lead metal strip 10 suspended. The heating element assembly 13 is located between the two side support plates 12 and includes a heat insulation shell 131 and a heating block 132. The heating block 132 is a metal block with a heating rod inserted inside. By energizing the heating rod, the entire heating block 132 is heated. The heat insulation shell 131 covers the sides and bottom of the heating block 132, leaving only the top surface of the heating block 132 in contact with the suspended part of the non-lead metal strip, thereby heating the non-lead metal strip.

[0047] The side support plate 12 also has a through hole 122, through which the power line 133 of the heating rod in the heating block 132 passes and is connected to the power source.

[0048] The number of notches 121 on the upper end of the side support plate 12 is the same as the number of rows of tabs in the battery. In this embodiment, two notches 121 are spaced apart on the upper end of the side support plate 12, and the distance between the two notches 121 is the same as the distance between the two rows of tabs on the battery. The two non-lead metal strips are heated by the same heating element assembly 13. The non-lead metal strips are flat and long, with a smooth surface, and their width is greater than or equal to the cross-sectional width of the tabs, and their thickness is 1mm to 3mm. The length of the heating block 132 is less than or equal to the distance between the two side support plates 12; the width of the heating block 132 is z, the width of each non-lead metal strip 10 is x, the number of non-lead metal strips is n, the distance between two adjacent non-lead metal strips is y, and z ≥ nx + (n-1)y.

[0049] In this example, the heating element assembly 13 uses contact heat conduction to heat the non-lead metal strip. In other embodiments, the heating element assembly 13 can also use non-contact methods such as high-frequency heating to heat the non-lead metal strip, with the high-frequency induction heating component positioned around the non-lead metal strip 10. In other embodiments, the side support plate 12 can be omitted, and the busbar 10 can be supported by directly creating a positioning groove on the upper surface of the heating element assembly 13.

[0050] The non-lead metal strip heating mechanism 1 also includes a lifting drive component A, which is fixed to the lower part of the mounting platform 3 by a mounting bracket. The first mounting plate is slidably mounted on the mounting bracket and the support frame is driven to slide up and down by the lifting drive component A.

[0051] The mounting bracket includes a second mounting plate 141 and a connecting column 142. The lifting drive assembly A is a servo motor 17. The second mounting plate 141 is fixed to the bottom of the mounting platform 3 via the connecting column 142. The second mounting plate 141 is rectangular in shape. To ensure the stability of the second mounting plate 141, it is preferable to fix one end of the connecting column 142 at each of the four corners of the second mounting plate 141, and the other end of the connecting column 142 is fixed to the bottom of the mounting platform 3. The servo motor 17 is fixed to the bottom of the second mounting plate 141. A nut is fixed on the first mounting plate 11. The output shaft of the servo motor 17 is connected to a lead screw via a coupling. The lead screw is threadedly connected to the nut and passes through the first mounting plate. The servo motor 17 drives the lead screw to rotate forward or backward, thereby driving the first mounting plate 11 to rise or fall.

[0052] The structure of the servo motor 17 driving the lead screw and nut in the above structure can also adopt a structure of direct drive by the motor and gear rack or electric cylinder. The above lifting drive component A is used to lift the first mounting plate 11 so that the heated non-lead metal strip 10 located at the top of the first mounting plate 11 comes into contact with the electrode tab 41 for melting and welding. After the welding is completed, the first mounting plate 11 is lowered so that the non-lead metal strip 10 on the first mounting plate 11 remains on the electrode tab 41, thus completing the welding.

[0053] The non-lead metal strip heating mechanism 1 also includes a lifting drive component B, which is fixed to the bottom of the first mounting plate 11. The lifting rod 19 of the lifting drive component B passes through the first mounting plate 11 and is connected to the heating body component 13, thereby driving the heating body component 13 to move up and down. In this embodiment, the lifting drive component B adopts a cylinder A16. In other embodiments, a hydraulic cylinder or an electric cylinder may also be used.

[0054] The lifting drive assembly B is used to lift the heating body assembly 13, so that the top surface of the heating block 132 contacts the suspended part of the non-lead metal strip 10, thereby heating the non-lead metal strip 10. Then, as the first mounting plate 11 rises, the heated non-lead metal strip 10 contacts the tab 41 and performs fusion welding. During the welding process, the first mounting plate 11 is kept in a slow rising state to avoid insufficient welding such as tab wire pulling caused by the melting of the tab. After the welding is completed, the lifting drive assembly B lowers the heating body assembly 13, so that the non-lead metal strip 10 is separated from the heating body assembly 13. The non-lead metal strip 10 and the tab 41 cool and solidify together. Then, the lifting drive assembly A drives the first mounting plate 11 to descend, leaving the non-lead metal strip 10 on the tab 41, completing the welding.

[0055] With the heating element assembly 13 of the present invention adopting a lifting structure, compared with placing the non-lead metal strip 10 directly on the heating element assembly 13, it can avoid the heating element assembly 13 contacting the non-lead metal strip 10 for a long time, causing the non-lead metal strip 10 to maintain a high temperature. When the high-temperature non-lead metal strip 10 contacts the tab 41, it is easy to over-melt and damage the tab 41.

[0056] On the other hand, the heating element assembly 13 and the non-lead metal strip 10 cannot be separated, which makes it difficult for the non-lead metal strip 10 and the tab 41 to cool and solidify. When the non-lead metal strip 10 and the tab 41 cool and solidify, the heating element assembly 13 needs to be powered off and cooled naturally, or an external cooling device needs to be used to force the heating element assembly 13 and the non-lead metal strip 10 to cool together. The whole process takes a long time and affects production efficiency. In addition, the frequent start-up and shutdown of the heating element assembly 13 not only increases energy consumption, but also shortens the service life of the heating element assembly 13.

[0057] To ensure sufficient installation and movement space for the aforementioned lifting drive assembly A and lifting drive assembly B, a third mounting plate 15 is provided between the first mounting plate 11 and the second mounting plate 141. The first mounting plate 11 and the third mounting plate 15 are fixedly connected by a column. The cylinder A16 is fixed on the third mounting plate 15, and the piston rod of the cylinder 16 passes through the first mounting plate 11 and the third mounting plate 15 and is fixed to the heating element assembly 13. Guide columns 152 are fixed at both ends of the bottom of the heating element assembly 13. A guide sleeve 151 is fixed on the first mounting plate 11. The heating element assembly 13 is slidably connected to the first mounting plate 11 through the cooperation of the guide columns 152 and the guide sleeve 151, and is driven to lift by the cylinder A16. The space formed between the first mounting plate 11 and the third mounting plate 15 also provides corresponding lifting space for the guide columns 152 on the heating element assembly 13.

[0058] The guide post structure at both ends of the heating element assembly 13 can ensure that the heating element assembly 13 is raised and lowered in a horizontal state, preventing the non-lead metal strip 10 from being unable to contact the heating element assembly 13 locally due to the horizontal tilt of the heating element assembly 13, which would lead to uneven heating of the non-lead metal strip 10 and affect the subsequent welding quality.

[0059] The third mounting plate 15 is also fixed with guide posts 152, and the second mounting plate 141 is fixed with guide sleeves 151. The third mounting plate 15 is slidably connected to the second mounting plate 141 through the cooperation of guide posts 152 and guide sleeves 151. There are four guide posts 152, which are located at the four corners of the third mounting plate, and the lower ends of the four guide posts 152 are fixedly connected into a whole through connecting plates 18.

[0060] The second mounting plate 141 is also provided with a clearance hole to prevent the end of the cylinder A16 from getting dry with the second mounting plate 141; the nut can also be fixed on the third mounting plate 15 and threadedly connected to the lead screw.

[0061] To balance production efficiency and equipment cost, four sets of heating element assemblies 13 are provided on the first mounting plate 11 in this embodiment. The four sets of heating element assemblies 13 are arranged sequentially at intervals along the width direction of the heating element assembly 13. Each heating element assembly 13 has a side support plate 12 at both ends. Each set of side support plates 12 supports two non-lead metal strips 10. A total of eight non-lead metal strips 10 are arranged on the entire first mounting plate 11. Each heating element assembly 13 is driven by a separate cylinder A16. The entire first mounting plate 11 or the third mounting plate 15 is driven to rise and fall by a lifting drive assembly A.

[0062] After placing the lead-free metal strip in the recess on the support frame, the heating element assembly is energized and heated. The heating element assembly is then raised to press against the lead-free metal strip. The lead-free metal strip is heated evenly through solid heat transfer. At the same time, the entire support frame rises, bringing the heated lead-free metal strip into contact with the electrode tab. The brazing filler layer on the outer surface of the lead-free metal strip and a small section at the bottom of the electrode tab fuse together. After welding is completed, the heating element assembly is lowered and removed, maintaining the welded state between the lead-free metal strip and the electrode tab. After cooling, the support frame is lowered to complete the welding.

[0063] like Figures 6 to 8 As shown, the battery positioning mechanism 2 includes a slide plate 20, on which one or more positioning holes 201 are provided. In order to match the number of non-lead metal strips 10 in the non-lead metal strip heating mechanism 1, the number of positioning holes 201 in this embodiment is four. The four positioning holes 201 are arranged sequentially at intervals along the width direction of the positioning holes 201. A battery 4 is inverted in each positioning hole 201. Each battery 4 is provided with two rows of tabs 41. A bottom support plate 22 is also fixed to the lower end face of the slide plate 20. The bottom support plate 22 is also provided with positioning holes 201. The width of the positioning holes 201 on the bottom support plate 22 is slightly smaller than the width of the positioning holes 201 on the slide plate 20, so that the bottom support plate 22 has support strips 202 on both sides of the width direction of the positioning holes 201 of the slide plate 20. After the inverted battery 4 is placed in the positioning hole 201, the two sides of the battery 4's shell rest on the support strips 202, and the tabs 41 of the battery 4 protrude from the positioning hole 201.

[0064] Each of the four positioning holes 201 has a clamping strip 23 at both ends along its length. A slider B25 is fixed to the bottom of the clamping strip 23. A guide rail B26 is fixed on the slide plate 20. The clamping strip 23 is slidably mounted on the slide plate 20 through the cooperation of the slider B25 and the guide rail B26. The clamping strip 23 moves along the length of the positioning hole 201. A cylinder B24 is also fixed on the slide plate 20. When the battery 4 is placed into the positioning hole 201, the cylinder B24 on the slide plate 20 drives the two clamping strips 23 to clamp and fix the two ends of the battery 4 along its length. This prevents the battery 4 from sliding along the positioning hole when the slide plate 20 moves the battery 4, thus preventing it from aligning with the non-lead metal strip 10 and affecting the welding process. It also prevents the battery 4 from shaking when the non-lead metal strip 10 contacts the tab 41, thus affecting the welding quality.

[0065] To ensure the stability of the movement of the clamping bar 23, sliders B25 are fixed at both ends and the middle of the clamping bar 23. Guide rails B26 are fixed on the slide plate 20 at positions corresponding to the sliders B25. At the same time, a cylinder B24 is fixed at the middle position of the two guide rails B26. Each clamping bar 23 is guided by three guide rails B26 and driven by two cylinders B24 at the same time, ensuring that the clamping bar 23 can firmly and stably clamp each battery 4, thereby ensuring the welding quality.

[0066] The positioning hole 201 is larger at the top and smaller at the bottom, with beveled sides, which guides the placement of the battery. The length of the positioning hole 201 is greater than the length of the battery 4, so that the battery can be easily removed after the tab 41 is welded to the lead-free metal strip, avoiding interference between the lead-free metal strip 10 and the positioning hole 201. Therefore, the clamping strips 23 on both sides also serve to keep the battery 4 in a centered position.

[0067] The upper cover 21 is also fixed on the slide plate 20. The upper cover 21 is also provided with corresponding positioning holes 201. The upper cover 21 covers the clamping bar 23, cylinder B24 and guide rail B26 and other components, protecting the corresponding parts and extending the service life of the mechanism.

[0068] The mounting platform 3 is equipped with a translation screw 5, which has a nut block. A connecting block 8 is fixed to one side of the slide plate 20, and the connecting block 8 is fixed to the nut block. A translation motor is also fixed on the mounting platform 3. The translation motor drives the translation screw 5 to rotate, thereby driving the slide plate 20 to translate. Limit block assemblies 28 are fixed at both ends of the slide plate 20 in the direction of movement. Limit switches that cooperate with the limit blocks 28 are fixed on the mounting platform 3. When the limit block assembly 28 touches the limit switch, the translation motor stops working, so that the slide plate 20 remains in the current position, waiting for the next instruction.

[0069] This invention proposes a novel dynamic contact fusion welding device, which adopts a modular split structure. The non-lead metal strip heating mechanism and the battery positioning mechanism are placed on the upper and lower parts of the mounting platform, respectively. The distance between the two is dynamically adjusted by the translation / flipping / lifting mechanism, realizing an integrated process of "heating-contact-welding". The device of this invention solves the problems of large size, high energy consumption, poor welding quality and low production efficiency of traditional processing equipment while ensuring welding quality.

[0070] Meanwhile, the method of heating prefabricated non-lead metal strips with a heating element assembly for welding to the electrode tabs avoids the safety hazards caused by directly heating the non-lead metal strips and the welding quality problems caused by uneven heating of the non-lead metal strips. Compared with the traditional method of welding electrode tabs with molds and molten lead, this method achieves clean production and avoids the environmental pollution caused by lead fumes, lead dust, and lead slag generated during the traditional production process.

[0071] In the description of this specification, references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0072] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention without departing from the principles and spirit of the present invention. Any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A welding device for battery tabs and non-lead metal strips, characterized in that, The battery includes a battery positioning mechanism (2) and a non-lead metal strip heating mechanism (1). The non-lead metal strip (10) is provided with brazing filler metal, and the melting point of the non-lead metal strip (10) is higher than the melting point of the tab (41). The non-lead metal strip heating mechanism (1) includes a heating element assembly (13) for heating the non-lead metal strip (10). The non-lead metal strip heating mechanism (1) and the battery positioning mechanism (2) are close to each other, and the tab (41) of the battery (4) is welded to the heated non-lead metal strip (10) by the brazing filler metal on the non-lead metal strip (10). The non-lead metal strip heating mechanism (1) also includes a support frame. The two ends of the non-lead metal strip (10) are respectively placed on the two ends of the support frame. The heating element assembly (13) is set on the support frame and located below the non-lead metal strip (10). The heating element assembly (13) adjusts the distance between itself and the non-lead metal strip (10) by a lifting drive assembly, thereby heating the non-lead metal strip (10).

2. The welding device for battery tabs and non-lead metal strips according to claim 1, characterized in that, The lifting drive assembly is fixed at the bottom of the support frame. The lifting rod (19) of the lifting drive assembly passes through the support frame and is connected to the heating body assembly (13), thereby driving the heating body assembly (13) to lift.

3. The welding device for battery tabs and non-lead metal strips according to claim 1, characterized in that, Guide posts (152) are fixed at both ends of the bottom of the heating element assembly (13), and guide sleeves (151) are fixed on the support frame. The heating element assembly (13) is slidably connected to the support frame through the cooperation of the guide posts (152) and the guide sleeves (151).

4. The welding device for battery tabs and non-lead metal strips according to claim 1, characterized in that, It also includes an installation platform (3), which is provided with a through hole. When the tab (41) of the battery (4) is welded to the non-lead metal strip (10), the non-lead metal strip heating mechanism (1) and the battery positioning mechanism (2) are located above and below the installation platform (3), respectively. After the battery (4) passes through the through hole, its tab (41) is welded to the non-lead metal strip (10), or the non-lead metal strip (10) passes through the through hole and is welded to the tab (41) of the battery (4), or the tab (41) of the battery (4) is welded to the non-lead metal strip (10) at the through hole.

5. The welding device for battery tabs and non-lead metal strips according to claim 4, characterized in that, The battery positioning mechanism (2) is slidably mounted on the mounting platform (3) and is driven by an electric cylinder, hydraulic cylinder, pneumatic cylinder, or gear rack structure.

6. The welding device for battery tabs and non-lead metal strips according to claim 4, characterized in that, The non-lead metal strip heating mechanism (1) also includes a lifting component, which is fixed to the lower part of the mounting platform (3) by a mounting bracket. The support frame is slidably mounted on the mounting bracket and is driven to slide up and down by the lifting component.

7. The welding device for battery tabs and non-lead metal strips according to claim 4, characterized in that, The bottom of the support frame is fixed with a third mounting plate (15) by a column. The lifting drive assembly is fixed at the bottom of the third mounting plate (15). The lifting rod (19) of the lifting drive assembly passes through the third mounting plate (15) and the support frame and is connected to the heating body assembly (13) to drive the heating body assembly (13) to lift.

8. The welding device for battery tabs and non-lead metal strips according to claim 7, characterized in that, The non-lead metal strip heating mechanism (1) also includes a lifting assembly. The lifting assembly is fixed to the lower part of the mounting platform (3) by a mounting bracket. The third mounting plate (15) is slidably mounted on the mounting bracket and is driven to slide up and down by the lifting assembly.

9. A welding device for battery tabs and non-lead metal strips, characterized in that, The battery includes a battery positioning mechanism (2) and a non-lead metal strip heating mechanism (1). The non-lead metal strip (10) is provided with brazing filler metal, and the melting point of the non-lead metal strip (10) is higher than the melting point of the tab (41). The non-lead metal strip heating mechanism (1) includes a heating element assembly (13) for heating the non-lead metal strip (10). The non-lead metal strip heating mechanism (1) and the battery positioning mechanism (2) are close to each other, and the tab (41) of the battery (4) is welded to the heated non-lead metal strip (10) by the brazing filler metal on the non-lead metal strip (10). The non-lead metal strip heating mechanism (1) also includes a support frame. The two ends of the non-lead metal strip (10) are respectively placed on the two ends of the support frame. The heating element assembly (13) is set on the support frame and located below the non-lead metal strip (10). The top surface of the heating element assembly (13) is in contact with the non-lead metal strip (10).

10. A welding device for battery tabs and non-lead metal strips according to claim 1 or 9, characterized in that, The heating element assembly (13) includes a heating block (132), which is a metal block with heating elements inserted inside. The entire heating block (132) heats up by energizing the heating elements.

11. The welding device for battery tabs and non-lead metal strips according to claim 10, characterized in that, The heating element assembly (13) also includes a heat insulation shell (131), which covers the heating block (132) around its perimeter and bottom, leaving only the top surface of the heating block (132) in contact with the non-lead metal strip (10), thereby allowing the non-lead metal strip (10) to be heated.

12. A welding device for battery tabs and non-lead metal strips according to claim 1 or 9, characterized in that, The width of the heating element assembly (13) is z, the width of each non-lead metal strip (10) is x, the number of non-lead metal strips (10) is n, the distance between two adjacent non-lead metal strips (10) is y, and z≥nx+(n-1)y.

13. A welding device for battery tabs and non-lead metal strips, characterized in that, The battery includes a battery positioning mechanism (2) and a non-lead metal strip heating mechanism (1). The non-lead metal strip (10) is provided with brazing filler metal, and the melting point of the non-lead metal strip (10) is higher than the melting point of the tab (41). The non-lead metal strip heating mechanism (1) includes a heating element assembly (13) for heating the non-lead metal strip (10). The non-lead metal strip heating mechanism (1) and the battery positioning mechanism (2) are close to each other, and the tab (41) of the battery (4) is welded to the heated non-lead metal strip (10) by the brazing filler metal on the non-lead metal strip (10). The non-lead metal strip heating mechanism (1) also includes a support frame. The two ends of the non-lead metal strip (10) are respectively placed on the two ends of the support frame. The heating element assembly (13) is a high-frequency induction heating assembly and is arranged around the non-lead metal strip (10).

14. A welding device for a battery tab and a non-lead metal strip according to claim 1, 9, or 13, characterized in that, The non-lead metal strip heating mechanism (1) and / or battery positioning mechanism (2) are brought together by a translation sliding mechanism, a flipping mechanism, or a lifting mechanism.

15. A welding device for battery tabs and non-lead metal strips according to claim 1, 9, or 13, characterized in that, The support frame has notches (121) at both ends for placing non-lead metal strips (10), and the number of notches (121), the number of non-lead metal strips (10), and the number of rows of tabs (41) in the battery (4) are the same; the positions of the notches (121), the positions of the non-lead metal strips (10), and the positions of the tabs (41) in the battery (4) also correspond.

16. A welding device for battery tabs and non-lead metal strips according to claim 1, 9, or 13, characterized in that, The support frame includes a first mounting plate (11) and a side support plate (12). The two side support plates (12) are fixed at both ends of the first mounting plate (11). Each side support plate (12) is also provided with a notch (121) at its upper end. The end of the non-lead metal strip (10) is located in the notch (121).

17. A welding device for a battery tab and a non-lead metal strip according to claim 1, 9, or 13, characterized in that, The battery positioning mechanism (2) is provided with a positioning hole (201) that allows the battery (4) to be inverted and exposes the tab (41), and the battery positioning mechanism (2) also includes a clamping mechanism for clamping and fixing the battery (4).

18. The welding device for battery tabs and non-lead metal strips according to claim 17, characterized in that, The battery positioning mechanism (2) includes a slide plate (20), on which a positioning hole (201) is provided. A support strip (202) is provided at the bottom of the positioning hole (201). The two sides of the battery (4) housing are placed on the support strip (202), and the tabs (41) of the battery (4) protrude from the positioning hole (201).

19. The welding device for battery tabs and non-lead metal strips according to claim 18, characterized in that, The lower end face of the slide plate (20) is also fixed with a bottom support plate (22). The bottom support plate (22) is also provided with a positioning hole (201). The width of the positioning hole (201) on the bottom support plate (22) is slightly smaller than the width of the positioning hole (201) on the slide plate (20), so that the bottom support plate (22) forms a support strip (202) in the width direction of the positioning hole (201) of the slide plate (20).

20. A welding device for a battery tab and a non-lead metal strip according to claim 18 or 19, characterized in that, The clamping mechanism includes a clamping bar (23), which is slidably disposed on the slide plate (20) and located on both sides of the battery (4). The battery positioning mechanism (2) includes a slide plate (20), and a clamping bar driving assembly is also fixed on the slide plate (20). The clamping bar driving assembly drives the clamping bar (23) to clamp and fix the battery (4).

21. A welding device for a battery tab and a non-lead metal strip according to claim 17, 18, or 19, characterized in that, The positioning hole (201) is larger at the top and smaller at the bottom, with sloping sides. The length of the positioning hole (201) is greater than the length of the battery (4).

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