Tal guide alignment apparatus and method for aligning tal guide by using the same

Abstract

According to an exemplary embodiment, a tab guide alignment apparatus is provided. The apparatus comprises: a first track; and an alignment block coupled to the rail, where the alignment block includes a second rail configured to move in the first direction relative to the first rail and a tab guide contact unit coupled to the second rail. Therefore, provided are: a tab guide alignment device for improving the accuracy of a tab guide adjustment process depending on the skill level of an operator; and a method of aligning a tab guide by using the tab guide alignment apparatus. In addition, the reliability of the pre-welding process can be improved.

Description

TECHNICAL FIELD

[0001] The technical idea of the present disclosure relates to a tab guide alignment apparatus and a method of aligning a tab guide using the same. This application claims the benefit of Korean Patent Application No. 10-2024-0001963, filed on January 5, 2024, the disclosure of which is incorporated herein by reference. BACKGROUND

[0002] Unlike primary batteries, secondary batteries can undergo multiple charge and discharge. Secondary batteries are widely used as energy sources for various wireless devices including mobile phones, notebook computers, and cordless vacuum cleaners. Recently, as the manufacturing cost of electric hybrid vehicles (HEVs) and battery electric vehicles (BEVs) has sharply decreased due to improvements in energy density and economies of scale, and as the mileage of BEVs has increased to match that of fuel vehicles, the main use of secondary batteries has shifted from mobile devices to mobility.

[0003] A battery cell is the most basic unit of a secondary battery, and improving the mechanical and electrical properties of the battery cell is the most effective and critical factor in improving the performance of the secondary battery. SUMMARY

[0004] TECHNICAL PROBLEM

[0005] The problem solved by the technical idea of the present disclosure is to provide a tab guide alignment apparatus having improved reliability and a method of aligning a tab guide using the same.

[0006] TECHNICAL SOLUTION

[0007] According to an exemplary embodiment of the technical idea of the present disclosure for solving the above problem, a tab guide alignment apparatus is provided. The apparatus includes a first rail, and an alignment block coupled to the rail, wherein the alignment block includes a second rail configured to move in a first direction with respect to the first rail, and a tab guide contact coupled to the second rail.

[0008] The tab guide contact is configured to align a tab guide of an ultrasonic welding device.

[0009] The alignment block further includes a reference contact coupled to the second rail.

[0010] The tab guide contact protrudes in the first direction with respect to the reference contact.

[0011] The alignment block further includes a position adjuster interposed between and coupled to each of the second rail and the reference contact.

[0012] The position adjuster is configured to move the alignment contact in the second direction.

[0013] The apparatus further comprises a vernier caliper coupled to the alignment contact.

[0014] The vernier caliper indicates the position of the alignment contact.

[0015] According to an exemplary embodiment, a tab guide alignment method is provided. The method comprises the steps of: aligning a first tab guide; moving a tab guide contact; and aligning a second tab guide, wherein the step of aligning the first tab guide comprises the step of adjusting a position of the first tab guide in a first direction such that the first tab guide contacts a tab guide contact of an alignment block of a tab guide alignment apparatus.

[0016] The tab guide alignment apparatus further comprises a first rail to which the alignment block is coupled, the alignment block comprising a second rail configured to move relative to the first rail in the first direction, wherein the tab guide contact is coupled to the second rail.

[0017] The alignment block further comprises an alignment contact coupled to the second rail, and the tab guide contact further projects relative to the alignment block in the first direction.

[0018] The method further comprises the step of aligning the alignment block by contacting the alignment contact with a reference block.

[0019] The alignment contact is aligned prior to aligning the first tab guide.

[0020] The step of moving the tab guide contact comprises the step of moving the tab guide contact in a second direction perpendicular to the first direction.

[0021] The step of aligning the second tab guide comprises the step of adjusting a position of the second tab guide in the first direction such that the second tab guide contacts the tab guide contact.

[0022] Advantageous effects

[0023] According to the exemplary embodiment of the present invention, a tab guide alignment apparatus and a method of aligning a tab guide using the apparatus can be provided to improve the accuracy of a tab guide adjustment process that relies on the skill of an operator. Therefore, the reliability of a pre-welding process can be improved.

[0024] Effects obtainable from the exemplary embodiments of the present disclosure are not limited to the above-mentioned effects, and other effects not mentioned above will be clearly understood and appreciated from the following description by those skilled in the art. That is, the unexpected effects of the exemplary embodiments of the present disclosure can also be derived from the exemplary embodiments of the present disclosure by those skilled in the art. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 FIG. 1 is a perspective view showing a secondary battery manufacturing apparatus according to an exemplary embodiment.

[0026] Figure 2 FIG. 2 is a perspective view showing a tab guide alignment apparatus according to another exemplary embodiment.

[0027] Figure 3 FIG. 3 is a perspective view showing an alignment block of the tab guide alignment apparatus.

[0028] Figure 4 FIG. 4 is a flowchart showing a method for aligning a tab guide according to an exemplary embodiment.

[0029] Figure 5 FIG. 5 is a perspective view showing a method for aligning a tab guide according to an exemplary embodiment. DETAILED DESCRIPTION

[0030] Hereinafter, preferred embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. It should be noted that the terms and words used in the present specification and claims should not be interpreted as having ordinary meanings or dictionary meanings, but should be interpreted as having concepts that are based on the technical idea of the present disclosure, in accordance with a principle that the inventor can define the terms as he or she chooses, in order to best describe the disclosure.

[0031] Accordingly, it should be understood that the embodiments described herein and illustrated in the drawings are merely the most preferred embodiments of the present disclosure, and that various equivalents and modifications can be made thereto without departing from the technical idea of the present disclosure.

[0032] Further, in describing the present disclosure, detailed descriptions of configurations or features known to the related art or the like can be omitted when it is determined that the configurations or features would obscure the nature of the present disclosure.

[0033] Because the embodiments of the present disclosure are provided to more fully explain the present disclosure to those skilled in the art, the shapes and sizes of the components in the drawings can be exaggerated, omitted, or schematically shown for the sake of clarity. Thus, the size or ratio of each component does not necessarily indicate its actual size or ratio.

[0034] (FIRST EMBODIMENT: APPARATUS)

[0035] Figure 1 FIG. 1 is a diagram illustrating a secondary battery manufacturing apparatus 100 according to an exemplary embodiment.

[0036] According to an exemplary embodiment, the secondary battery manufacturing apparatus 100 can be configured to weld electrode tabs ET of an electrode assembly EA. According to an exemplary embodiment, the secondary battery manufacturing apparatus 100 can weld the electrode tabs ET using ultrasonic waves. The welding of the electrode tabs ET is one of the key processes that determine the performance of the electrode assembly EA, as an incomplete welding of the electrode tabs ET can result in a reduced capacity of a battery cell including the electrode assembly EA.

[0037] The secondary battery manufacturing apparatus 100 can include a fixing module 110, first and second tab guides 121 and 123, and a processing module 130. The fixing module 110 can include a support plate 111 and a pressing device 113. The processing module 130 can include a welding head 133 and an anvil 131.

[0038] The electrode assembly EA can include a plurality of electrodes. Each of the plurality of electrodes can be one of a positive electrode and a negative electrode. Accordingly, each of the plurality of electrodes of the electrode assembly can include one of a positive electrode tab and a negative electrode tab. Accordingly, the electrode assembly EA can include a plurality of electrode tabs ET.

[0039] According to an exemplary embodiment, the welding by the secondary battery manufacturing apparatus 100 can be pre-welding. Due to the recent increase in the energy density of secondary batteries, the number of electrodes to be welded has significantly increased, and tens or more electrode tabs ET are simultaneously welded. In order to reliably weld a large number of electrode tabs ET, the welding of the plurality of electrode tabs ET can include two steps: pre-welding and main welding. As a non-limiting example, the pre-welding can be ultrasonic welding, and the main welding can be laser welding.

[0040] After pre-welding the plurality of electrode tabs ET, the plurality of electrode tabs ET can be welded together with an electrode lead. The electrode lead can be an external connection terminal of a battery cell. Here, the battery cell is a basic unit of a lithium ion battery (i.e., a secondary battery). In addition to the electrode assembly EA, the battery cell includes an electrolyte and a case. The battery cell is classified into a lithium ion cell, a lithium ion polymer cell, and a lithium polymer cell according to the composition of the electrode assembly EA and the electrolyte. The lithium ion polymer cell is increasing its share in secondary batteries due to its low possibility of electrolyte spillage and ease of manufacture.

[0041] Based on the shape of the cell casing, battery cells are classified as: cylindrical cells, in which the electrode assembly EA is embedded in a cylindrical metal can; prismatic cells, in which the electrode assembly EA is embedded in a prismatic metal can; and pouch cells, in which the electrode assembly EA is embedded in a pouch casing of aluminum laminate.

[0042] Electrode assemblies EA include a positive electrode, a negative electrode, and a separator inserted between the positive and negative electrodes. Electrode assemblies EA are classified into wound type and stacked type based on their assembly method. Wound type consists of wound positive and negative electrodes and a separator inserted between them. Stacked type includes multiple positive and negative electrodes stacked sequentially, and multiple separators inserted between them.

[0043] The positive electrode may include a positive current collector and a positive active material. The negative electrode may include a negative current collector and a negative active material.

[0044] The thickness of the positive current collector ranges from approximately 3 μm to approximately 500 μm. The positive current collector can have high conductivity and will not cause chemical changes in the final manufactured secondary battery. The positive current collector can include, for example, stainless steel, aluminum, nickel, titanium, calcined carbon, and aluminum. The positive current collector can also include stainless steel with a surface treated with carbon, nickel, titanium, silver, etc. The surface of the positive current collector can include micro-irregular structures to increase the adhesion of the active material. The positive current collector can have shapes such as membranes, sheets, foils, meshes, porous materials, foams, nonwovens, etc.

[0045] The thickness of the negative electrode current collector ranges from approximately 3 μm to approximately 500 μm. The negative electrode current collector does not cause chemical changes in the final manufactured secondary battery and can have high conductivity. The negative electrode current collector can include copper, stainless steel, aluminum, nickel, titanium, calcined carbon, and aluminum-cadmium alloys. It can also include stainless steel with a surface treated with carbon, nickel, titanium, silver, etc. The surface of the negative electrode current collector can include micro-irregular structures to increase the adhesion of the active material. The negative electrode current collector can have shapes such as membranes, sheets, foils, meshes, porous materials, foams, and nonwovens.

[0046] A cathode active material is a substance that can induce an electrochemical reaction. Cathode active materials can be lithium transition metal oxides. Cathode active materials can be, for example, layered compounds, such as lithium cobalt oxide (LiCoO2) and lithium nickel oxide (LiNiO2) substituted with one or more transition metals; lithium manganese oxide substituted with one or more transition metals; or compounds of the formula LiNi... 1-y M y Lithium-nickel based oxides represented by O2 (where M is any one of Co, Mn, Al, Cu, Fe, Mg, B, Cr, Zn, and Ga, and 0.01 ≤ y ≤ 0.7); such as Li 1+z Ni 1 / 3 Co 1 / 3Mn 1 / 3 O2, Li 1+z Ni 0.4 Mn 0.4 Co 0.2 O2 represented by the formula Li 1+ z Ni b Mn c Co 1-(b+c+d) M d O (2-e) A e (where -0.5 ≤ z ≤ 0.5, 0.1 ≤ b ≤ 0.8, 0.1 ≤ c ≤ 0.8, 0 ≤ d ≤ 0.2, 0 ≤ e ≤ 0.2, b + c + d < 1, M is any one of Al, Mg, Cr, Ti, Si, Y, and A is any one of F, P, Cl) lithium nickel cobalt manganese composite oxide; represented by the formula Li 1+x M 1-y M’ y PO 4-z X z (where M is a transition metal, more specifically any one of Fe, Mn, Co, and Ni, M’ is any one of Al, Mg, and Ti, X is any one of F, S, and N, -0.5 ≤ x ≤ +0.5, 0 ≤ y ≤ 0.5, and 0 ≤ z ≤ 0.1) olivine-based lithium metal phosphate.

[0047] The negative electrode active material may include carbon, such as non-graphitized carbon, graphitized carbon, etc. The negative electrode active material may include metal composite oxides, for example, Li x Fe2O3 (0 ≤ x ≤ 1), Li x WO2 (0 ≤ x ≤ 1), Sn x Me 1-x Me’ y O z (where Me is any one of Mn, Fe, Pb, and Ge, Me’ is any one of Al, B, P, Si, elements of Group 1, Group 2, Group 3 of the periodic table, and halogens; 0 < x ≤ 1; 1 ≤ y ≤ 3; 1 ≤ z ≤ 8). The negative electrode active material may include, for example, lithium metal; lithium alloys; silicon-based alloys; tin-based alloys. The negative electrode active material may include metal oxides, for example, SnO, SnO2, PbO, PbO2, Pb2O3, Pb3O4, Sb2O3, Sb2O4, Sb2O5, GeO, GeO2, Bi2O3, Bi2O4, Bi2O5, etc. The negative electrode active material may, for example, include conductive polymers such as polyacetylene; Li-Co-Ni-based materials; etc.

[0048] The support plate 111 can be configured to support the electrode assembly EA. The electrode assembly EA can be disposed on the upper surface 111T of the support plate 111. The upper surface 111T of the support plate 111 can abut against the electrode assembly EA.

[0049] In the following text, the support plate 111 will be defined by two directions that are generally parallel to the upper surface 111T as the X direction and the Y direction, and by a direction that is generally perpendicular to the upper surface 111T of the support plate 111 as the Z direction. Each of the X, Y, and Z directions may be substantially perpendicular to each other. Unless otherwise defined, the above orientations are the same in all figures. The Z direction may be the orientation of the positive, negative, and diaphragm stack of the electrode assembly EA. The Y direction may be the orientation of the electrode tab ET protruding from the electrode assembly EA.

[0050] The lower surface 113B of the pressing device 113 can abut against the electrode assembly EA. The pressing device 113 can be configured to apply pressure to the electrode assembly EA. The pressing device 113 can be configured to apply pressure to the electrode assembly EA together with the support plate 111, thereby fixing the electrode assembly EA. The electrode assembly EA can be held in place by the pressure applied by the support plate 111 and the pressing device 113, the vertical drag force, and the frictional force caused by the vertical drag force.

[0051] The first tab guide 121 and the second tab guide 123 may be spaced apart from each other in the Z direction. Each of the first tab guide 121 and the second tab guide 123 may be configured to move in the Z direction. The first tab guide 121 and the second tab guide 123 may be inserted between the fixing module 110 and the processing module 130.

[0052] The first tab guide 121 and the second tab guide 123 can collect multiple electrode tabs ET. The first tab guide 121 and the second tab guide 123 can be configured to change the shape of the multiple electrode tabs ET. The shape of each of the multiple electrode tabs ET can be changed to include a circular portion (or a U-shaped portion) by moving the first tab guide 121 and the second tab guide 123 in the Z direction. By changing the shape of the multiple electrode tabs ET by the first tab guide 121 and the second tab guide 123, damage to the multiple electrode tabs ET during subsequent processing of the electrode assembly EA can be prevented, and the reliability of manufacturing secondary batteries can be improved.

[0053] The positions of the first tab guide 121 and the second tab guide 123 in the Y direction determine the shape of the multiple electrode tabs ET during the pre-welding of the multiple electrode tabs ET, and the precise positioning of the first tab guide 121 and the second tab guide 123 in the Y direction is crucial for process consistency and the quality of the electrode assembly EA.

[0054] When welding multiple electrode tabs ET using the secondary battery manufacturing apparatus 100, the anvil 131 can be configured to support the multiple electrode tabs ET. According to an exemplary embodiment, the anvil 131 can be a support clamp. The anvil 131 can be configured to hold the multiple electrode tabs ET in place such that energy delivered by the welding head 133 can be efficiently transferred to the multiple electrode tabs ET. The anvil 131 can include either a knurled shape or a ribbed shape for holding the multiple electrode tabs ET.

[0055] The welding head 133 can be configured to provide ultrasonic energy to a plurality of electrode tabs ET. The frequency of the ultrasonic waves provided by the welding head 133 to the plurality of electrode tabs ET can be in the range of about 18,000 Hz to about 1 GHz. The welding head may include a transducer for converting AC or DC power into mechanical vibrations and an amplifier for amplifying the mechanical vibrations. The ultrasonic energy can generate frictional heat in the plurality of electrode tabs ET, thereby allowing the plurality of electrode tabs ET to be welded.

[0056] The welding head 133 may be an ultrasonic resonator and may include a repeating structure with a spatial period, the spatial period being half, equal to, or an integer multiple of the ultrasonic wavelength. The repeating unit structure of the welding head 133 may include either a knurled shape or a ribbed shape. As a non-limiting example, the welding head 133 may include aluminum alloy, titanium alloy, and mold steel.

[0057] Figure 2 This is a perspective view showing a tab guide alignment device 200 according to other exemplary embodiments.

[0058] Figure 3 This is a perspective view showing the alignment block 220 of the tab guide alignment device 200.

[0059] Reference Figures 1 to 3 The tab guide alignment device 200 may include a first track 210, an alignment block 220, and a vernier caliper 230. The tab guide alignment device 200 can be used to align the first tab guide 121 and the second tab guide 123. The tab guide alignment device 200 can also be used to align the positions of the first tab guide 121 and the second tab guide 123 in the Y direction.

[0060] The first track 210 may include a fastener 211 for securing the tab guide alignment device 200 to the LMS 300. The LMS 300 may include a transfer track and a tray configured to move along the transfer track. The first track 210 may be secured to the tray of the LMS 300.

[0061] Alignment block 220 can be connected to first track 210. Alignment block 220 may include second track 221, track retainer 223, alignment contact 225, position adjuster 227 and tab guide contact 229.

[0062] The second track 221 can be connected to the first track 210. The second track 221 can be configured to move along the first track 210. The first track 210 can extend along the Y direction. The second track 221 can be configured to move along the Y direction.

[0063] The track retainer 223 can be configured to secure the second track 221 and the first track 210. The track retainer 223 can also be configured to fix the relative positions of the second track 221 and the first track 210. After the second track 221 is moved to position the tab guide contact 229, the second track 221 can be secured to the first track 210 by the track retainer 223. As a non-limiting example, the retainer 1223 may include a fixing bolt.

[0064] The alignment contact 225 can be coupled to the second track 221. The alignment contact 225 can be welded to the second track 221 or mechanically coupled by means of, for example, bolts. The alignment contact 225 can also be integrally formed with the second track, for example, by casting.

[0065] The alignment contact 225 can be configured to contact the reference block DB. The alignment block 220 can be positioned by moving the alignment block 220 in the Y direction so that the alignment contact 225 contacts the reference block DB. More specifically, when the alignment contact 225 contacts the reference block DB, the tab guide contact 229 can be positioned to align the first tab guide 121 and the second tab guide 123.

[0066] The tab guide contact 229 can be connected to the position adjuster 227. The position adjuster 227 can be configured to adjust the position of the tab guide contact 229 in the Z direction. The position adjuster 227 can be connected to the second rail 221. The position adjuster 227 can be inserted between the second rail 221 and the tab guide contact 229. The position adjuster 227 can be connected to the end of the second rail 221 in the Y direction. The position adjuster 227 can extend along the Z direction.

[0067] Vernier caliper 230 can be connected to alignment block 220. Vernier caliper 230 can be configured to measure the position of alignment block 220 in the Y direction. Therefore, after alignment block 220 is aligned, if the alignment of alignment block 220 is lost due to repeated alignment of the first tab guide 121 and the second tab guide 123, alignment block 220 can be realigned based on the reading of vernier caliper 230.

[0068] (Second Implementation Method)

[0069] Figure 4 This is a flowchart illustrating a method for aligning a tab guide according to an exemplary embodiment.

[0070] Figure 5 This is a perspective view illustrating a method for aligning a tab guide according to an exemplary embodiment.

[0071] Reference Figures 2 to 4 At P110, alignment block 220 can be aligned. Aligning alignment block 220 may include moving alignment block 220 in the Y direction such that alignment contact 225 contacts reference block DB. After alignment block 220 is aligned, a reference position (e.g., zero point) for vernier caliper 230 can be established. That is, the original position of alignment block 220 can be the reference position (e.g., zero point) of vernier caliper 230.

[0072] Next, refer to Figures 3 to 5 At P120, the first tab guide 121 can be aligned. Aligning the first tab guide 121 may include adjusting the position of the first tab guide 121 in the Y direction (i.e., moving the first tab guide 121 in the Y direction) so that the first tab guide 121 contacts the tab guide contact portion 229.

[0073] Next, at P130, the tab guide contact 229 can be moved. The tab guide contact 229 can move in the Z direction. The tab guide contact 229 can move from a position for aligning with the first tab guide 121 to a position for aligning with the second tab guide 123. The tab guide contact 229 can move in response to the movement of the position adjuster 227. The movement of the position adjuster 227 can be based on manual operation by the operator, or it can be based on the movement of a servo motor and a screw.

[0074] Subsequently, at P140, the second tab guide 123 can be aligned. Aligning the second tab guide 123 may include adjusting the position of the second tab guide 123 in the Y direction (i.e., moving the second tab guide 123 in the Y direction) so that the second tab guide 123 contacts the tab guide contact portion 229.

[0075] exist Figure 4 In the illustration, the second electrode guide 123 is shown to be aligned after the first electrode guide 121 is aligned; however, this is for illustrative purposes only and does not limit the technical concept of this disclosure in any way. That is, the first electrode guide 121 can be aligned after the second electrode guide 123 is aligned.

[0076] The present disclosure has been described in more detail above with reference to the accompanying drawings and embodiments. However, it should be understood that the configurations shown in the drawings or embodiments described herein are merely one embodiment of the present disclosure and do not represent all the technical concepts of the present disclosure. Various equivalents and modifications may exist at the time of submission of this disclosure.

Claims

1. A tab guide alignment device, the tab guide alignment device comprising: First track; as well as An alignment block, which is coupled to the track, wherein the alignment block includes a second track and a tab guide contact portion, the second track being configured to move relative to the first track in a first direction, and the tab guide contact portion being coupled to the second track.

2. The electrode guide alignment device according to claim 1, wherein, The electrode guide contact portion is configured to align with the electrode guide of the ultrasonic welding device.

3. The electrode guide alignment device according to claim 1, wherein, The alignment block also includes an alignment contact portion, which is connected to the second track.

4. The electrode guide alignment device according to claim 3, wherein, The electrode guide contact portion protrudes in the first direction relative to the alignment contact portion.

5. The electrode guide alignment device according to claim 1, wherein, The alignment block also includes a position adjuster that is inserted between the second track and the alignment contact and is connected to each of the second track and the alignment contact.

6. The electrode guide alignment device according to claim 5, wherein, The position adjuster is configured to move the alignment contact in a second direction.

7. The electrode guide alignment device according to claim 1, wherein the electrode guide alignment device further comprises: A vernier caliper, which is connected to the alignment contact.

8. The electrode guide alignment device according to claim 7, wherein, The vernier caliper indicates the position of the alignment contact.

9. A method for aligning a tab guide, the method comprising the following steps: Align with the first electrode guide; Contact part of the movable electrode guide; as well as Align with the second electrode guide, wherein... The step of aligning the first tab guide includes the following steps: adjusting the position of the first tab guide in a first direction so that the first tab guide contacts the tab guide contact portion of the alignment block of the tab guide alignment device.

10. The electrode guide alignment method according to claim 9, wherein, The electrode guide alignment device also includes a first track. The alignment block is connected to the first track. The alignment block includes a second track configured to move relative to the first track in the first direction, wherein... The electrode guide contact portion is connected to the second track.

11. The electrode guide alignment method according to claim 10, wherein, The alignment block further includes an alignment contact portion, which is coupled to the second track, and The electrode guide contact portion protrudes further relative to the alignment block in the first direction.

12. The electrode guide alignment method according to claim 11, further comprising the following steps: The alignment block is aligned by bringing the alignment contact portion into contact with the reference block.

13. The electrode guide alignment method according to claim 12, wherein, The alignment contact is aligned before being aligned with the first tab guide.

14. The electrode guide alignment method according to claim 9, wherein, The step of moving the electrode guide contact portion includes the following steps: moving the electrode guide contact portion in a second direction perpendicular to the first direction.

15. The electrode guide alignment method according to claim 9, wherein, The step of aligning the second electrode guide includes the following steps: adjusting the position of the second electrode guide in the first direction so that the second electrode guide contacts the electrode guide contact portion.

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