Welding device and method for manufacturing electrode by using welding device

Abstract

The invention relates to a welding apparatus and a method of manufacturing an electrode by using the welding apparatus. The welding apparatus includes: a driving portion generating ultrasonic waves; the welding head is connected to the driving part; the welding head is configured to be positioned on one side of a welding object, the anvil is configured to be positioned on the other side of the welding object, the welding head and the anvil together are configured to pressurize the welding object, and the welding head comprises a main body part; a welded portion formed along an outer surface of the main body portion, in which the welded portion includes: a first welded portion formed along the outer surface of the main body portion; and a second welded portion formed on one side of the first welded portion.

Description

Technical Field

[0001] This disclosure relates to a welding apparatus and a method for manufacturing electrodes using the welding apparatus. Background Technology

[0002] While primary batteries are not designed for recharging, secondary (also known as rechargeable) batteries are designed for discharging and recharging. Among secondary batteries, low-capacity batteries are widely used in portable small electronic devices such as smartphones, feature phones, laptops, digital cameras, and camcorders, while high-capacity batteries are widely used as power sources for motors in hybrid and electric vehicles, as well as for storing electricity (e.g., household and / or utility-scale power storage). A secondary battery typically includes an electrode assembly containing positive and negative electrodes, a housing that houses the two electrodes, and electrode terminals connected to the electrode assembly.

[0003] Electrodes forming electrode assemblies can be formed by welding the metal layer of a composite matrix material consisting of polymer and metal layers to a general-purpose metal matrix material. However, the metal layer of the composite matrix material is relatively thin, on the order of several micrometers, resulting in poor weldability with the general-purpose matrix material.

[0004] The information disclosed in this Background section is intended to enhance understanding of the background technology of this disclosure. This section may contain information that does not constitute related (or prior art). Summary of the Invention

[0005] Embodiments of this disclosure provide a welding apparatus and a method for manufacturing electrodes using the welding apparatus, which is used to improve the welding strength between base materials by improving the shape of the welding surface when welding electrode base materials.

[0006] Embodiments of this disclosure provide a welding apparatus, including: a drive portion for generating ultrasonic waves; a welding head connected to the drive portion for pressurizing a workpiece; and an anvil disposed opposite to the welding head and configured to pressurize the workpiece together with the welding head, wherein the welding head includes: a body portion; a welding portion formed along an outer surface of the body portion, the welding portion including: a first welding portion continuously formed along the outer surface of the body portion; and a second welding portion formed on one side of the first welding portion to protrude from the first welding portion.

[0007] Embodiments of this disclosure provide a welding apparatus, including: a drive portion configured to generate ultrasonic waves; a welding head connected to the drive portion; and an anvil, wherein the welding head is configured to be positioned on one side of a workpiece to be welded, and the anvil is configured to be positioned on the other side of the workpiece to be welded, wherein the welding head and the anvil together are configured to apply pressure to the workpiece to be welded, wherein the welding head includes: a body portion; and a welding portion formed along an outer surface of the body portion, wherein the welding portion includes: a first welding portion formed along an outer surface of the body portion; and a second welding portion formed on one side of the first welding portion to protrude from the first welding portion.

[0008] In one embodiment, multiple second welding portions may be formed at constant intervals along the perimeter of the first welding portion on one side of the first welding portion.

[0009] In one embodiment, the second welding portion includes a plurality of second welding portions spaced apart at a predetermined interval.

[0010] In an embodiment, the length of the second weld portion along the periphery of the first weld portion can be 8 mm to 10 mm.

[0011] In one embodiment, the second weld portion has a length of about 8 mm to about 10 mm along the periphery of the first weld portion.

[0012] In one embodiment, the second weld portion may be configured to contact the first weld portion.

[0013] In this embodiment, the second welded portion contacts the first welded portion.

[0014] In one embodiment, the welding head may include a drive shaft disposed on one side of the main body.

[0015] In one embodiment, the welding head also includes a drive shaft on one side of the main body.

[0016] In one implementation, the drive shaft can be connected to the drive section and rotate the welding head.

[0017] In one embodiment, the drive shaft is connected to the drive section and configured to rotate the welding head.

[0018] In one implementation, the main body may have a cylindrical shape.

[0019] In this embodiment, the main body has a substantially cylindrical shape.

[0020] In this embodiment, the welding object may include a first base material and a second base material, and the welding head and the anvil may simultaneously apply pressure to the first base material and the second base material.

[0021] In one embodiment, the welding object includes a first substrate material and a second substrate material, and the welding head and anvil are configured together to simultaneously pressurize the first substrate material and the second substrate material.

[0022] In one embodiment, the anvil may include a first main body portion, and the first main body portion may include a corresponding portion corresponding to the welding portion of the welding head.

[0023] In one embodiment, the anvil includes a first main body portion, wherein the first main body portion includes a corresponding portion corresponding to the welding portion.

[0024] In an implementation, the corresponding portion may include a first corresponding portion and a second corresponding portion. The first corresponding portion may be arranged to correspond to the first welding portion, and the second corresponding portion may be arranged to correspond to the second welding portion.

[0025] In the implementation, the corresponding portion includes a first corresponding portion and a second corresponding portion, wherein the first corresponding portion corresponds to the first welding portion and the second corresponding portion corresponds to the second welding portion.

[0026] Embodiments of this disclosure provide a method for manufacturing an electrode, comprising: coating an active material onto a region of a first substrate material; arranging a second substrate material to overlap the first substrate material in another region of the first substrate material other than the region coated with the active material; ultrasonically welding the overlapping regions of the first and second substrate materials; punching the first and second substrate materials that have been welded together; and cutting substrate material tabs of the punched first and second substrate materials.

[0027] Embodiments of this disclosure provide a method for manufacturing an electrode, comprising: coating an active material onto a first region of a first substrate material; arranging a second substrate material to overlap the first substrate material in a second region of the first substrate material other than the first region; welding the second region such that the first substrate material and the second substrate material are welded to each other; punching the first substrate material and the second substrate material; and cutting substrate material tabs.

[0028] In one embodiment, the second matrix material may be disposed on each of the opposite sides of the first matrix material.

[0029] In one embodiment, the second matrix material is disposed on each side of the first matrix material.

[0030] In an embodiment, the first matrix material may include a metal layer and a polymer layer.

[0031] In one embodiment, the first matrix material includes a metal layer and a polymer layer.

[0032] In one embodiment, a first matrix material and a second matrix material can be welded to each other by a welding apparatus comprising: a drive portion for generating ultrasonic waves; a welding head connected to the drive portion for applying pressure to the workpiece; and an anvil disposed opposite to the welding head and configured to apply pressure to the workpiece together with the welding head, wherein the welding head comprises: a body portion; and a welding portion formed along the outer surface of the body portion, the welding portion comprising: a first welding portion continuously formed along the outer surface of the body portion; and a second welding portion formed on one side of the first welding portion to protrude from the first welding portion.

[0033] In one embodiment, welding is performed by a welding apparatus comprising: a drive portion configured to generate ultrasonic waves; a welding head connected to the drive portion; and an anvil, wherein the welding head is configured to be positioned on one side of the workpiece to be welded, and the anvil is configured to be positioned on the other side of the workpiece to be welded, wherein the welding head and the anvil together are configured to apply pressure to the workpiece to be welded, wherein the welding head includes: a body portion; and a welding portion formed along an outer surface of the body portion, wherein the welding portion includes: a first welding portion formed along an outer surface of the body portion; and a second welding portion formed on one side of the first welding portion to protrude from the first welding portion.

[0034] In one embodiment, multiple second welding portions may be formed at constant intervals along the perimeter of the first welding portion on one side of the first welding portion.

[0035] In one embodiment, the second welding portion includes a plurality of second welding portions spaced apart at a predetermined interval.

[0036] In an embodiment, the length of the second weld portion along the periphery of the first weld portion can be 8 mm to 10 mm.

[0037] In one embodiment, the second weld portion has a length of about 8 mm to about 10 mm along the periphery of the first weld portion.

[0038] In one embodiment, the second weld portion may be configured to contact the first weld portion.

[0039] In this embodiment, the second welded portion contacts the first welded portion.

[0040] In one embodiment, the anvil may include a first main body portion, and the first main body portion may include a corresponding portion corresponding to the welding portion of the welding head.

[0041] In one embodiment, the anvil includes a first main body portion, wherein the first main body portion includes a corresponding portion corresponding to the welding portion.

[0042] In an implementation, the corresponding portion may include a first corresponding portion and a second corresponding portion. The first corresponding portion may be arranged to correspond to the first welding portion, and the second corresponding portion may be arranged to correspond to the second welding portion.

[0043] In the implementation, the corresponding portion includes a first corresponding portion and a second corresponding portion, wherein the first corresponding portion corresponds to the first welding portion and the second corresponding portion corresponds to the second welding portion.

[0044] In this embodiment, the welding head and the anvil can simultaneously pressurize the first matrix material and the second matrix material.

[0045] In one embodiment, the welding head and the anvil are configured together to simultaneously pressurize the first matrix material and the second matrix material. Attached Figure Description

[0046] The accompanying drawings illustrate embodiments of the present disclosure and, together with the detailed description thereof, further describe aspects and features of the present disclosure. Therefore, the present disclosure should not be construed as limited to the drawings.

[0047] Figure 1 This is a schematic diagram illustrating a welding apparatus according to an embodiment of the present disclosure;

[0048] Figure 2 It is based on the embodiments of this disclosure. Figure 1 A magnified view of region A;

[0049] Figure 3 This illustrates an embodiment according to the present disclosure. Figure 1 A schematic diagram of the welding apparatus;

[0050] Figure 4 It is based on the embodiments of this disclosure. Figure 3 A magnified view of region B;

[0051] Figure 5 This is a flowchart illustrating an electrode manufacturing method according to an embodiment of the present disclosure;

[0052] Figures 6A to 6F This illustrates an embodiment according to the present disclosure. Figure 5 A schematic diagram of the electrode manufacturing method;

[0053] Figure 7 This illustrates an embodiment according to the present disclosure, including through... Figure 5 A schematic diagram of an electrode assembly manufactured by the electrode manufacturing method; and

[0054] Figure 8 This illustrates embodiments according to the present disclosure, including... Figure 7 A schematic diagram of the electrode assembly of the secondary battery. Detailed Implementation

[0055] In the following description, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. The terms or words used in this specification and claims should not be construed as limited to their ordinary or dictionary meaning, but should be interpreted as meanings and concepts consistent with the technical spirit of the present disclosure, based on the inventor's appropriate definition of the terms as he / she may for his / her own lexicographer.

[0056] The embodiments described in this specification and the constructions shown in the accompanying drawings are only some of the embodiments of this disclosure and do not represent all the technical ideas, aspects, and features of this disclosure. Therefore, it should be understood that various equivalents and modifications that can replace or modify the embodiments described herein may exist at the time of filing this application.

[0057] It will be understood that when an element or layer is referred to as being "on" another element or layer, "connected" to another element or layer, or "bonded" to another element or layer, it can be directly on, directly connected to, or directly bonded to the other element or layer, or there may be one or more intermediate elements or layers. When an element or layer is referred to as being "directly on" another element or layer, "directly connected" to another element or layer, or "directly bonded" to another element or layer, there are no intermediate elements or layers. For example, when a first element is described as being "bonded" or "connected" to a second element, the first element can be directly bonded or connected to the second element, or the first element can be indirectly bonded or connected to the second element via one or more intermediate elements.

[0058] The embodiments described herein can be explained with reference to the cross-sectional and / or plan views, which serve as exemplary diagrams of this disclosure. In the drawings, the thickness of films and regions may be exaggerated for the purpose of effectively describing the technical content. Therefore, the regions presented as examples in the drawings have a general nature, and the shape of the illustrated regions can be used to illustrate a specific shape of the device region. Therefore, this should not be construed as limiting the scope of this disclosure. Although terms such as first, second, and third are used to describe various components in the various embodiments herein, the components should not be limited to these terms. These terms are used only to distinguish one component from another. The embodiments described and illustrated herein include supplementary embodiments thereof. Throughout the specification, the same reference numerals denote the same elements.

[0059] As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items. Furthermore, when describing embodiments of this disclosure, the use of “may” refers to “one or more embodiments of this disclosure.” Expressions such as “at least one of…” and “any one of…” modify the entire list of elements, not individual elements within that list, when following a list of elements. When a list of elements A, B, and C is specified using phrases such as “at least one of A, B, and C,” “at least one of A, B, or C,” “at least one selected from the group of A, B, and C,” or “at least one selected from A, B, and C,” the phrase may refer to any and all suitable combinations or subsets of A, B, and C, such as A, B, C, A and B, A and C, B and C, or A and B and C. As used herein, the terms “use,” “using…,” and “being used” may be considered synonymous with the terms “utilize,” “using…,” and “being exploited,” respectively. As used herein, the terms “substantially,” “about,” and similar terms are used as approximate terms rather than as terms of degree, and are intended to explain the inherent variations in measured or calculated values ​​that would be recognized by one of ordinary skill in the art.

[0060] It will be understood that although the terms “first,” “second,” “third,” etc., may be used herein to describe various elements, components, regions, layers, and / or portions, these elements, components, regions, layers, and / or portions should not be limited by these terms. These terms are used to distinguish one element, component, region, layer, or portion from another element, component, region, layer, or portion. Therefore, without departing from the teachings of the exemplary embodiments, the first element, first component, first region, first layer, or first portion discussed below may be referred to as a second element, second component, second region, second layer, or second portion.

[0061] For ease of description, spatial relational terms such as “below,” “under,” “down,” “above,” “above,” etc., are used herein to describe the relationship of one element or feature to another element or feature as shown in the figure. It will be understood that, in addition to the orientation depicted in the figure, spatial relational terms are intended to cover different orientations of the device in use or operation. For example, if the device in the figure is flipped, an element described as “below” or “under” other elements or features will be oriented as “above” or “above” other elements or features. Therefore, the term “below” can cover both above and below orientations. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatial relational descriptions used herein should be interpreted accordingly.

[0062] The terminology used herein is for the purpose of describing embodiments of this disclosure and is not intended to be limiting of this disclosure. As used herein, the singular forms “a” and “an” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that, when used in this specification, the terms “comprising,” “including,” “including,” and / or “containing” indicate the presence of stated features, numbers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, numbers, steps, operations, elements, components, and / or groups thereof.

[0063] Furthermore, any numerical range disclosed and / or described herein is intended to include all subranges containing the same numerical precision within the described range. For example, the range “1.0 to 10.0” is intended to include all subranges between (and including) the minimum value of 1.0 and the maximum value of 10.0, that is, all subranges having a minimum value equal to or greater than 1.0 and a maximum value equal to or less than 10.0, such as, for example, 2.4 to 7.6. Any maximum numerical limit described herein is intended to include all lower numerical limits contained therein, and any minimum numerical limit described in this specification is intended to include all higher numerical limits contained therein. Therefore, the applicant reserves the right to amend this specification (including the claims) to expressly describe any subranges contained within the range expressly described herein.

[0064] Referring to two compared elements, features, etc., as “identical” can mean that they are “substantially identical.” Therefore, the phrase “substantially identical” can include cases with deviations considered low in the art (e.g., 5% or less). Furthermore, when a parameter is said to be uniform in a given region, it can mean that it is uniform in terms of average value.

[0065] Throughout this specification, unless otherwise stated, each element may be singular or plural.

[0066] Arranging any element "above (or below)" or "on (below)" an element can mean that the arbitrary element can be positioned to contact the upper (or lower) surface of the element, and another element can be inserted between the element and the arbitrary element positioned on (or below) the element.

[0067] Furthermore, it will be understood that when a component is referred to as “linked,” “combined,” or “connected” to another component, these components can be directly “combined,” “linked,” or “connected” to each other, or additional components can be “inserted” between these components.

[0068] Throughout this specification, when “A and / or B” is stated, it means A, B, or A and B, unless otherwise stated. That is, “and / or” includes any or all combinations of the listed items. When “C to D” is stated, it means C or greater and D or less, unless otherwise stated.

[0069] The terminology used in this specification is for describing embodiments of this disclosure and is not intended to limit this disclosure.

[0070] Figure 1 This is a schematic diagram showing a welding apparatus 1 according to an embodiment of the present disclosure. Figure 2 It is based on the embodiments of this disclosure. Figure 1 A magnified view of region A.

[0071] refer to Figure 1 and Figure 2 The welding device 1 may include a driving part 10 and a welding horn 20. The welding horn 20 may include a main body part 21, a driving shaft 22 and a welding part 23.

[0072] The drive unit 10 can be connected to the welding head 20 and can control the operation of the welding head 20. In one embodiment, the drive unit 10 can convert an alternating current (AC) of about 60 Hz into a high-frequency current equal to or greater than about 20 kHz, convert electrical energy into ultrasonic waves (which are mechanical energy), and amplify the ultrasonic waves to transmit them to the welding head 20. Furthermore, the drive unit 10 can rotate the welding head 20 by applying mechanical energy to the drive shaft 22.

[0073] The welding head 20 may include a main body 21 and a drive shaft 22.

[0074] The welding portion 23 may be formed along the outer surface of the main body portion 21. The welding portion 23 may include a first welding portion 24 and a plurality of second welding portions 25, the first welding portion 24 being continuously formed along the outer surface of the main body portion 21, and the plurality of second welding portions 25 being formed on one side of the first welding portion 24 in a shape protruding from the first welding portion 24.

[0075] In one embodiment, the main body portion 21 may have a cylindrical shape. The first weld portion 24 may be formed to wrap around or surround the outer surface of the cylindrical main body portion 21. A plurality of second weld portions 25 may contact the first weld portion 24 and are formed on one side of the first weld portion 24 at a predetermined spacing d2. In this disclosure, "spacing d2" refers to the spacing between adjacent second weld portions 25 of the plurality of second weld portions 25 along the periphery direction of the first weld portion 24.

[0076] The welded portion 23 formed in this way can be ultrasonically welded while pressure is applied to the welded object.

[0077] In one embodiment, the drive unit 10 can transmit mechanical energy to the drive shaft 22 to rotate the main body 21. When the drive shaft 22 rotates and the main body 21 rotates, a uniform welding pattern can be formed on the welding object.

[0078] Figure 3 This illustrates an embodiment according to the present disclosure. Figure 1 A schematic diagram of welding device 1.

[0079] refer to Figures 1 to 3 The welding device 1 may include a welding head 20 and an anvil 30.

[0080] The welding head 20 may include a main body portion 21 and a drive shaft 22, and the welding portion 23 may be formed along the outer surface of the main body portion 21. The welding portion 23 may include a first welding portion 24 and a plurality of second welding portions 25, the first welding portion 24 being formed along the outer surface of the main body portion 21, and the plurality of second welding portions 25 being formed on one side of the first welding portion 24 in a shape protruding from the first welding portion 24.

[0081] In one embodiment, the main body portion 21 may have a cylindrical shape. The first weld portion 24 may be formed to wrap around or surround the outer surface of the cylindrical main body portion 21. A plurality of second weld portions 25 may contact the first weld portion 24 and are formed on one side of the first weld portion 24 at a predetermined spacing d2.

[0082] The anvil 30 can be arranged opposite to the welding head 20 and can include a first main body portion.

[0083] The first main body portion may include a corresponding portion corresponding to the welding portion 23 of the welding head 20, and the corresponding portion may have a smooth shape, wherein, unlike the welding portion 23, it does not form a tip for ultrasonic welding. In an embodiment, the corresponding portion may include a first corresponding portion 34 and a second corresponding portion 35, and the first corresponding portion 34 and the second corresponding portion 35 may each have substantially the same shape as the first welding portion 24 and the second welding portion 25 of the welding head 20, and may be arranged to correspond to the first welding portion 24 and the second welding portion 25 of the welding head 20, respectively.

[0084] The welding head 20 and anvil 30 arranged in this way can be used to apply pressure to opposite sides of the object to be welded and to ultrasonically weld the object to be welded in the pattern of the first welding portion 24 and the second welding portion 25.

[0085] Meanwhile, the welding object may include a first base material 40 and a second base material 50.

[0086] The first substrate 40 may be formed in the form of a polymer layer 40P disposed between metal layers 40M, and the second substrate 50 may consist only of metal layers. In an embodiment, the second substrate 50 may be arranged such that its end regions overlap with the outer surface of the first substrate 40, and may be ultrasonically welded to the metal layer 40M of the first substrate 40 by means of a welding head 20 and an anvil 30.

[0087] The metal layer 40M of the first substrate 40 and the metal layer of the second substrate 50 may include, but are not limited to, metal foil containing aluminum or aluminum alloy, copper foil, nickel foil, stainless steel foil or titanium foil.

[0088] In this embodiment, the first substrate material 40 can be used as an electrode plate of the secondary battery. Since the first substrate material 40 may include a polymer layer 40P between metal layers 40M, the difference in elongation between the metal layers 40M and the polymer layer 40P allows for the control of any short circuits in the electrode that would occur if the secondary battery were to be penetrated. However, due to the insulating properties of the polymer layer 40P of the first substrate material 40, welding relative to a second substrate material 50 consisting only of metal may be required to connect the electrode substrate material's terminals to the terminals of an external strip terminal.

[0089] Figure 4 It is based on the embodiments of this disclosure. Figure 3 A magnified view of region B.

[0090] refer to Figure 3 and Figure 4 A welding pattern wp having a shape substantially the same as the first welding portion 24 and the second welding portion 25 of the welding head 20 can be formed in the area where the first substrate material 40 and the second substrate material 50 overlap. The first welding portion 24 can be patterned by welding the area where the first substrate material 40 and the second substrate material 50 overlap, and the second welding portion 25 can be patterned by welding an area of ​​the second substrate material 50. Although not shown in the figures, the second substrate material 50 can be arranged and welded on each side of the first substrate material 40, and on the opposite side of the welding pattern wp formed by the welding head 20, the first corresponding portion 34 and the second corresponding portion 35 of the anvil 30 can be arranged to correspond to the first welding portion 24 and the second welding portion 25 of the welding head 20, respectively, and pressure is simultaneously applied to the first substrate material 40 and the second substrate material 50 arranged on each side of the first substrate material 40, thereby promoting the formation of the welding pattern wp.

[0091] As a result, by welding not only the areas where the first base material 40 and the second base material 50 overlap, but also the areas where the second base material 50 overlaps, the welding strength between the first base material 40 and the second base material 50 can be increased.

[0092] Figure 5 This is a flowchart illustrating an electrode manufacturing method according to an embodiment of the present disclosure. Figures 6A to 6F This illustrates an embodiment according to the present disclosure. Figure 5 A schematic diagram of the electrode manufacturing method.

[0093] refer to Figure 5 The electrode manufacturing method may include coating an active material onto a first substrate material (S100), arranging a second substrate material to overlap with the first substrate material in a region of the first substrate material other than the region coated with the active material (S200), ultrasonically welding the overlapping regions of the first and second substrate materials (S300), punching the first and second substrate materials to be welded (S400), and cutting substrate material terminals of the punched first and second substrate materials (S500).

[0094] refer to Figure 5 and Figure 6A In S100, when the active material is coated onto the first substrate material, an uncoated portion 41 may be formed in a region of the first substrate material 40, and the active material 42 may be coated in regions of the first substrate material 40 other than the region where the uncoated portion 41 is formed. The active material 42 to be coated may vary depending on the type of electrode (such as a positive electrode or a negative electrode).

[0095] In one embodiment, when manufacturing the positive electrode, a compound capable of reversible lithium insertion and extraction (e.g., a lithiation insertion compound) can be used as an active material 42 coated on a region of the first substrate material 40. In another embodiment, a composite oxide of lithium and a metal selected from cobalt, manganese, nickel, and combinations thereof can be used.

[0096] Composite oxides may include lithium transition metal composite oxides, and non-limiting examples include lithium nickel-based oxides, lithium cobalt-based oxides, lithium manganese-based oxides, lithium iron phosphate-based compounds, cobalt-free nickel manganese-based oxides, or combinations thereof.

[0097] In embodiments, the composite oxide may include compounds represented by any of the following chemical formulas: Li a A 1-b X b O 2-c D c (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.05), Lia Mn 2-b X b O 4-c D c (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.05), Li a Ni 1-b-c Co b X c O 2-α D α (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.5, 0<α<2), Li a Ni 1-b-c Mn b X c O 2-α D α (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.5, 0<α<2), Li a Ni b Co c L 1 d G e O2 (0.90≤a≤1.8, 0≤b≤0.9, 0≤c≤0.5, 0≤d≤0.5, 0≤e≤0.1), Li a NiG b O2 (0.90≤a≤1.8, 0.001≤b≤0.1), Li a CoG b O2 (0.90≤a≤1.8, 0.001≤b≤0.1), Li a Mn 1-b G b O2 (0.90≤a≤1.8, 0.001≤b≤0.1), Li a Mn2G b O4 (0.90≤a≤1.8, 0.001≤b≤0.1), Li a Mn 1-g G g PO4 (0.90≤a≤1.8, 0≤g≤0.5), Li (3-f) Fe2(PO4)3 (0≤f≤2), Li a FePO4 (0.90≤A≤1.8), where A is Ni, Co, Mn or a combination thereof; X is Al, Ni, Co, Mn, Cr, Fe, Mg, Sr, V, rare earth elements or a combination thereof; D is O, F, S, P or a combination thereof; G is Al, Cr, Mn, Fe, Mg, La, Ce, Sr, V or a combination thereof; and L 1 It can include Mn, Al, or combinations thereof.

[0098] In an embodiment, when manufacturing a negative electrode, the active material 42 coated on an area of the first substrate material 40 may include a material capable of reversibly intercalating or deintercalating lithium ions, lithium metal, an alloy of lithium metal, a material that can be doped with lithium or de-doped with lithium therefrom, or a transition metal oxide.

[0099] The material capable of reversibly intercalating or deintercalating lithium ions may be a carbon-based negative electrode active material. For example, crystalline carbon, amorphous carbon, or a combination thereof. Non-limiting examples of crystalline carbon include graphite, such as natural graphite or artificial graphite, and non-limiting examples of amorphous carbon include soft carbon or hard carbon, mesophase pitch carbide, calcined coke, etc.

[0100] Non-limiting examples of the material that can be doped with lithium or de-doped with lithium therefrom may include a Si-based negative electrode active material or a Sn-based negative electrode active material. The Si-based negative electrode active material may include silicon, a silicon-carbon composite, SiO x (0 < x < 2), a Si-based alloy, or a combination thereof.

[0101] The silicon-carbon composite may include a composite of silicon and amorphous carbon. According to an embodiment, the silicon-carbon composite may exist in the form of silicon particles and amorphous carbon coated on the surface of the silicon particles.

[0102] The silicon-carbon composite may further include crystalline carbon. In an embodiment, the silicon-carbon composite may include a core containing crystalline carbon and silicon particles, and an amorphous carbon coating disposed on the surface of the core.

[0103] The first substrate material 40 may include a polymer layer and metal layers provided on each side of the polymer layer. The metal layers may serve as electrode plates, and the material forming the metal layers may vary depending on the type of electrode to be manufactured (such as a negative electrode or a positive electrode).

[0104] In an embodiment, when manufacturing a positive electrode, the metal layer of the first substrate material 40 may include a metal foil including aluminum or an aluminum alloy. In an embodiment, when manufacturing a negative electrode, the metal layer of the first substrate material 40 may include a copper foil, a nickel foil, a stainless steel foil, or a titanium foil, but is not limited thereto.

[0105] Reference Figure 6B , in an embodiment, when manufacturing a positive electrode, an insulating region may be further formed in an area of the first substrate material 40 other than the area coated with the active material. In an embodiment, an insulating region 43 including polyimide (PI) or ceramic may be additionally formed between the uncoated portion 41 and the active material 42.

[0106] Reference Figure 5 and Figure 6CIn S200 (where the second substrate material can be arranged to overlap with the first substrate material), the second substrate material 50 can be arranged to overlap with the region of the first substrate material 40 where the uncoated portion 41 is formed, in the region of the first substrate material 40 excluding the region on which the active material is coated. The second substrate material 50 may include a metal layer, and the material forming the metal layer may vary depending on the type of electrode to be manufactured (such as a negative electrode or a positive electrode).

[0107] In one embodiment, when manufacturing the positive electrode, the metal layer of the second substrate material 50 may include a metal foil, which may include aluminum or an aluminum alloy. In another embodiment, when manufacturing the negative electrode, the metal layer of the second substrate material 50 may include, but is not limited to, copper foil, nickel foil, stainless steel foil, or titanium foil.

[0108] In S300, which ultrasonically welds the area where the first substrate material and the second substrate material overlap, the first substrate material 40 and the second substrate material 50 can be ultrasonically welded to each other by a welding device to form a certain pattern.

[0109] The welding apparatus may include a welding head, and the welding head may include a main body and a welding part.

[0110] The welded portion may be formed along the outer surface of the main body portion. The welded portion may include a first welded portion and a plurality of second welded portions, the first welded portion being formed continuously along the outer surface of the main body portion, and the plurality of second welded portions being formed at a constant spacing d2 on one side of the first welded portion in a shape protruding from the first welded portion.

[0111] refer to Figure 6D A welding pattern wp having a shape substantially the same as the first welding portion 24 and the second welding portion 25 of the welding head of the welding apparatus can be formed in the area where the first base material 40 and the second base material 50 overlap. The first welding portion 24 can be patterned by ultrasonically welding the area where the first base material 40 and the second base material 50 overlap, and the second welding portion 25 can be patterned by ultrasonically welding an area of ​​the second base material 50. Not only can the area where the first base material 40 and the second base material 50 overlap be welded, but a portion of the second base material 50 can also be additionally ultrasonically welded by the second welding portion 25.

[0112] Although not shown in the figures, the second substrate material 50 can be arranged and welded on each side of the first substrate material 40. On the side opposite to the side where the weld pattern wp is formed by the welding head, the first corresponding portion 34 and the second corresponding portion 35 of the anvil 30 can be arranged to correspond to the first welding portion 24 and the second welding portion 25 of the welding head 20, respectively, and pressure is applied to the first substrate material 40 and the second substrate material 50 arranged on opposite sides of the first substrate material 40, thereby allowing the weld pattern wp to be easily formed.

[0113] In this way, not only can the overlapping areas of the first base material 40 and the second base material 50 be welded, but some areas of the second base material 50 can also be additionally welded through the second welding portion 25. Therefore, the overall weldability can be enhanced, and the increased flowability and wrinkling of the first base material 40 and the second base material 50 during the blanking process can be prevented, thereby reducing the possibility of burrs and improving the blanking quality.

[0114] The length d1 of the second weld portion 25 along the periphery of the first weld portion 24 can be approximately 8 mm to approximately 10 mm. When the length d1 of the second weld portion 25 is less than approximately 8 mm, the area where the second base material 50 is welded to each other can be reduced, making it difficult to enhance weldability. When the length d1 of the second weld portion 25 exceeds approximately 10 mm, the area where the second base material 50 is welded to each other can be wider than the area where the base material connecting piece is formed during the punching process, making it difficult to form the base material connecting piece.

[0115] refer to Figure 5 and Figure 6E In the punching operation S400 on the first and second base materials to be welded, the first base material 40 and the second base material 50 to be welded can be punched along the shape of the cutting line P.

[0116] If the welding of the first substrate material 40 and the second substrate material 50 is not properly performed, the fluidity increases during the blanking process, increasing the likelihood of wrinkles and burrs, thus reducing the blanking quality. However, when the welding apparatus according to an embodiment of the present disclosure is used to weld not only the overlapping area between the first substrate material 40 and the second substrate material 50, but also some portions of the second substrate material 50, the weldability of the first substrate material 40 and the second substrate material 50 can be enhanced, thereby preventing increased fluidity and wrinkles in the first substrate material 40 and the second substrate material 50, and reducing the likelihood of burrs, thus improving the blanking quality.

[0117] refer to Figure 5 and Figure 6FIn operation S500, which involves cutting substrate material connecting pieces from the first substrate material 40 and the second substrate material 50, a substrate material connecting piece can be formed on the upper end of the welding pattern wp from the second substrate material 50. The length can be adjusted as needed by performing the process of cutting the substrate material connecting piece along the cutting line P.

[0118] A region of the substrate material patch may include a portion of the second substrate material 50 welded by a second welding portion of the welding head. This welding region may pre-weld the substrate material patch, thereby increasing the uniformity of the cut surface during the cutting process of the substrate material patch.

[0119] As a result, by using the first welding portion and the second welding portion of the welding apparatus according to an embodiment of the present disclosure, not only are the overlapping areas of the first substrate material 40 and the second substrate material 50 welded, but also a portion of the second substrate material 50 is welded, thereby enhancing the weldability of the first substrate material 40 and the second substrate material 50. By enhancing weldability, increased flowability and wrinkling of the first substrate material 40 and the second substrate material 50 can be prevented, thus reducing the possibility of burrs and improving the blanking quality. Furthermore, the quality and performance of the electrode can be improved by improving the blanking quality of the electrode manufacturing process.

[0120] Figure 7 This illustrates an embodiment according to the present disclosure, including through... Figure 5 A schematic diagram of an electrode assembly manufactured by the electrode manufacturing method.

[0121] refer to Figure 7 The electrode assembly may include a negative electrode plate 112, a positive electrode plate 114, and a diaphragm 116 manufactured using an electrode manufacturing method according to an embodiment of the present disclosure. Figure 8 This illustrates embodiments according to the present disclosure, including... Figure 7 A schematic diagram of the secondary battery of electrode assembly 110.

[0122] refer to Figure 7 and Figure 8The electrode assembly 110 may include a diaphragm 116, a negative electrode plate 112, and a positive electrode plate 114 (with the diaphragm 116 located between the negative electrode plate 112 and the positive electrode plate 114), and may be formed by stacking or winding the negative electrode plate 112, diaphragm 116, and positive electrode plate 114 in a core shape to form a sheet or film shape. Furthermore, the electrode assembly 110 may be stacked rather than coiled, and the shape of the electrode assembly 110 is not limited in this disclosure. Additionally, the electrode assembly 110 may be a Z-stacked electrode assembly, wherein the positive electrode plate and the negative electrode plate are inserted on opposite sides of a diaphragm 116 folded in a Z-stack configuration. Furthermore, the electrode assembly 110 may be housed in a housing by stacking one or more electrode assemblies 110 such that their long sides are adjacent to each other, and the number of electrode assemblies is not limited in this disclosure. The negative electrode plate 112 includes a negative electrode substrate material 112b, a negative electrode active material layer 112c disposed on the negative electrode substrate material 112b, and an insulating layer 115. The negative electrode substrate material tab 112a can extend outward from the uncoated portion of the negative electrode active material layer 112c of the negative electrode substrate material 112b, where it is not located. The negative electrode substrate material tab 112a is soldered to the negative electrode lead 152 of the strip terminal 150 for electrical connection to the external environment. An insulating layer 115, including PI or ceramic, can be disposed on the uncoated portion where the negative electrode active material layer 112c is not disposed. The positive electrode plate 114 includes a positive electrode substrate material 114b, a positive electrode active material layer 114c disposed on the positive electrode substrate material 114b, and an insulating layer 115. The positive electrode substrate material tab 114a can extend outward from the uncoated portion of the positive electrode active material layer 114c of the positive electrode substrate material 114b, where it is not located. The positive electrode substrate material tab 114a is soldered to the positive electrode lead 154 of the strip terminal 150 for electrical connection to the external environment. An insulating layer 115, including PI or ceramic, can be disposed on the uncoated portion of the electrode where the positive electrode active material layer 114c is not disposed. A separator 116 is configured to prevent any short circuit between the negative electrode plate 112 and the positive electrode plate 114, while allowing the movement of lithium ions. The separator 116 may include a polyethylene membrane, a polypropylene membrane, a polyethylene-polypropylene membrane, etc.

[0123] refer to Figure 8 A typical secondary battery 100 includes an electrode assembly 110 and a pouch 130 for housing the electrode assembly 110.

[0124] Electrode assembly 110 includes a first electrode plate (i.e., negative electrode plate 112), a second electrode plate (i.e., positive electrode plate 114), and a diaphragm 116 located between the first and second electrode plates. Negative electrode plate 112 includes a negative electrode substrate material tab 112a electrically connected to an uncoated portion of the negative electrode, and positive electrode plate 114 includes a positive electrode substrate material tab 114a electrically connected to an uncoated portion of the positive electrode. Negative electrode substrate material tabs 112a and positive electrode substrate material tabs 114a are soldered to negative electrode leads 152 and positive electrode leads 154 of strip terminal 150, thereby electrically connecting to the external environment. A tab film 156 for insulation from bag 130 is attached to negative electrode leads 152 and positive electrode leads 154.

[0125] The bag 130 is sealed such that the sealing portions 132 at the edges are in contact with each other, while simultaneously accommodating the electrode assembly 110. The bag 130 is sealed and a tab membrane 156 is placed between the sealing portions 132. As used herein, the form in which the tab membrane 156 is attached to each of the negative electrode lead 152 and the positive electrode lead 154 is referred to as a "separable tab membrane" (i.e., the sealing structure is referred to as a separable sealing structure).

[0126] The sealing portion 132 of the bag 130 comprises a thermosetting material and has a structure that achieves a seal by bonding the thermosetting layers together. Since thermosetting materials typically have weak adhesion to metals, a thin-film form of a terminal lead 156 is attached to the electrode leads and fused to the bag 130.

[0127] This disclosure is not limited thereto, and the housing can be configured in various shapes such as circular or square. The housing may include metal (including aluminum, aluminum alloy, nickel-plated steel, or the like) or laminated film or plastic forming a bag.

[0128] As a result, by using the welding apparatus according to the embodiments of the present disclosure, not only the overlapping areas of the first substrate material 40 and the second substrate material 50 can be welded, but also some areas of the second substrate material 50 can be welded, thereby enhancing the weldability of the first substrate material 40 and the second substrate material 50. By enhancing weldability, increased flowability and wrinkling of the first substrate material 40 and the second substrate material 50 can be prevented, thus reducing the possibility of burrs and forming an electrode with improved quality. Furthermore, with the improved quality of the electrode, the performance of the electrode assembly including the electrode can be improved, and the performance of the secondary battery using the electrode assembly can also be improved (including reduced cell resistance).

[0129] Although embodiments of this disclosure have been described above, this disclosure is not limited thereto. Various modifications and variations can be made to it within the spirit of this disclosure by those skilled in the art.

[0130] This application claims priority and benefit to Korean Application No. 10-2024-0126049, filed on September 13, 2024, with the Korean Intellectual Property Office, the entire disclosure of which is incorporated herein by reference.

Claims

1. A welding apparatus, comprising: The drive unit is configured to generate ultrasonic waves; The welding head is connected to the drive section; as well as Anvil, The welding head is configured to be positioned on one side of the object being welded, and the anvil is configured to be positioned on the other side of the object being welded. The welding head and the anvil are configured together to apply pressure to the object being welded. The welding head includes: The main body; and The welded portion is formed along the outer surface of the main body portion. The welded portion includes: A first welded portion is formed along the outer surface of the main body portion; and The second weld portion is formed on one side of the first weld portion to protrude from the first weld portion.

2. The welding apparatus according to claim 1, wherein the second welding portion comprises a plurality of second welding portions spaced apart at a predetermined interval.

3. The welding apparatus according to claim 2, wherein the second welding portion has a length of 8 mm to 10 mm along the periphery of the first welding portion.

4. The welding apparatus according to claim 1, wherein the second welding portion is in contact with the first welding portion.

5. The welding apparatus according to claim 1, wherein the welding head further includes a drive shaft on one side of the main body portion.

6. The welding apparatus of claim 5, wherein the drive shaft is connected to the drive portion and configured to rotate the welding head.

7. The welding apparatus according to claim 1, wherein the main body portion has a substantially cylindrical shape.

8. The welding apparatus of claim 1, wherein the object to be welded comprises a first substrate material and a second substrate material, and wherein the welding head and the anvil are configured together to simultaneously pressurize the first substrate material and the second substrate material.

9. The welding apparatus according to claim 1, wherein the anvil comprises a first main body portion, and wherein the first main body portion comprises a corresponding portion corresponding to the welding portion.

10. The welding apparatus according to claim 9, wherein the corresponding portion includes a first corresponding portion and a second corresponding portion, wherein the first corresponding portion corresponds to the first welding portion, and the second corresponding portion corresponds to the second welding portion.

11. A method for manufacturing an electrode, comprising: An active substance is coated onto a first region of a first substrate material; The second matrix material is arranged to overlap with the first matrix material in a second region of the first matrix material other than the first region; The second region is welded so that the first substrate material and the second substrate material are welded to each other; The first matrix material and the second matrix material are punched; and Cut the substrate material connecting piece.

12. The method of claim 11, wherein the second matrix material is disposed on each side of the first matrix material.

13. The method of claim 11, wherein the first matrix material comprises a metal layer and a polymer layer.

14. The method of claim 11, wherein the welding is performed by a welding apparatus, the welding apparatus comprising: The drive unit is configured to generate ultrasonic waves; The welding head is connected to the drive section; as well as Anvil, The welding head is configured to be positioned on one side of the object being welded, and the anvil is configured to be positioned on the other side of the object being welded. The welding head and the anvil are configured together to apply pressure to the object being welded. The welding head includes: The main body; and The welded portion is formed along the outer surface of the main body portion. The welded portion includes: A first welded portion is formed along the outer surface of the main body portion; and The second weld portion is formed on one side of the first weld portion to protrude from the first weld portion.

15. The method of claim 14, wherein the second weld portion comprises a plurality of second weld portions spaced apart at a predetermined interval.

16. The method of claim 15, wherein the second weld portion has a length of 8 mm to 10 mm along the periphery of the first weld portion.

17. The method of claim 14, wherein the second weld portion contacts the first weld portion.

18. The method of claim 14, wherein the anvil comprises a first body portion, and wherein the first body portion comprises a corresponding portion corresponding to the weld portion.

19. The method of claim 18, wherein the corresponding portion comprises a first corresponding portion and a second corresponding portion, wherein the first corresponding portion corresponds to the first welded portion, and the second corresponding portion corresponds to the second welded portion.

20. The method of claim 14, wherein the welding head and the anvil are configured to simultaneously pressurize the first matrix material and the second matrix material.

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