Ultrasonic welding device and welding equipment

Abstract

The utility model relates to the technical field of ultrasonic welding, and discloses an ultrasonic welding device and welding equipment.The ultrasonic welding device comprises a base roller and an ultrasonic welding head, the base roller is used for bearing membrane materials, the ultrasonic welding head comprises a welding wheel, and the axis of the welding wheel and the axis of the base roller are in different planes; the welding wheel can roll along the base roller; wherein the welding wheel comprises a groove, the groove is formed in the periphery of the welding wheel in a surrounding mode, the shape of the groove is matched with that of the base roller, and the groove is used for pressing a membrane material on the base roller. And the ultrasonic welding device can enable welding to be more uniform.

Description

Technical Field

[0001] This utility model relates to the field of ultrasonic welding technology, specifically to an ultrasonic welding device and welding equipment. Background Technology

[0002] Ultrasonic welding is a technique that uses high-frequency vibration to join materials together. Current techniques typically involve ultrasonic welding using welding heads positioned on both sides of the material and a base. Specifically, the end face of the welding head presses the material onto the base. Ultrasonic welding equipment causes the welding head to generate high-frequency mechanical vibrations, transferring vibrational energy to the contact surface. The vibrations generate localized high temperatures at the contact surface, melting the material surfaces and bonding them together under pressure.

[0003] The width of the weld is limited by the size of the welding head end face. If you want to increase the width, you need to increase the width of the end face. However, increasing the width will increase the power requirements of the ultrasonic welding machine and make it difficult to ensure the uniformity of the pressure of the welding head on the material, resulting in uneven welding. Utility Model Content

[0004] In view of this, the present invention provides an ultrasonic welding device and welding equipment to solve the problem of uneven welding after the welding width is increased.

[0005] In a first aspect, this utility model provides an ultrasonic welding device, including a base roller and an ultrasonic welding head. The base roller is used to carry a film material, and the ultrasonic welding head includes a welding wheel. The axis of the welding wheel is opposite to the axis of the base roller, and the welding wheel can roll along the base roller. The welding wheel includes a groove, which is disposed around the outer periphery of the welding wheel. The shape of the groove matches the shape of the base roller, and the groove is used to press the film material against the base roller.

[0006] Beneficial effects: On the one hand, applying pressure to the membrane material using concave grooves can increase the width of the membrane material pressed onto the base roller; on the other hand, since the grooves surround the outer circumference of the welding wheel, the grooves do not press all the membrane material to be welded at the same time during welding. Instead, the membrane material is gradually pressed onto the base roller as the welding wheel rolls, thereby reducing the power requirements of the ultrasonic welding machine and improving the uniformity of pressure. Therefore, the ultrasonic welding device can make the welding more uniform.

[0007] In one alternative embodiment, the axis of the welding wheel is perpendicular to and out of plane with the axis of the base roller.

[0008] Beneficial effect: By making the axes perpendicular to each other, the groove is made to be annular on the outer circumference of the welding wheel, which effectively reduces the axial dimension of the welding wheel.

[0009] In one alternative implementation, the grooves form an annular loop connected end to end.

[0010] Beneficial effects: During the rolling process, each part of the groove can be repeatedly pressed against the base roller, so the circumference of the groove can be smaller than the size of the film material in the axial direction of the base roller, which helps to reduce the diameter of the welding wheel.

[0011] In one optional embodiment, the ultrasonic welding head further includes a rotating shaft, the welding wheel is disposed on the rotating shaft, and the axis of the welding wheel and the axis of the rotating shaft are collinear.

[0012] Beneficial effects: The coaxial arrangement of the welding wheel and the rotating shaft can further improve the uniformity of the pressure of the welding wheel on the base roller during rotation.

[0013] In one alternative embodiment, the base roller is rotatable.

[0014] Beneficial effect: After welding is completed, the base roller can rotate with the membrane material being conveyed, avoiding damage to the membrane material caused by the base roller applying tangential force to the membrane material.

[0015] In one alternative embodiment, the ultrasonic welding apparatus includes a guide assembly for guiding the membrane material to be welded around the base roller.

[0016] Beneficial effect: The membrane material is pre-wrapped on the base roller, which can prevent the membrane material from forming indentations when the welding roller presses on the membrane material.

[0017] In one optional embodiment, the guiding assembly includes a rotatable first guide roller and a second guide roller, the first guide roller and the second guide roller being disposed on the side of the base roller away from the ultrasonic welding head, and arranged sequentially along the conveying direction of the membrane material.

[0018] Beneficial effects: The first and second guide rollers can rotate with the conveying of the membrane material, avoiding damage to the membrane material caused by the first and second guide rollers applying tangential force to the membrane material.

[0019] In one alternative embodiment, the second guide roller is a drive roller.

[0020] Beneficial effects: By setting the second guide roller located downstream as the active roller, the tension of the membrane material can be maintained after welding, avoiding the appearance of micro-bubbles or other defects between adjacent membrane layers after welding.

[0021] In one alternative embodiment, the surface of the base roller is provided with a first protrusion, and the surface of the groove is provided with a second protrusion, the first protrusion and the second protrusion being used to fix the film material during welding.

[0022] Beneficial effects: The first protrusion helps the base roller hold the membrane material in place, and the second protrusion helps the welding wheel hold the membrane material in place so that the membrane material can be ultrasonically welded.

[0023] Secondly, this utility model also provides a welding device, including the ultrasonic welding apparatus provided by this utility model.

[0024] Beneficial effects: Since the welding equipment includes an ultrasonic welding device, it has the corresponding beneficial effects brought by the ultrasonic welding device provided by this utility model, which will not be elaborated here. Attached Figure Description

[0025] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0026] Figure 1 This is a perspective view of an ultrasonic welding device according to an embodiment of the present invention;

[0027] Figure 2 for Figure 1 Front view of an embodiment of the ultrasonic welding apparatus shown;

[0028] Figure 3 for Figure 2 A partial view of region A in the embodiment of the ultrasonic welding apparatus shown.

[0029] Explanation of reference numerals in the attached figures:

[0030] 1. Base roller; 101. First protrusion; 2. Ultrasonic welding head; 201. Welding wheel; 2011. Groove; 2012. Second protrusion; 202. Rotating shaft; 301. First guide roller; 302. Second guide roller; 4. Membrane material. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0032] It should be understood that the terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms "a," "an," and "comprising" as used herein may also mean including the plural forms. The terms "comprising," "including," and "having" are inclusive and therefore indicate the presence of the stated features, elements, and / or components, but do not exclude the presence or addition of one or more other features, elements, components, and / or combinations thereof.

[0033] Although terms such as "first," "second," etc., may be used in this document to describe multiple elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another. Unless the context clearly indicates otherwise, terms such as "first," "second," and other numerical terms used herein do not imply order or sequence. Furthermore, in the description of this application, unless otherwise expressly specified and limited, the terms "set up" and "connected" should be interpreted broadly; for example, they may refer to a fixed connection, a detachable connection, or an integral connection; they may refer to a direct connection or an indirect connection via an intermediate medium. Those skilled in the art will understand the specific meaning of the above terms in this application based on the specific circumstances.

[0034] For ease of description, spatial relative terms may be used in the text to describe the relationship of one element or feature relative to another element or feature, as shown in the figure. These relative terms include, for example, "end," "length," "inner," "outer," etc. Such spatial relative terms are intended to include different orientations of the mechanism in use or operation, in addition to those depicted in the figure. For example, if the mechanism in the figure is flipped, then an element described as "below other elements or features" or "below other elements or features" will subsequently be oriented as "above other elements or features" or "above other elements or features." Therefore, the example term "below" can include both upper and lower orientations. The mechanism may be otherwise oriented (rotated 90 degrees or in other directions), and the spatial relative descriptors used in the text will be interpreted accordingly.

[0035] Ultrasonic welding is a technique that uses high-frequency vibration to join materials together, suitable for welding films such as copper foil. The basic principle of ultrasonic welding is to generate high-frequency mechanical vibrations using ultrasonic welding equipment, transferring vibrational energy to the contact surface of the copper foil. The vibrations generate localized high temperatures at the contact surface, melting the surface of the copper foil and bonding it together under pressure.

[0036] In related technologies, the end face size of the ultrasonic welding head 2 is generally small, which affects the width of a single weld and slows down the welding efficiency. This is mainly due to two factors: firstly, a larger end face requires a higher power ultrasonic welding machine to meet the welding requirements, leading to increased implementation costs; secondly, a larger end face makes it difficult to ensure uniform pressure applied by the ultrasonic welding head 2 to the membrane material 4, resulting in poor welding in areas with weaker pressure.

[0037] Therefore, this utility model provides an ultrasonic welding device and a welding equipment with an ultrasonic welding device. The ultrasonic welding device can overcome the problems of increased power requirements and difficulty in ensuring pressure uniformity of ultrasonic welding machines, thereby helping to increase the width of a single weld.

[0038] The following is combined with Figures 1 to 3 The following describes embodiments of the present invention.

[0039] Reference Figure 1 and Figure 2 The ultrasonic welding apparatus provided according to the embodiments of the present invention includes a base roller 1 and an ultrasonic welding head 2.

[0040] Specifically, the base roller 1 is used to support the membrane material 4, and the ultrasonic welding head 2 includes a welding wheel 201. The axis of the welding wheel 201 is not parallel to the axis of the base roller 1, and the welding wheel 201 can roll along the base roller 1. The welding wheel 201 includes a groove 2011, which is arranged around the outer periphery of the welding wheel 201. The shape of the groove 2011 matches the shape of the base roller 1, and the groove 2011 is used to press the membrane material 4 against the base roller 1.

[0041] For example, the ultrasonic welding apparatus can perform welding in the following manner.

[0042] First, the multilayer membrane material 4 to be welded is placed on the base roller 1. Then, the ultrasonic welding head 2 presses down close to the base roller 1, and the base roller 1 is embedded in the groove 2011, so that the surface of the base roller 1 and the surface of the groove 2011 together press the membrane material 4. Under appropriate pressure, the welding wheel 201 applies ultrasonic vibration to the part of the membrane material 4 that is pressed down, so that the multilayer membrane material 4 is bonded together.

[0043] As the welding wheel 201 rolls from one end of the base roller 1 to the other in the axial direction, the portion of the membrane material 4 pressed by the groove 2011 also moves along the axial direction of the base roller 1, so that the welding wheel 201 gradually welds the membrane material 4 along the axial direction of the base roller 1.

[0044] On the one hand, applying pressure to the membrane material 4 using the concave groove 2011 can increase the width of the membrane material 4 pressed onto the base roller 1; on the other hand, since the groove 2011 surrounds the outer circumference of the welding wheel 201, the groove 2011 will not press all the membrane materials 4 to be welded at the same time during welding. Instead, as the welding wheel 201 rolls, the membrane material 4 is gradually pressed onto the base roller 1 for welding, thereby reducing the power requirements of the ultrasonic welding machine and improving the uniformity of pressure. Therefore, the ultrasonic welding device can make the welding more uniform.

[0045] It is understandable that the shape of the groove 2011 matches the shape of the base roller 1, meaning that during the rolling welding process of the welding wheel 201, the plane where the axis of the base roller 1 is located and perpendicular to the axis of the welding wheel 201 is used as the reference plane. The curvature of the intersection line of the groove 2011 and the reference plane is theoretically the same as the curvature of the surface of the base roller 1. Therefore, the groove 2011 can apply pressure to the membrane material 4 more evenly.

[0046] In order to make the shape of the groove 2011 match the shape of the base roller 1, the way the groove 2011 surrounds the outer periphery of the welding wheel 201 needs to be determined according to the included angle between the axes of the welding wheel 201 and the base roller 1.

[0047] For example, in some embodiments not shown, the axis of the welding wheel 201 is out of plane with the axis of the base roller 1, but they are not perpendicular. In this case, the groove 2011 needs to be spirally wrapped around the outer circumference of the welding wheel 201 so that the groove 2011 can maintain pressure on the membrane material 4 during rolling. However, the spirally extended groove 2011 will increase the axial dimension of the welding wheel 201, which is not conducive to the design of the ultrasonic welding head 2.

[0048] Optionally, refer to Figure 1 and Figure 2 In some embodiments, the axis of the welding wheel 201 is perpendicular to and out of plane with the axis of the base roller 1. In this case, the groove 2011 is adapted to extend circumferentially around the outer periphery of the welding wheel 201, effectively reducing the axial dimension of the welding wheel 201.

[0049] Furthermore, in some embodiments, the groove 2011 forms an annular shape with its ends connected. During the rolling process, each part of the groove 2011 can be repeatedly pressed against the base roller 1. Therefore, the circumference of the groove 2011 can be smaller than the dimension of the film material 4 in the axial direction of the base roller 1 (that is, the length of the area to be welded), which helps to reduce the diameter of the welding wheel 201.

[0050] In some embodiments, the ultrasonic welding head 2 further includes a rotating shaft 202, and a welding wheel 201 is disposed on the rotating shaft 202, with the axis of the welding wheel 201 and the axis of the rotating shaft 202 being collinear. The welding wheel 201 rotates as the rotating shaft 202 rotates, thereby rolling along the base roller 1. The welding wheel 201 and the rotating shaft 202 are coaxially arranged, which can further improve the uniformity of the pressure of the welding wheel 201 on the base roller 1 during rotation. The rotating shaft 202 is used to connect to an ultrasonic welding machine that provides ultrasonic vibration, thereby transmitting the ultrasonic vibration to the welding wheel 201.

[0051] It should be noted that after each welding operation, the welded membrane material 4 needs to be removed so that the membrane material 4 to be welded reaches the base roller 1. In order to avoid the base roller 1 applying tangential force to the membrane material 4 during the movement of the membrane material 4, the relevant technology generally lifts the membrane material 4 first to separate it from the base roller 1 before moving the membrane material 4. This is not only cumbersome to operate, but also often requires manual intervention, which is not conducive to the automation of the welding process.

[0052] In some embodiments, the base roller 1 can rotate. After welding is completed, the base roller 1 can rotate synchronously with the conveying of the membrane material 4 to avoid the base roller 1 applying tangential force to the membrane material 4, which would cause damage to the membrane material 4.

[0053] It is understandable that "the base roller 1 can rotate" includes two implementations: the base roller 1 is the driving roller and the base roller 1 is the driven roller. As long as the linear velocity of the surface of the base roller 1 and the conveying speed of the film material 4 can be kept consistent, there is no limitation here.

[0054] In some embodiments, the ultrasonic welding apparatus includes a guide assembly for guiding the membrane material 4 around the base roller 1. In other words, referring to... Figure 2 and Figure 3 The membrane material 4 has a wrap-around angle on the base roller 1, and the membrane material 4 welded by the ultrasonic welding head 2 is located within the wrap-around angle. Since the membrane material 4 and the base roller 1 are pre-bonded together within the wrap-around angle, this part of the membrane material 4 does not need to undergo large deformation (e.g., bending deformation) during the process of the welding wheel 201 pressing against the base roller 1 and the welding wheel 201 rolling along the base roller 1. This makes it less likely for the membrane material 4 to generate indentations during the welding process, thus improving the welding quality of the membrane material 4.

[0055] For example, in some embodiments, the guiding assembly includes a rotatable first guide roller 301 and a second guide roller 302, the first guide roller 301 and the second guide roller 302 being disposed on the side of the base roller 1 away from the ultrasonic welding head 2, and the first guide roller 301, the base roller 1 and the second guide roller 302 being arranged sequentially along the conveying direction of the membrane material 4.

[0056] The first guide roller 301 and the second guide roller 302 are adapted to guide the film material 4 provided in the form of a strip. The first guide roller 301 and the second guide roller 302 can rotate as the film material 4 is conveyed, so as to avoid the first guide roller 301 and the second guide roller 302 applying tangential force to the film material 4, which would cause damage to the film material 4.

[0057] Furthermore, in some embodiments, the second guide roller 302 is an active roller, that is, after welding is completed, the membrane material 4 is conveyed forward under the traction of the second guide roller 302. At the same time, the force of the second guide roller 302 makes the membrane material 4 between the base roller 1 and the second guide roller 302 tensile, thereby maintaining the tension of the membrane material 4 after welding and avoiding the appearance of micro bubbles or other defects between adjacent membrane materials 4 after welding.

[0058] Specific reference Figure 1 and Figure 2 The guiding assembly includes two second guide rollers 302, with the membrane material 4 sandwiched between them. The two second guide rollers 302 rotate in opposite directions at the same speed, thereby conveying the membrane material 4 downstream. The design of using two second guide rollers 302 can apply force evenly to the membrane material 4 from both sides, avoiding defects such as slippage, misalignment, and tearing of the multilayer membrane material 4 due to uneven force distribution.

[0059] Correspondingly, the first guide roller 301 and the base roller 1 can be configured as driven rollers, thereby avoiding the occurrence of wrinkles or tears in the membrane material 4 during the conveying process due to asynchronous speeds among multiple driving rollers.

[0060] Obviously, for membrane material 4 provided by other means, the guide assembly can adopt a design different from that of the first guide roller 301 and the second guide roller 302.

[0061] For example, in some embodiments not shown, the membrane material 4 is provided in a long strip shape. In this case, the guide assembly can be designed as clamps. Two sets of clamps are arranged on the side of the base roller 1 away from the ultrasonic welding head 2 and clamp the two ends of the membrane material 4 respectively, so that the membrane material 4 bends and wraps around the base roller 1.

[0062] Reference Figure 3 In some embodiments, the surface of the base roller 1 is provided with a first protrusion 101, and the surface of the groove 2011 is provided with a second protrusion 2012. The first protrusion 101 and the second protrusion 2012 are used to fix the membrane material 4 during welding. The first protrusion 101 helps the base roller 1 to fix the membrane material 4, and the second protrusion 2012 helps the welding wheel 201 to fix the membrane material 4 so as to perform ultrasonic welding on the membrane material 4.

[0063] The welding equipment provided according to the embodiments of this utility model includes the ultrasonic welding device of this utility model, and thus also has the beneficial effects brought by the ultrasonic welding device, which will not be described in detail here.

[0064] In addition, welding equipment may include unwinding rolls and rewinding rolls, thereby making the welding equipment suitable for welding coils.

[0065] Taking the welding of two layers of membrane material 4 as an example, this paper introduces the ultrasonic welding device and the operation process of the welding equipment of this invention. Of course, this invention is also applicable to the ultrasonic welding of membrane materials 4 with more layers, which will not be elaborated here.

[0066] First, the two layers of film material 4 to be welded are placed on two unwinding rollers in the form of material rolls. The head of the material roll passes through an ultrasonic welding device and is received by a take-up roller.

[0067] During the welding process, the unwinding roller and the second guide roller 302, among other active rollers, propel the membrane material 4 forward by one step (i.e., the length of one welding operation) before stopping. At this point, all membrane materials 4 are stationary, remaining in place with a fixed tension.

[0068] Next, the ultrasonic welding head 2 presses down on one side of the base roller 1. Once the required pressure is reached, the ultrasonic waves are activated (or the ultrasonic vibration can remain on continuously). The ultrasonic welding head 2 rolls and welds from one end to the other on the upper surface of the base roller 1. Because the concave curvature of the ultrasonic welding head 2 matches the surface curvature of the base roller 1, and the membrane material 4 is wrapped around the base roller 1, no indentations or damage to the membrane material 4 will be generated on its surface. During the rolling welding process, the pressure and external factors faced by all welding areas are consistent, ensuring uniform welding.

[0069] After this step is completed, the ultrasonic welding head 2 is lifted at the other end, ready for the next welding operation.

[0070] The driving roller starts to rotate and moves forward one step to begin the next welding. During this process, the driven rollers, such as the base roller 1, rotate in the same direction as the membrane material 4, so their surfaces will not cause lateral scratches to the membrane material 4.

[0071] Although embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. An ultrasonic welding apparatus, characterized in that, include: Base roller (1), the base roller (1) is used to support the membrane material (4); An ultrasonic welding head (2) includes a welding wheel (201), the axis of which is not parallel to the axis of the base roller (1), and the welding wheel (201) is capable of rolling along the base roller (1). The welding wheel (201) includes a groove (2011) which is arranged around the outer periphery of the welding wheel (201). The shape of the groove (2011) matches the shape of the base roller (1). The groove (2011) is used to press the film material (4) against the base roller (1).

2. The ultrasonic welding apparatus according to claim 1, characterized in that, The axis of the welding wheel (201) is perpendicular to and out of plane with the axis of the base roller (1).

3. The ultrasonic welding apparatus according to claim 2, characterized in that, The groove (2011) forms a ring that is connected end to end.

4. The ultrasonic welding apparatus according to any one of claims 1 to 3, characterized in that, The ultrasonic welding head (2) also includes a rotating shaft (202), and the welding wheel (201) is disposed on the rotating shaft (202). The axis of the welding wheel (201) and the axis of the rotating shaft (202) are collinear.

5. The ultrasonic welding apparatus according to claim 1, characterized in that, The base roller (1) is rotatable.

6. The ultrasonic welding apparatus according to claim 5, characterized in that, The ultrasonic welding device includes a guide assembly for wrapping the membrane material (4) to be welded around the base roller (1).

7. The ultrasonic welding apparatus according to claim 6, characterized in that, The guiding assembly includes a rotatable first guide roller (301) and a second guide roller (302). The first guide roller (301) and the second guide roller (302) are disposed on the side of the base roller (1) away from the ultrasonic welding head (2). Along the conveying direction of the membrane material (4), the first guide roller (301), the base roller (1), and the second guide roller (302) are arranged in sequence.

8. The ultrasonic welding apparatus according to claim 7, characterized in that, The second guide roller (302) is an active roller.

9. The ultrasonic welding apparatus according to claim 1, characterized in that, The surface of the base roller (1) is provided with a first protrusion (101), and the surface of the groove (2011) is provided with a second protrusion (2012). The first protrusion (101) and the second protrusion (2012) are used to fix the film material (4) during welding.

10. A welding device, characterized in that, The ultrasonic welding apparatus includes any one of claims 1 to 9.

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