Ultrasonic horn and welding device having the same

Abstract

The utility model discloses an ultrasonic wave welding head and welding device with it relates to ultrasonic wave welding equipment field. The ultrasonic wave welding head includes: swing bar and work part, swing bar is along the first direction extension setting, work part one end connects swing bar, and the other end end surface of work part is the welding end surface, and the welding end surface is used for with the contact of the work piece to be welded, wherein, the size of work part along the second direction is the width of work part, and the width of work part gradually increases in the direction to the welding end surface, and the second direction is perpendicular with the first direction. According to the ultrasonic wave welding head of the utility model embodiment, the welding area is increased, and the amplitude consistency of welding end surface output is high, which helps to improve the welding quality and efficiency.

Description

Technical Field

[0001] This utility model relates to the field of ultrasonic welding equipment, and more particularly to an ultrasonic welding head and a welding device having the same. Background Technology

[0002] With the development of battery technology, the demand for fast charging has driven the continuous increase in the welding area of ​​the electrode tabs, and the number of foil layers has also increased accordingly. However, some existing ultrasonic welding heads are unable to meet the requirements of welding large-print current collectors, and have problems such as small welding area and uneven amplitude distribution, which restricts the further improvement of battery manufacturing process.

[0003] Therefore, there is room for improvement in ultrasonic welding heads. Utility Model Content

[0004] The present invention aims to at least solve one of the technical problems existing in the prior art. Therefore, the first aspect of the present invention aims to provide an ultrasonic welding head that increases the welding area and simultaneously provides high amplitude consistency of the output from the welding end face, thereby helping to improve welding quality and efficiency.

[0005] The second aspect of this utility model aims to provide a welding device having the above-mentioned ultrasonic welding head.

[0006] An ultrasonic welding head according to a first aspect embodiment of the present invention includes: a swing arm and a working part, the swing arm extending along a first direction; one end of the working part is connected to the swing arm, and the other end face of the working part is a welding end face, the welding end face being used to contact the workpiece to be welded; wherein, the dimension of the working part along a second direction is the width of the working part, the width of the working part gradually increases in the direction toward the welding end face, and the second direction is perpendicular to the first direction.

[0007] According to the embodiments of the present invention, the ultrasonic welding head, by having a working part whose width gradually increases in the direction towards the welding end face, increases the area of ​​the welding end face accordingly, thereby achieving a larger welding coverage area, suitable for welding needs such as large weld stamp current collectors. Simultaneously, this expanded working part structure helps improve the distribution of ultrasonic vibration energy on the welding end face, enhances the consistency of output amplitude, makes the welding more uniform and stable, and thus significantly improves welding strength and welding quality.

[0008] According to some optional embodiments of the present invention, the working part has a dimension along a third direction equal to the thickness of the working part, and the thickness of the working part gradually increases in the direction toward the welding end face. The third direction is perpendicular to both the first direction and the second direction.

[0009] Alternatively, the working part may be provided with a reduction hole.

[0010] In some optional embodiments, the reduced hole is a blind hole or a through hole extending along a third direction, which is perpendicular to both the first direction and the second direction.

[0011] Alternatively, the number of holes is at least two, and they are arranged at intervals along the second direction.

[0012] In some specific embodiments, the working part has two first side surfaces arranged along the second direction; the extension direction of the reducing hole adjacent to the first side surface is parallel to the first side surface.

[0013] According to some optional embodiments of the present invention, the ultrasonic welding head has at least one of a protrusion, a groove, or a tooth pattern on the welding end face.

[0014] Optionally, the ultrasonic welding head further includes: an acoustic rod, one end of which is connected to the swing arm, the acoustic rod serving as an ultrasonic sound source; and a clamping block connected to the end of the swing arm away from the working part.

[0015] According to some optional embodiments, the swing arm includes: a first segment connected between the acoustic rod and the clamping block; and a second segment connected between the acoustic rod and the working part; wherein the first segment and the second segment are both connected to the acoustic rod via an arc transition.

[0016] A welding apparatus according to a second aspect of the present invention includes an ultrasonic welding head according to a first aspect of the present invention.

[0017] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0018] The above and / or additional aspects and advantages of this utility model will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0019] Figure 1 This is a schematic diagram of the structure of an ultrasonic welding head in some embodiments of the present invention;

[0020] Figure 2 This is another structural schematic diagram of the ultrasonic welding head in some embodiments of this utility model;

[0021] Figure 3 This is a front view of the ultrasonic welding head in some embodiments of this utility model;

[0022] Figure 4 This is a side view of the ultrasonic welding head in some embodiments of the present invention;

[0023] Figure 5 for Figure 1 A magnified view of a portion of point A in the middle;

[0024] Figure 6 for Figure 2 A magnified view of a portion of point B in the middle;

[0025] Figure 7 for Figure 4 A magnified view of a portion of point C.

[0026] Figure label:

[0027] 100 ultrasonic welding head

[0028] Pendulum 10, First segment 12, Second segment 14

[0029] Working part 30, welding end face 31, reduced hole 32, first side surface 33

[0030] Acoustic rod 50

[0031] Clamping block 70. Detailed Implementation

[0032] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.

[0033] In the description of this utility model, it should be understood that the terms "length," "width," "thickness," "upper," and "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, features defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more.

[0034] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0035] The following is for reference. Figures 1-7 Description of an ultrasonic welding head 100 according to a first aspect embodiment of the present invention.

[0036] like Figure 1 and Figure 2 As shown, the ultrasonic welding head 100 according to an embodiment of the present invention includes: a swing arm 10 and a working part 30.

[0037] The swing arm 10 extends along a first direction. The swing arm 10 extends along the first direction to provide structural support for the entire welding head and is responsible for transmitting ultrasonic vibrations from the generator to the working part 30.

[0038] One end of the working part 30 is connected to the swing arm 10, and the other end face of the working part 30 is a welding end face 31, which is used to contact the workpiece to be welded. The dimension of the working part 30 along the second direction is the width of the working part 30, and the width of the working part 30 gradually increases in the direction toward the welding end face 31. The second direction is perpendicular to the first direction.

[0039] First, this configuration increases the area of ​​the welding end face 31.

[0040] Specifically, the working section 30, in its width along the second direction (perpendicular to the first direction where the rocker arm 10 is located), gradually increases in the direction toward the welding end face 31, thereby expanding the area of ​​the entire welding end face 31. This enlarged welding end face 31 can cover a larger welding area in one go, which not only greatly improves welding efficiency but is also particularly suitable for large-area welding tasks such as welding large-diameter current collectors. When using this welding head with a larger welding end face 31, areas that would otherwise require multiple small-area welds can be covered in one operation. This method avoids the problems of weld discontinuity or uneven stress distribution that may be caused by multiple positioning and welding operations, thus improving the overall welding quality. Furthermore, covering the welding area in one go helps maintain the consistency of internal stress in the weld, reducing the risk of weld cracking due to localized stress concentration, further enhancing the stability and reliability of the welded structure.

[0041] Secondly, please combine Figures 1-3The width of the working section 30 gradually increases in the direction towards the welding end face 31. This progressively widening working section 30 allows for a more uniform energy distribution over a larger welding area. Traditional welding heads, due to structural limitations, often struggle to ensure amplitude consistency across the entire welding area when welding large areas, potentially leading to localized poor welding or over-welding. However, as the width of the working section 30 gradually increases, the expanded shape more effectively transmits and distributes vibrational energy, resulting in a more uniform amplitude across the welding end face 31. This not only further improves the welding effect but also reduces the risk of product defects caused by uneven energy distribution, thereby improving welding quality and achieving more stable welding results.

[0042] In summary, the ultrasonic welding head 100 of this utility model improves welding efficiency by increasing the area of ​​the welding end face 31, making it more suitable for large-area welding tasks; at the same time, its expansion shape helps to uniformly output amplitude and improve welding quality, thereby achieving efficient and stable ultrasonic welding effect.

[0043] According to some optional embodiments of the present invention, such as Figures 4-7 As shown, the dimension of the working part 30 along the third direction is the thickness of the working part 30. The thickness of the working part 30 gradually increases in the direction toward the welding end face 31. The third direction is perpendicular to both the first direction and the second direction.

[0044] This configuration further increases the area of ​​the welding end face 31, improving welding efficiency.

[0045] Secondly, with the increased thickness of the working section 30, the structural rigidity of the ultrasonic welding head 100 is enhanced, which helps to transmit ultrasonic vibrations to the welding zone more efficiently, reduces energy loss, and ensures that greater welding force can be uniformly applied to the surface of the workpiece to be welded. Furthermore, the thickened design also improves the overall durability and fatigue resistance of the welding head, making it more able to withstand long-term, high-intensity use. This improves the stability of the ultrasonic welding head 100, making it particularly suitable for applications requiring high welding strength and durability.

[0046] In some alternative embodiments, such as Figures 1-3 , Figures 5-6 As shown, the working part 30 is provided with a reduction hole 32.

[0047] The reduced hole 32 can effectively reduce the vibration mass of the welding head during operation. By removing unnecessary material, the weight of the welding head is reduced, thereby improving the vibration transmission efficiency and allowing ultrasonic energy to be more concentrated on the welding area, thus improving the welding effect.

[0048] Furthermore, the reduced aperture 32 helps optimize the resonant frequency of the welding head, making it more precisely matched to the operating frequency of the ultrasonic generator. It's important to understand that when the welding head's resonant frequency matches the ultrasonic generator's operating frequency, energy loss is minimized, and ultrasonic energy can be more effectively transferred to the material being welded, improving welding efficiency and quality.

[0049] When the resonant frequencies of the ultrasonic generator and the welding head are matched, not only is the energy conversion efficiency improved, but the stability of the entire welding process is also enhanced. This means that more consistent and reliable welding results can be obtained when using the equipment for extended periods or performing repetitive welding tasks.

[0050] Furthermore, the ultrasonic welding head 100 generates a lot of heat during the welding process. The reduction hole 32 helps to dissipate heat and cool down the welding head, thereby ensuring welding stability.

[0051] Optionally, the number and position of the reducing holes 32 are highly flexible and can be set according to actual usage requirements. By controlling the position and number of the reducing holes 32, they can be more accurately matched to the operating frequency of the ultrasonic generator, improving energy conversion efficiency and welding quality. Furthermore, the number of reducing holes 32 can be determined based on acoustic simulation calculations, and they can be set above the position where the amplitude output on the weld end face is relatively weak (i.e., the 1 / 4 wavelength or 3 / 4 wavelength position).

[0052] Specifically, the attenuation aperture 32 can be positioned at 1 / 4 wavelength or 3 / 4 wavelength. This position represents the minimum amplitude output area, and placing the attenuation aperture 32 at this position helps maintain the resonant characteristics of the ultrasonic vibration. By creating the attenuation aperture 32 at a position where the amplitude output is weaker, the mass of the propagation medium can be reduced without compromising structural strength, thereby increasing the output amplitude gain and improving the uniformity of the amplitude distribution across the entire weld end face and the overall output efficiency.

[0053] Optionally, in some specific embodiments, such as Figure 1 , Figure 3 and Figure 5 As shown, the shape of the reducing hole 32 can be elongated. Or, as... Figure 2 and Figure 6 As shown, the shape of the reducing hole 32 can be rhomboid or the like.

[0054] Furthermore, the reduced hole 32 is a blind hole, or a through hole extending along a third direction, which is perpendicular to both the first and second directions.

[0055] When the reduction hole 32 is constructed as a blind hole, it does not penetrate the entire working part 30, but only forms a recess on one side. This design effectively reduces the weight of the ultrasonic welding head 100 without affecting its overall strength, thereby optimizing the resonant frequency, improving energy conversion efficiency, and ultimately enhancing welding efficiency and quality. Constructing it as a blind hole helps maintain the integrity and rigidity of the welding end face 31. Furthermore, the blind hole reduces stress concentration within the material, extending the service life of the welding head by dispersing stress points.

[0056] When the reducing hole 32 is constructed as a through hole extending along a third direction, a completely penetrating hole will be formed on the ultrasonic welding head 100. This configuration can significantly reduce the weight of the ultrasonic welding head 100 and allow for greater adjustment of the resonant frequency of the ultrasonic welding head 100, enabling it to better match the operating frequency of the ultrasonic generator and achieve better energy transfer. By setting the through hole, the ultrasonic energy distribution can be made more uniform, improving welding quality and consistency.

[0057] Furthermore, there are at least two holes 32, which are spaced apart along the second direction.

[0058] The multiple reduction holes 32 effectively reduce the weight of the ultrasonic welding head 100, facilitating more precise adjustment of the resonant frequency and ensuring a better match between the ultrasonic welding head 100 and the operating frequency of the ultrasonic generator, thereby improving energy conversion efficiency. Furthermore, the multiple reduction holes 32 also help improve the vibration mode, allowing ultrasonic energy to be distributed more evenly across the welding area, thus enhancing welding quality and consistency.

[0059] Further, optionally, combined Figure 5 and Figure 6 The working part 30 has two first side surfaces 33, which are arranged along a second direction; the extension direction of the reducing hole 32 adjacent to the first side surface 33 is parallel to the first side surface 33.

[0060] First, this layout helps maintain the symmetry and balance of the working section 30 on both sides along the second direction. Since the reducing hole 32 extends parallel to the first side 33, it ensures that the welding head maintains good symmetry during vibration. This symmetry effectively reduces unnecessary lateral vibration or displacement, allowing ultrasonic energy to be applied more concentratedly and efficiently to the welding area.

[0061] Secondly, the arrangement of the reducing holes 32 parallel to the first side 33 helps to distribute stress evenly, avoid the occurrence of local stress concentration, thereby extending the service life of the welding head and reducing the risk of welding head damage caused by stress concentration.

[0062] According to some optional embodiments of the present invention, the welding end face 31 is provided with at least one of the following: protrusion, groove, and tooth pattern.

[0063] Here, the protrusions can concentrate pressure on specific points during welding, which helps to penetrate the surface oxide layer or contaminants, ensuring more direct energy transfer to the material being welded and improving weld strength. Optionally, the cross-sectional shape of the protrusions is very flexible. It can be a regular or irregular shape such as a triangle, quadrilateral, or circle. Specific settings can be made according to actual needs, and this application does not impose any restrictions.

[0064] The groove can accommodate excess material or spillage generated during the welding process, preventing it from spreading and affecting the welding quality. It also helps to control the temperature distribution within the welding area and reduce the heat-affected zone.

[0065] The serrated structure helps provide more mechanical interlocking points to enhance the strength and sealing of the weld joint. The serrations also help align the workpieces to be welded in the early stages of welding, ensuring precise welding positioning.

[0066] These protrusions, grooves, and serrations can be selected and combined according to specific welding needs, enabling the welding head to handle welding tasks of different materials and shapes more flexibly and efficiently, thereby improving the application range and flexibility of ultrasonic welding technology.

[0067] Based on some optional embodiments of this utility model, please refer to... Figure 1 , Figure 2 and Figure 4 As shown, the ultrasonic welding head 100 also includes an acoustic rod 50 and a clamping block 70. One end of the acoustic rod 50 is connected to the swing arm 10, and the acoustic rod 50 serves as an ultrasonic sound source. The clamping block 70 is connected to the end of the swing arm 10 away from the working part 30.

[0068] The acoustic rod 50 serves as the transmission medium for ultrasonic waves, efficiently transmitting the vibrations generated by the ultrasonic generator to the swing arm 10, and then to the working part 30 for welding operations. This design ensures efficient transmission and concentrated application of ultrasonic energy. The clamping block 70 is connected to the end of the swing arm 10 furthest from the working part 30, used to securely fix the entire welding head assembly, facilitating installation and adjustment, and ensuring the stability and accuracy of the ultrasonic welding head 100 during operation, thereby improving welding efficiency and quality.

[0069] Further optional, see Figures 1-4 The swing arm 10 includes a first segment 12 and a second segment 14. The first segment 12 is connected between the acoustic rod 50 and the clamping block 70. The second segment 14 is connected between the acoustic rod 50 and the working part 30. Both the first segment 12 and the second segment 14 are connected to the acoustic rod 50 by an arc transition.

[0070] In the above technical solution, the first rod segment 12 is connected between the acoustic rod 50 and the clamping block 70, mainly responsible for stabilizing the entire structure and ensuring that the ultrasonic waves can be transmitted efficiently and stably from the acoustic rod 50 to the swing rod 10; the second rod segment 14 is located between the acoustic rod 50 and the working part 30, and is responsible for accurately transmitting the ultrasonic vibrations to the working part 30 to complete the welding task.

[0071] The first segment 12, the second segment 14, and the acoustic rod 50 are all connected by a circular arc transition. This circular arc transition structure not only enhances the smoothness of the overall structure and reduces stress concentration points, but also helps to improve the smoothness of the ultrasonic transmission path and reduce energy loss.

[0072] In addition, the arc transition connection method can absorb and disperse the reverse impact force generated during the welding process to a certain extent, thus extending the service life of the welding head.

[0073] This design allows the ultrasonic welding head 100 to maintain high strength and stability while improving operational flexibility and adaptability.

[0074] The welding apparatus according to a second aspect of the present invention includes the ultrasonic welding head 100 in the first aspect of the present invention.

[0075] By utilizing the improved ultrasonic welding head 100, the welding device achieves more efficient energy transfer and a more uniform amplitude distribution, thereby improving welding efficiency and quality. This welding device not only expands the welding area but also ensures the consistency and stability of the weld.

[0076] The following is for reference. Figure 1 , Figures 3-5 and Figure 7 The ultrasonic welding head 100 according to a specific embodiment of the present invention is described in detail below. It is to be understood that the following description is merely illustrative and not intended to limit the scope of the invention.

[0077] Reference Figure 1 The ultrasonic welding head 100 includes: a swing arm 10, a working part 30, an acoustic rod 50, and a clamping block 70.

[0078] One end of the acoustic rod 50 is connected to the swing arm 10, and the acoustic rod 50 is used as an ultrasonic sound source.

[0079] The swing arm 10 is set to extend along the first direction.

[0080] Reference Figures 3-4 The pendulum 10 includes: a first segment 12 and a second segment 14.

[0081] The first rod segment 12 connects the acoustic rod 50 and the clamping block 70. The second rod segment 14 connects the acoustic rod 50 and the working part 30. Both the first rod segment 12 and the second rod segment 14 are connected to the acoustic rod 50 via an arc transition.

[0082] One end of the working part 30 is connected to the swing arm 10, and the other end face of the working part 30 is a welding end face 31, which is used to contact the workpiece to be welded. The clamping block 70 is connected to the end of the swing arm 10 away from the working part 30.

[0083] The dimension of the working part 30 along the second direction is the width of the working part 30. The width of the working part 30 gradually increases in the direction toward the welding end face 31. The second direction is perpendicular to the first direction.

[0084] Reference Figure 7 The dimension of the working part 30 along the third direction is the thickness of the working part 30. The thickness of the working part 30 gradually increases in the direction toward the welding end face 31. The third direction is perpendicular to both the first direction and the second direction.

[0085] Reference Figure 5 The working part 30 is provided with a reducing hole 32. The reducing hole 32 is a through hole that extends along a third direction, and the third direction is perpendicular to both the first direction and the second direction.

[0086] There are at least two holes 32, which are spaced apart along the second direction.

[0087] Reference Figure 5 and Figure 7 The working part 30 has two first side surfaces 33, which are arranged along a second direction.

[0088] The extension direction of the reducing hole 32 adjacent to the first side surface 33 is parallel to the first side surface 33.

[0089] Other components of the ultrasonic welding head 100 according to the embodiments of the present invention, such as the welding device and its operation, are known to those skilled in the art and will not be described in detail here.

[0090] In this specification, the terms "embodiment," "example," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0091] Although embodiments of the present invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the claims and their equivalents.

Claims

1. An ultrasonic welding head, characterized in that, include: A swing arm, which extends along a first direction; The working part has one end connected to the swing arm and the other end face of the working part is a welding end face, which is used to contact the workpiece to be welded; The dimension of the working part along the second direction is the width of the working part, and the width of the working part gradually increases in the direction toward the welding end face. The second direction is perpendicular to the first direction.

2. The ultrasonic welding head according to claim 1, characterized in that, The dimension of the working part along the third direction is the thickness of the working part. The thickness of the working part gradually increases in the direction toward the welding end face. The third direction is perpendicular to both the first direction and the second direction.

3. The ultrasonic welding head according to claim 1, characterized in that, The working part is provided with a reduction hole.

4. The ultrasonic welding head according to claim 3, characterized in that, The reduced hole is either a blind hole or a through hole extending along a third direction, which is perpendicular to both the first direction and the second direction.

5. The ultrasonic welding head according to claim 3, characterized in that, The number of holes is at least two, and they are arranged at intervals along the second direction.

6. The ultrasonic welding head according to claim 5, characterized in that, The working part has two first sides, which are arranged along the second direction; The extension direction of the reduction hole adjacent to the first side is parallel to the first side.

7. The ultrasonic welding head according to claim 1, characterized in that, The welding end face is provided with at least one of the following: protrusion, groove, or tooth pattern.

8. The ultrasonic welding head according to any one of claims 1-7, characterized in that, Also includes: An acoustic rod, one end of which is connected to the swing arm, is used as an ultrasonic sound source; A clamping block is attached to the end of the swing arm that is away from the working part.

9. The ultrasonic welding head according to claim 8, characterized in that, The swing arm includes: A first segment, the first segment being connected between the acoustic rod and the clamping block; The second rod segment connects the acoustic rod and the working part; The first rod segment and the second rod segment are both connected to the acoustic rod via an arc transition.

10. A welding apparatus, characterized in that, Includes the ultrasonic welding head according to any one of claims 1-9.

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