Tab welding device

Abstract

Provided is a tab ultrasonic welding method. The tab ultrasonic welding method includes the steps of: sequentially unwinding a first foil material (11), a composite foil material (12), and a second foil material (13) to sequentially laminate the first foil material (11), the composite foil material (12), and the second foil material (13) to form an intermediate body of a laminated foil material; adopting an ultrasonic welding method to weld the first foil material (11) and the second foil material (13) to opposite surfaces of the composite foil material (12) respectively to obtain a laminated foil material (1); laminating the laminated foil material (1) to a set number of layers n (n is 1 or more) to form a laminate (21); and adopting an ultrasonic welding method to weld the laminate (21) and a tab (22) to form a tab assembly (2). First, the first foil material (11), the composite foil material (12), and the second foil material (13) are sequentially laminated. During welding, energy is directly applied to the first foil material (11) and the second foil material (13) by ultrasonic welding, and the energy generated by the direct contact of the ultrasonic welding with the composite foil material (12) can be reduced, effectively avoiding problems such as over-welding, through-welding, and temporary welding in the welding process and ensuring the welding effect.

Description

Cross-reference to Related Applications

[0001] This application claims the priority of a Chinese patent application with the application number 202210268293.6 and the title "Tab Ultrasonic Welding Method" filed on March 18, 2022, claims the priority of a Chinese patent application with the application number 202210268416.6 and the title "Tab Welding Device" filed on March 18, 2022, claims the priority of an international patent application with the application number PCT / CN2022 / 094895 and the title "Tab Ultrasonic Welding Method" filed on May 25, 2022, and claims the priority of an international patent application with the application number PCT / CN2022 / 094907 and the title "Tab Welding Device" filed on May 25, 2022, the entire contents of which are incorporated herein by reference.

Technical Field

[0002] The present invention relates to the field of battery processing technology, and in particular, to a tab ultrasonic welding method and a tab welding device.

Background Art

[0003] In the process of tab welding with lithium-ion battery electrode foil materials, the conventional welding methods adopt laser welding and ultrasonic welding. Laser welding is a high-efficiency precision welding method that uses a laser beam with a high energy density as a heat source. The welding process is a heat conduction type, that is, the surface of the material is heated by laser radiation, and the heat on the surface diffuses into the interior by heat conduction. By controlling parameters such as the width, energy, peak power, and repetition frequency of the laser pulse, the material is melted to form a specific molten pool. Ultrasonic welding converts the current of 50 / 60 Hz into electrical energy of 15, 20, 30, or 40 KHz by an ultrasonic generator. The converted high-frequency electrical energy is converted back into mechanical motion of the same frequency by a transducer, and then the mechanical motion is transmitted to the welding head by a set of horn devices that can change the amplitude. The welding head transmits the received vibration energy to the joint of the workpiece to be welded. In this area, the vibration energy is converted into heat energy in a friction manner to melt the plastic and form a welding area.

[0004] Existing battery electrode foil materials generally adopt composite foil materials. The structure of the composite foil material is successively a lower layer, an intermediate layer, and an upper layer. Both the lower layer and the upper layer adopt foil materials, and the intermediate layer adopts a plastic film. Since the strength of the plastic film is low, and the lower layer and the upper layer are only 2 μm to 3 μm, their own ductility and tensile strength are too high, and the absorption performance is not strong. When using the above two welding methods, it is easy to cause over-welding and through-welding, and when the power is too small, it is easy to cause problems such as temporary welding. Summary of the Invention Problems to be Solved by the Invention

[0005] Based on this, it is necessary to provide a tab ultrasonic welding method and a tab welding device that can effectively avoid the problems of over-welding, through-welding, and temporary welding in the welding process, ensure the welding effect, and ensure the conductivity. Means for Solving the Problems

[0006] The tab ultrasonic welding method includes: Step (1) of sequentially unwinding a first foil material, a composite foil material, and a second foil material to sequentially laminate the first foil material, the composite foil material, and the second foil material to form an intermediate body of a laminated foil material; Step (2) of adopting an ultrasonic welding method to weld the first foil material and the second foil material to opposite surfaces of the composite foil material respectively to obtain a laminated foil material; Step (3) of laminating the laminated foil material to a set number of layers n or more to form a laminate; Step (4) of adopting an ultrasonic welding method to weld the laminate and a tab to form a tab assembly.

[0007] In one embodiment, the method further includes, between step (1) and step (2), pressing the intermediate body of the laminated foil material.

[0008] In one embodiment, the conditions of the ultrasonic welding in step (2) are as follows: The welding pressure is 0.2 to 0.5 Mpa, The welding frequency is 20 to 50 Khz, and the welding speed is 10 to 15 r / min, and one or more of them are selected.

[0009] In one embodiment, the conditions of the ultrasonic welding in step (4) are as follows: The welding pressure is 0.2 to 0.5 Mpa, The welding frequency is 30 to 40 Khz, and the welding time is 0.3 to 0.5 s, and one or more of them are selected.

[0010] In one embodiment, in step (2), the first foil material and the second foil material are welded to opposite sides of the composite foil material respectively by adopting a continuous welding method.

[0011] In one embodiment, the thicknesses of the first foil material and the second foil material are 10 to 15 μm, and the thickness of the composite foil material is 5 to 8 μm.

[0012] In one embodiment, step (4) further includes: determining the area of the first ultrasonic welding head according to the area of the welding region where the laminate and the tab are welded, and the area of the first ultrasonic welding head is larger than the area of the welding region where the laminate and the tab are welded.

[0013] In one embodiment, the first foil material and the second foil material are each independently selected from the group consisting of aluminum foil, copper foil, and tin foil.

[0014] In one embodiment, the tab ultrasonic welding method further includes measuring the welding tensile force of the tab assembly, and when the welding tensile force is 20 N or more, determining it as a qualified product.

[0015] In one embodiment, before step (4), further: When n is greater than 1, it includes the step (3a) of sequentially welding the n-layer laminated foil material by adopting an ultrasonic welding method.

[0016] In one embodiment, the conditions of the ultrasonic welding in step (3a) are the welding pressure is 0.2 to 0.5 Mpa, the welding frequency is 30 to 40 Khz, the welding time is one or more selected from 0.3 to 0.5 s.

[0017] In one embodiment, the set number of layers n is 15 to 40.

[0018] In one embodiment, n is equal to 1.

[0019] The tab welding device is a feeding mechanism including a first feeding assembly for feeding out a first foil material, a second feeding assembly for feeding out a second foil material, and a third feeding assembly for feeding out a composite foil material, wherein the first feeding assembly, the second feeding assembly and the third feeding assembly are used to sequentially laminate the first foil material, the composite foil material and the second foil material to form an intermediate body of the laminated foil material; a first welding mechanism for welding the first foil material and the second foil material to opposite surfaces of the composite foil material respectively; a second welding mechanism for welding the laminate to the tab to form a tab assembly, wherein the laminate is formed by laminating the laminated foil material to a set number of layers n or more.

[0020] In one embodiment, the tab welding device further includes a pressing mechanism, the pressing mechanism includes a first pressing roller and a second pressing roller installed oppositely, and the first pressing roller and the second pressing roller are used to cooperate with each other to press the intermediate body of the laminated foil material. The first welding mechanism is installed downstream of the pressing mechanism.

[0021] In one embodiment, a pressing channel for pressing the laminated foil material is formed between the first pressing roller and the second pressing roller, and the pressing mechanism further includes a pressing roller driving unit for driving the first pressing roller and the second pressing roller to rotate synchronously.

[0022] In one embodiment, the tab welding device further includes a pressure detection mechanism for detecting the welding pressure applied perpendicularly to the laminated foil material by the first welding mechanism.

[0023] In one embodiment, the tab welding device further includes a synchronization induction mechanism. The first unwinding assembly, the second unwinding assembly, and the third unwinding assembly each include an unwinding roller and an unwinding driving unit for driving the unwinding roller to rotate. The synchronization induction mechanism is used to induce whether the unwinding rollers of the first unwinding assembly, the second unwinding assembly, and the third unwinding assembly rotate synchronously.

[0024] In one embodiment, the tab welding device further includes a control module communicably connected to the synchronization induction mechanism and the pressure detection mechanism, and controllably connected to the unwinding driving unit and the first welding mechanism.

[0025] In one embodiment, the first welding mechanism includes a driving seam welding head, a driven seam welding part, and a welding head driving unit for driving the driving seam welding head to rotate. The driving seam welding head and the driven seam welding part are arranged to face each other, and a first welding channel for welding the laminated foil material is formed between the driving seam welding head and the driven seam welding part.

[0026] In one embodiment, the first unwinding assembly and the second unwinding assembly are symmetrically installed. The third unwinding assembly is installed between the first unwinding assembly and the second unwinding assembly in a first direction. The third unwinding assembly has a gap from each of the first unwinding assembly and the second unwinding assembly in a second direction. The first direction intersects with the second direction.

[0027] In one embodiment, the tab welding device is installed corresponding to the second welding mechanism, and further includes a tab loading mechanism for transporting the tab to a tab welding station.

[0028] In one embodiment, the second welding mechanism includes a final welding head and a final welding driving part for driving the final welding head to move up and down. A second welding channel for welding the laminated foil material and the tab is formed between the final welding head and the tab loading mechanism.

[0029] In one embodiment, the tab welding device further includes a tab arrival detection mechanism for detecting whether the tab has reached the tab welding station. The tab arrival detection mechanism is communicably connected to the control module, and the control module is controllably connected to the final welding driving part.

[0030] In one embodiment, the tab welding device further includes a winding mechanism for winding the tab assembly welded by the second welding mechanism.

[0031] In one embodiment, the tab welding device further includes a cutting mechanism for cutting the laminated foil material welded by the first welding mechanism, a laminating mechanism for laminating the cut laminated foil material to a set number of layers n, and a third welding mechanism for sequentially welding the laminated foil material laminated to n layers by the laminating mechanism to form a laminate.

[0032] In one embodiment, the tab welding device further includes a first mounting table located below the cutting mechanism and a second mounting table located below the third welding mechanism. The first mounting table is used for mounting the cut laminated foil material. The laminating mechanism includes a suction element for sucking the laminated foil material on the first mounting table, and a suction element driving unit that drives the suction element to move so as to move the laminated foil material on the first mounting table to the second mounting table.

[0033] In one embodiment, the tab welding device further includes a scrap winding mechanism for winding up the scrap generated when the laminated foil material is cut by the cutting mechanism.

Advantages of the Invention

[0034] The tab ultrasonic welding method provided by the present invention first sequentially laminates a first foil material, a composite foil material, and a second foil material, and adopts an ultrasonic welding method for welding. During welding, energy is directly applied to the first foil material and the second foil material by ultrasonic welding. The first foil material and the second foil material play a role in protecting the composite foil material, and the energy generated by the direct contact of ultrasonic welding with the composite foil material can be reduced. The risk of the composite foil material being easily broken during the welding process can be reduced, and the problems of over-welding, through-welding, and temporary welding in the welding process can be effectively avoided. The welding effect of the first foil material, the composite foil material, and the second foil material can be ensured. Then, an ultrasonic welding method is adopted to weld the laminate and the tab, increasing the tab welding tensile strength, bringing the laminate and the tab into contact, and improving the conductivity.

Brief Description of the Drawings

[0035] The accompanying drawings that form a part of this application are provided to provide a further understanding of the present invention. The schematic embodiments and descriptions thereof of the present invention are for interpreting the present invention and do not unduly limit the present invention.

[0036] To more clearly explain the technical solution in the embodiment of the present invention, the drawings necessary for the description of the embodiment are briefly introduced below. However, the drawings in the following description are only a part of the embodiments of the present invention, and it is obvious that those skilled in the art can obtain other drawings based on these drawings without creative effort.

[0037]

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Mode for Carrying Out the Invention

[0038] To more clearly and easily understand the above objects, features, and advantages of the present invention, the following will describe in detail the specific embodiments of the present invention with reference to the accompanying drawings. In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention can be implemented in many different ways from those described in the present invention, and those skilled in the art can make similar improvements without departing from the content of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0039] In the description of the present invention, terms such as "center", "longitudinal direction", "lateral direction", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial direction", "radial direction", "circumferential direction", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for facilitating the description of the present invention and simplifying the description, and do not indicate or imply that the device or element mentioned must have a specific orientation and be constructed and operated in a specific orientation. Therefore, it should be understood that it should not be construed as limiting the present invention.

[0040] Furthermore, the terms "first" and "second" are for illustrative purposes only and should not be construed as indicating relative importance, suggesting, or implicitly indicating the number of technical features shown. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of those features. In the description of the present invention, "a plurality" means at least two, for example, two, three, etc., unless otherwise specified.

[0041] In the present invention, unless otherwise specifically stated and limited, terms such as "attachment", "connection", "connection", "fixation", etc. should be understood in a broad sense. For example, it may be a fixed connection, a removable connection, or an integral one, and may be a mechanical connection or an electrical connection. It may be directly connected or indirectly connected through an intermediate medium. Unless otherwise specified, it may also be the internal communication between two elements or the interaction relationship between two elements. Those skilled in the art can understand the specific meaning of the above terms in the present invention according to specific situations.

[0042] In the present invention, unless otherwise specifically stated and limited, the fact that the first feature is "above" or "below" the second feature may mean that the first and second features may be in direct contact, or the first and second features may be indirectly in contact through an intermediate medium. Furthermore, the fact that the first feature is "above", "upper", and "upper surface" of the second feature may mean that the first feature may be directly above or obliquely above the second feature, or may simply indicate that the horizontal height of the first feature is higher than the horizontal height of the second feature. The fact that the first feature is "below", "lower", and "lower surface" of the second feature may mean that the first feature may be directly below or obliquely below the second feature, or may simply indicate that the horizontal height of the first feature is lower than the horizontal height of the second feature.

[0043] In addition, when an element is "fixed" or "installed" to another element, it may be directly disposed on the other element, or there may be intermediate elements. When one element is considered to be "connected" to another element, it may be directly connected to the other element, or intermediate elements may be present at the same time. The terms "vertical", "horizontal", "upper", "lower", "left", "right" and similar expressions used in this specification are for illustrative purposes only and do not mean the only embodiment.

[0044] The first embodiment of the present invention provides a tab ultrasonic welding method and a tab welding apparatus capable of welding a first foil material 11, a composite foil material, a second foil material and a tab.

[0045] The composite foil material 12 includes a third foil material, a fourth foil material, and a plastic film layer disposed between the third foil material and the fourth foil material. The third foil material and the fourth foil material are each adhered to the plastic film layer. In other possible embodiments, the third foil material, the plastic film layer, and the fourth foil material are sequentially connected by thermal fusion. The thickness of the third foil material and the fourth foil material is 2 μm to 3 μm.

[0046] Referring to FIGS. 1, 2, and 3, the tab ultrasonic welding method includes: Step (1) of sequentially unwinding the first foil material 11, the composite foil material 12, and the second foil material 13 to sequentially laminate the first foil material 11, the composite foil material 12, and the second foil material 13 to form an intermediate body of the laminated foil material 1, wherein the first foil material 11 and the second foil material 13 are each independently selected from the group consisting of aluminum foil, copper foil, and tin foil; Step (2) of welding the first foil material 11 and the second foil material 13 to opposite sides of the composite foil material 12 respectively by adopting an ultrasonic welding method to obtain the laminated foil material 1; Step (3) of laminating the laminated foil material 1 to a set number of layers n (n is 1 or more) to form a laminate 21; Step (4) of welding the laminate 21 and the tab 22 by adopting an ultrasonic welding method to form a tab assembly 2.

[0047] Referring to FIG. 2, the first foil material 11, the composite foil material 12, and the second foil material 13 are welded by adopting an ultrasonic welding method. Ultrasonic welding utilizes high-frequency vibration waves to transmit them to the surfaces of two objects to be welded, and under pressure, the surfaces of the two objects are rubbed against each other to form molecular layer fusion. During welding, energy is directly applied to the first foil material 11 and the second foil material 13 by ultrasonic welding. The first foil material 11 and the second foil material 13 play a role in protecting the composite foil material 12, and the energy generated by the direct contact of ultrasonic welding with the composite foil material 12 can be reduced. The risk that the composite foil material 12 is easily broken during the welding process can be reduced, and problems such as over-welding, through-welding, and temporary welding in the welding process can be effectively avoided, ensuring the welding effect of the laminated foil material 1.

[0048] In step (1), the first foil material 11, the composite foil material 12, and the second foil material 13 are respectively wound around the unwinding rollers. By driving the unwinding rollers to rotate under the drive of the unwinding drive unit, sequential unwinding of the first foil material 11, the composite foil material 12, and the second foil material 13 can be realized. Here, the unwinding drive unit adopts a motor. Since the first foil material 11, the composite foil material 12, and the second foil material 13 are all thin materials, they do not have high strength and cannot withstand a large tearing force. When welding the first foil material 11, the composite foil material 12, and the second foil material 13, it is necessary to ensure the fixation of the relative positions. Otherwise, cracks will occur after welding, and in severe cases, cutting will occur and continuous production cannot be carried out. Therefore, before welding, the first foil material 11, the composite foil material 12, and the second foil material 13 are sequentially laminated, and the first foil material 11, the composite foil material 12, and the second foil material 13 are conveyed in the same direction. At the same time, by making the conveying speeds of the first foil material 11, the composite foil material 12, and the second foil material 13 consistent during transportation, the speed difference among the three is reduced, thereby ensuring the fixation of the relative positions of the first foil material 11, the composite foil material 12, and the second foil material 13, and further improving the welding quality of the first foil material 11, the composite foil material 12, and the second foil material 13.

[0049] Specifically, the first foil material 11, the composite foil material 12, and the second foil material 13 are all horizontally conveyed to a welding station that welds the first foil material 11 and the second foil material 13 to opposite sides of the composite foil material 12 respectively, thereby reducing the occurrence of creases and wrinkles during the conveyance of the first foil material 11, the composite foil material 12, and the second foil material 13, effectively ensuring flatness during welding, and further ensuring welding quality.

[0050] In order to realize that the first foil material 11, the composite foil material 12, and the second foil material 13 are all horizontally conveyed to the welding station, they are installed as follows. The unwinding rollers around which the first foil material 11 is wound and the unwinding rollers around which the second foil material 13 is wound are symmetrically installed. The unwinding roller around which the composite foil material 12 is wound is installed between the unwinding roller around which the first foil material 11 is wound and the unwinding roller around which the second foil material 13 is wound in the first direction, and has a gap from the unwinding roller around which the first foil material 11 is wound and the unwinding roller around which the second foil material 13 is wound respectively in the second direction. The first direction and the second direction intersect perpendicularly. The composite foil material 12 is installed parallel to the first foil material 11 and the second foil material 13 respectively, and the composite foil material 12 is located between the first foil material 11 and the second foil material 13. At the same time, the first foil material 11 and the second foil material 13 are symmetrically installed with respect to the composite foil material 12. When the first foil material 11 and the second foil material 13 are unwound respectively, the first foil material 11 and the second foil material 13 can enter the welding station through paths of the same length, reducing the tension difference between the first foil material 11 and the second foil material 13, and ensuring flatness when the first foil material 11, the composite foil material 12, and the second foil material 13 are laminated.

[0051] Referring to FIG. 2, in step (2), the first foil material 11 and the second foil material 13 are welded to opposite surfaces of the composite foil material 12 by adopting a continuous welding method. It should be noted that the first foil material 11, the composite foil material 12, and the second foil material 13 are welded during conveyance, and continuous weld marks are formed between the first foil material 11 and the composite foil material 12 and between the second foil material 13 and the composite foil material 12. There is no need to temporarily stop the first foil material 11, the composite foil material 12, and the second foil material 13 during conveyance, the welding time is greatly shortened, and the welding efficiency is improved.

[0052] In order to ensure the accuracy of the relative positions of the first foil material 11, the composite foil material 12, and the second foil material 13, between step (1) and step (2), by pressing the intermediate body of the laminated foil material 1 so that the distance between the first foil material 11, the composite foil material 12, and the second foil material 13 becomes smaller, the first foil material 11 and the second foil material 13 are each brought into close contact with the composite foil material 12, and the step of making relative displacement less likely to occur is further included. For example, before being pressed, the distance between each of the first foil material 11 and the second foil material 13 and the composite foil material 12 is 0.5 to 1 mm, and the distance between the first foil material 11, the second foil material 13, and the composite foil material 12 after being pressed is 0 to 0.2 mm.

[0053] The thicknesses of the first foil material 11 and the second foil material 13 can be selected between 10 and 15 μm, and the thickness of the composite foil material 12 can be selected between 5 and 8 μm. In this embodiment, the thicknesses of the first foil material 11 and the second foil material 13 are 12 μm, and the thickness of the composite foil material is 6 μm.

[0054] Referring to FIG. 2, in one embodiment, the welding of the first foil material 11, the composite foil material 12 and the second foil material 13 adopts an ultrasonic seam welding method, includes two seam welding heads 3, and the two seam welding heads 3 are respectively installed on the upper and lower sides of the laminated foil material 1 and are symmetrically installed with respect to the laminated foil material 1. When the first foil material 11 and the second foil material 13 are welded to the opposite two sides of the composite foil material 12 respectively by adopting the ultrasonic welding method, a welding area of 30 to 50 mm is secured in advance, the welding pressure of the ultrasonic welding is 0.2 to 0.5 Mpa, the welding frequency is 20 to 50 Khz, the welding speed is 10 to 15 r / min, the diameter of the ultrasonic welding head is about 100 mm, and the ultrasonic welding head is a circular welding head. For example, the ultrasonic welding head is in the shape of a circular roller.

[0055] Referring to FIG. 3, when the laminate 21 and the tab 22 are welded by adopting the ultrasonic welding method, the first ultrasonic welding head 5 is adopted, and the first ultrasonic welding head 5 may be of any shape. The first ultrasonic welding head 5 adopts a spur welding head. In this embodiment, the first ultrasonic welding head 5 is square. The welding pressure of the ultrasonic welding is 0.2 to 0.5 Mpa, the welding frequency is 30 to 40 Khz, and the welding time is 0.3 to 0.5 s. The laminate 21 and the tab 22 are welded by adopting the ultrasonic welding method to increase the welding tensile strength of the tab 22, and the laminate 21 and the tab 22 are brought into contact to ensure electrical conductivity. When the laminate 21 and the tab 22 are welded, the area of the first ultrasonic welding head 5 used for welding is determined according to the area of the welding region where the laminate 21 and the tab 22 are welded, and the area of the first ultrasonic welding head 5 is larger than the area of the welding region where the laminate 21 and the tab 22 are welded. It should be noted that the area of the first ultrasonic welding head 5 is linearly related to the area of the welding region where the laminate 21 and the tab 22 are welded.

[0056] After step (4) is completed, the welding tensile force of the tab assembly 2 is measured. When the welding tensile force is 20 N or more, it is determined as a qualified product that meets the welding requirements.

[0057] Referring to FIGS. 4, 5 and 6, an embodiment of the present invention relates to a tab welding apparatus 10 including a pay - out mechanism 100, a pressing mechanism 200, a first welding mechanism 300, a second welding mechanism 400 and a take - up mechanism 500. The pay - out mechanism 100 is used to pay out a first foil material 11, a second foil material 13 and a composite foil material 12. The first foil material 11, the composite foil material 12 and the second foil material 13 are sequentially laminated to form an intermediate body of a laminated foil material 1. The pressing mechanism 200 is used to press the intermediate body of the laminated foil material 1. The first welding mechanism 300 is used to weld the first foil material 11 and the second foil material 13 to opposite sides of the composite foil material 12 respectively. The second welding mechanism 400 is used to weld the laminate to a tab to form a tab assembly. Here, the laminate is formed by laminating the laminated foil material to a set number of layers n (n is 1 or more). The take - up mechanism 500 is used to take up the tab assembly welded by the second welding mechanism 400.

[0058] Referring to FIGS. 4 and 5, the unwinding mechanism 100 includes a first unwinding assembly 110 for unwinding the first foil material 11, a second unwinding assembly 120 for unwinding the second foil material 13, and a third unwinding assembly 130 for unwinding the composite foil material 12. The first unwinding assembly 110, the second unwinding assembly 120, and the third unwinding assembly 130 are used to sequentially laminate the first foil material 11, the composite foil material 12, and the second foil material 13 to form the laminated foil material 1. The first unwinding assembly 110, the second unwinding assembly 120, and the third unwinding assembly 130 all include an unwinding roller and an unwinding drive unit for driving the unwinding roller to rotate. The unwinding drive unit employs a motor. The first unwinding assembly 110 and the second unwinding assembly 120 are symmetrically installed. The third unwinding assembly 130 is installed between the first unwinding assembly 110 and the second unwinding assembly 120 in the first direction. The third unwinding assembly 130 has a gap from the first unwinding assembly 110 and the second unwinding assembly 120 respectively in the second direction, and the first direction and the second direction intersect perpendicularly. By installing in this way, it can be realized that the first foil material 11, the composite foil material 12, and the second foil material 13 are all conveyed in the horizontal direction, the phenomenon of creases and wrinkles during the conveyance of the first foil material 11, the composite foil material 12, and the second foil material 13 can be reduced, the flatness during welding can be effectively ensured, and further the welding quality can be ensured.

[0059] In addition, the composite foil material 12 is installed parallel to the first foil material 11 and the second foil material 13 respectively, and the composite foil material 12 is located between the first foil material 11 and the second foil material 13. At the same time, the first foil material 11 and the second foil material 13 are symmetrically installed with respect to the composite foil material 12. When the first foil material 11 and the second foil material 13 are unwound respectively, the first foil material 11 and the second foil material 13 can enter the welding station through the same-length path, and the tension difference between the first foil material 11 and the second foil material 13 can be reduced. The unwinding tension of the first unwinding assembly 110 and the second unwinding assembly 120 is 100 - 200 N, and the unwinding tension of the third unwinding assembly 130 is 100 - 200 N.

[0060] In this embodiment, the composite foil material 12 includes a third foil material, a fourth foil material, and a plastic film layer disposed between the third foil material and the fourth foil material, and the third foil material and the fourth foil material are each adhered to the plastic film layer. In other possible embodiments, the third foil material, the plastic film layer, and the fourth foil material are sequentially connected by heat fusion.

[0061] Referring to FIG. 4, the tab welding device 10 includes a synchronous induction mechanism and a control module. The synchronous induction mechanism is used to induce whether the unwinding rollers of the first unwinding assembly 110, the second unwinding assembly 120, and the third unwinding assembly 130 rotate synchronously. The control module is communicably connected to the synchronous induction mechanism and is controllably connected to the connection of the unwinding drive parts of the first unwinding assembly 110, the second unwinding assembly 120, and the third unwinding assembly 130. The control module is used to realize automatic control. For example, a PLC may be adopted, or an MCS-51 single-chip microcomputer may be adopted.

[0062] In this embodiment, the synchronous induction mechanism includes a first motor rotation speed detection module, a second motor rotation speed detection module, and a third motor rotation speed detection module. The first motor rotation speed detection module is used to detect the rotation speed of the unwinding drive part of the first unwinding assembly 110. The second motor rotation speed detection module is used to detect the rotation speed of the unwinding drive part of the second unwinding assembly 120. The third motor rotation speed detection module is used to detect the rotation speed of the unwinding drive part of the third unwinding assembly 130. The first motor rotation speed detection module, the second motor rotation speed detection module, and the third motor rotation speed detection module all adopt rotation speed sensors.

[0063] The first motor rotation speed detection module, the second motor rotation speed detection module, and the third motor rotation speed detection module transmit the detected signals to the control module, and the control module determines whether the payout drive parts of the first payout assembly 110, the second payout assembly 120, and the third payout assembly 130 rotate synchronously and whether the rotation speeds match based on the received signals.

[0064] In other possible embodiments, the first motor rotation speed detection module, the second motor rotation speed detection module, and the third motor rotation speed detection module may all employ a motor rotation speed detection circuit. The first motor rotation speed detection module, the second motor rotation speed detection module, and the third motor rotation speed detection module are electrically connected to the payout drive parts of the first payout assembly 110, the second payout assembly 120, and the third payout assembly 130, respectively.

[0065] In other embodiments, the synchronization induction mechanism includes a first payout roller rotation speed detection module, a second payout roller rotation speed detection module, and a third payout roller rotation speed detection module. The first payout roller rotation speed detection module is used to detect the rotation speed of the payout roller of the first payout assembly 110. The second payout roller rotation speed detection module is used to detect the rotation speed of the payout roller of the second payout assembly 120. The third payout roller rotation speed detection module is used to detect the rotation speed of the payout roller of the third payout assembly 130. The first payout roller rotation speed detection module, the second payout roller rotation speed detection module, and the third payout roller rotation speed detection module all employ a rotation speed sensor.

[0066] Referring to FIGS. 4 and 5, the pressing mechanism 200 includes a first pressing roller 210 and a second pressing roller 220 installed oppositely, and the first pressing roller 210 and the second pressing roller 220 are used together to press the laminated foil material 1. The first pressing roller 210 and the second pressing roller 220 are symmetrically installed. A pressing channel for pressing the laminated foil material 1 is formed between the first pressing roller 210 and the second pressing roller 220.

[0067] The pressing mechanism 200 can reduce the distance between the first foil material 11, the composite foil material 12 and the second foil material 13, thereby making the first foil material 11, the composite foil material 12 and the second foil material 13 in close contact with each other, making it difficult to cause relative displacement, ensuring the fixation of the relative positions of the first foil material 11, the composite foil material 12 and the second foil material 13, and further improving the welding quality of the first foil material 11, the composite foil material 12 and the second foil material 13. In one embodiment, before being pressed by the pressing mechanism 200, the distance between each of the first foil material 11 and the second foil material 13 and the composite foil material 12 is 0.5 - 1 mm, and after being pressed by the first pressing roller 210 and the second pressing roller 220, the distance between the first foil material 11, the second foil material 13 and the composite foil material 12 is 0 - 0.2 mm.

[0068] The pressing mechanism 200 further includes a pressing roller driving part for driving the first pressing roller 210 and the second pressing roller 220 to rotate synchronously. The pressing roller driving part employs a motor. The first pressing roller 210 and the second pressing roller 220 employ a metal material. Specifically, the materials of the first pressing roller 210 and the second pressing roller 220 are aluminum and their surfaces are oxidized.

[0069] Referring to FIGS. 4 and 5, the first welding mechanism 300 employs an ultrasonic welding mechanism. The first welding mechanism 300 includes a driving beam welding head 310, a driven beam welding part 320, a driving beam welding driving part 330 for driving the driving beam welding head 310 to rotate, and a transducer. The transducer is used to drive the driving beam welding head 310 to vibrate along the axial direction of the driving beam welding head 310. By driving the driving beam welding head 310 to vibrate by the transducer, the driving beam welding head 310 ultrasonically welds the laminated foil material 1. The driving beam welding driving part 330 can drive the driving beam welding head 310 to rotate and move the laminated foil material 1 horizontally.

[0070] The driving beam welding head 310 and the driven beam welding part 320 are installed to face each other, and a first welding channel for welding the laminated foil material 1 is formed between the driving beam welding head 310 and the driven beam welding part 320. Specifically, the driven beam welding part 320 includes a driven beam welding head 321 and a driven beam welding driving part 322 for driving the driven beam welding head 321 to move up and down. A first welding channel is formed between the driving beam welding head 310 and the driven beam welding head 321. The driving beam welding head 310 is located above the laminated foil material 1, and the driving beam welding head 310 welds the top surface of the laminated foil material 1. The driven beam welding head 321 is located below the laminated foil material 1, and the driven beam welding head 321 welds the bottom surface of the laminated foil material 1. By the cooperation of the driving beam welding head 310 and the driven beam welding head 321, the first foil material 11 and the second foil material 13 can be welded to the opposite two surfaces of the composite foil material 12 respectively, and the welding between the first foil material 11 and the composite foil material 12 and the welding between the second foil material 13 and the composite foil material 12 are carried out simultaneously, improving the welding efficiency and quality.

[0071] The driven seam welding drive unit 322 employs an air cylinder. The driven seam welding drive unit 322 can provide an upward acting force to the driven seam welding head 321, whereby the driven seam welding head 321 can apply pressure to the laminated foil material 1, bringing the driven seam welding head 321 into close contact with the laminated foil material 1 and effectively improving the welding quality. Both the driving seam welding head 310 and the driven seam welding head 321 employ circular welding heads, and a welding working surface is provided on the outer periphery of the circular welding head, with the contact surface between the circular welding head and the laminated foil material 1 being reduced. In one embodiment, the welding area of the laminated foil material 1 is 30 - 50 mm, the frequency of the first welding mechanism 300 is 20 - 50 Khz, the power is 2500 W, the welding pressure is 0.2 - 0.5 Mpa, and the welding speed is 8 - 12 r / min.

[0072] Referring to FIGS. 4 and 5, the tab welding device 10 further includes a pressure detection mechanism for detecting the welding pressure vertically applied by the first welding mechanism 300 to the laminated foil material 1. The control module is communicably connected to the pressure detection mechanism and controllably connected to the first welding mechanism 300. The pressure detection mechanism employs a pressure sensor.

[0073] Specifically, the pressure detection mechanism is installed on the driven seam welding head 321. The pressure detection mechanism detects the welding pressure applied to the laminated foil material 1 in real time and transmits the data to the control module. For example, when the pressure detection mechanism detects that the welding pressure applied to the laminated foil material 1 is greater than the set value, the control module controls the driven seam welding drive unit 322 to operate, moving the driven seam welding head 321 downward, thereby reducing the welding pressure. In one embodiment, the adjustment range of the welding pressure is 0.2 - 0.8 MPa.

[0074] Referring to FIGS. 4, 5 and 6, the tab welding device 10 is installed corresponding to the second welding mechanism 400, and further includes a tab loading mechanism 700 for transporting the tab 800 to the tab welding station. The tab welding station is located on the bottom surface of the laminated foil material 1. The tab loading mechanism 700 includes a limit assembly 710 and a tab transport assembly 720. The limit assembly 710 has a limit groove capable of accommodating the tab 800, and the inner wall of the limit groove can form a limit for the tab 800 so that it can be accommodated at a predetermined position and shape. The limit groove communicates with the delivery port of the tab transport assembly 720 and is used to transport the tab 800 into the limit groove. The tab transport assembly 720 employs a vibrating disk.

[0075] The second welding mechanism 400 includes a final welding head and a final welding drive unit 420 for driving the final welding head to move up and down. A second welding channel for welding the laminated foil material 1 and the tab 800 is formed between the final welding head and the tab loading mechanism 700. By welding the laminated foil material 1 and the tab 800, the welding tensile strength of the tab 800 can be increased, and the conductivity can be ensured by the contact between the laminated foil material 1 and the tab 800. The second welding mechanism 400 employs an ultrasonic welding mechanism. The final welding head employs a square welding head. In one embodiment, the frequency of the second welding mechanism 400 is 30 - 40 Khz, the power is 5500 W, the welding pressure is 0.2 - 0.5 Mpa, and the welding time is 0.3 - 0.5 s.

[0076] Referring to FIGS. 4, 5 and 6, the tab welding device 10 further includes a tab arrival detection mechanism for detecting whether the tab 800 has reached the tab welding station. The tab arrival detection mechanism is communicably connected to the control module, and the control module is controllably connected to the final welding drive unit 420. When the tab arrival detection mechanism detects that the tab 800 has reached the tab welding station, the control module controls the final welding drive unit 420 to operate, moving the final welding head downward, thereby welding the laminated foil material 1 and the tab 800.

[0077] Referring to FIGS. 4 and 5, the take-up mechanism 500 includes a take-up roller and a take-up driving unit. The take-up driving unit is used to drive the take-up roller to rotate so as to take up the tab assembly welded by the second welding mechanism 400. The control module controls the take-up mechanism 500. In one embodiment, the take-up tension of the take-up mechanism 500 is 100 - 220 N. It should be noted that the first foil material 11 fed out by the first unwinding assembly 110, the second foil material 13 fed out by the second unwinding assembly 120, and the composite foil material 12 fed out by the third unwinding assembly 130 all reach the take-up mechanism 500 through the pressing mechanism 200, the first welding mechanism 300, and the second welding mechanism 400. By controlling the unwinding speeds of the first unwinding assembly 110, the second unwinding assembly 120, and the third unwinding assembly 130 and the take-up speed of the take-up mechanism 500, the unwinding tension and the take-up tension can be adjusted.

[0078] When in use, the tab welding device 10 of the present invention first passes the first ends of the first foil material 11 fed out by the first unwinding assembly 110, the second foil material 13 fed out by the second unwinding assembly 120, and the composite foil material 12 fed out by the third unwinding assembly 130 through the pressing mechanism 200, the first welding mechanism 300, and the second welding mechanism 400 in sequence and installs them on the take-up mechanism 500.

[0079] The control module controls the driving units of the first unwinding assembly 110, the second unwinding assembly 120, and the third unwinding assembly 130 to operate synchronously, so as to move the take-up rollers of the first unwinding assembly 110, the second unwinding assembly 120, and the third unwinding assembly 130 to rotate synchronously. At the same time, the control module controls the take-up driving unit to operate so as to move the take-up roller to rotate, thereby moving the first foil material 11, the second foil material 13, and the composite foil material 12 at the same speed.

[0080] The pressing roller driving unit drives the first pressing roller 210 and the second pressing roller 220 to rotate synchronously, so that the first pressing roller 210 and the second pressing roller 220 cooperate with each other to press the laminated foil material 1, prepare for the welding of the laminated foil material 1, and move the laminated foil material 1 horizontally by the rotation of the first pressing roller 210 and the second pressing roller 220.

[0081] The control module controls the operation of the first welding mechanism 300 to weld the first foil material 11 and the second foil material 13 to the opposite two sides of the composite foil material 12 respectively. Here, the driving seam welding head 310 is located above the laminated foil material 1, and the driving seam welding head 310 welds the top surface of the laminated foil material 1. The driven seam welding head 321 is located below the laminated foil material 1, and the driven seam welding head 321 welds the top surface of the laminated foil material 1. By the cooperation of the driving seam welding head 310 and the driven seam welding head 321, the first foil material 11 and the second foil material 13 can be welded to the opposite two sides of the composite foil material 12 respectively, and the welding between the first foil material 11 and the composite foil material 12 and the welding between the second foil material 13 and the composite foil material 12 are carried out simultaneously, improving the welding efficiency and quality.

[0082] When the tab loading mechanism 700 operates, it transports the tab 800 to the tab welding station. The tab arrival detection mechanism detects in real time whether the tab 800 has reached the tab welding station. When the tab arrival detection mechanism detects that the tab 800 has reached the tab welding station, the control module controls the operation of the final welding driving unit 420 to move the final welding head downward, thereby welding the laminated foil material 1 and the tab 800. After the welding is completed, the winding mechanism 500 is used to wind the tab assembly welded by the second welding mechanism 400.

[0083] The second embodiment of the present invention provides a tab ultrasonic welding method and a tab welding device capable of welding a first foil material, a composite foil material, a second foil material and a tab.

[0084] An embodiment of the present invention provides a tab ultrasonic welding method. This processing method can weld a first foil material 11, a composite foil material 12, and a second foil material 13 to obtain a laminated foil material 1, and can also weld a plurality of layers of the laminated foil material 1 to form a laminate 21, and can also weld the laminate 21 and a tab 22.

[0085] Referring to FIGS. 7, 8, 9, and 10, the tab ultrasonic welding method includes: Step (1) of sequentially unwinding the first foil material 11, the composite foil material 12, and the second foil material 13 to sequentially laminate the first foil material 11, the composite foil material 12, and the second foil material 13 to form an intermediate body of the laminated foil material 1, wherein the first foil material 11 and the second foil material 13 are each independently selected from the group consisting of aluminum foil, copper foil, and tin foil; Step (2) of adopting an ultrasonic welding method to weld the first foil material 11 and the second foil material 13 to opposite sides of the composite foil material 12 respectively to obtain the laminated foil material 1; Step (3) of laminating the laminated foil material 1 to a set number of layers n to form a laminate; Step (4) of adopting an ultrasonic welding method to weld the laminate 21 and the tab 22 to form a tab assembly 2.

[0086] When n is greater than 1, before step (4), it further includes step (3a) of adopting an ultrasonic welding method to sequentially weld the n layers of the laminated foil material.

[0087] Referring to FIG. 8, the first foil material 11, the composite foil material 12, and the second foil material 13 are welded by adopting an ultrasonic welding method. Ultrasonic welding utilizes high-frequency vibration waves to transmit them to the surfaces of two objects to be welded, and under pressure, the surfaces of the two objects are rubbed against each other to form molecular layer fusion. During welding, energy is directly applied to the first foil material 11 and the second foil material 13 by ultrasonic welding. The first foil material 11 and the second foil material 13 play a role in protecting the composite foil material 12, and the energy generated by the direct contact of ultrasonic welding with the composite foil material 12 can be reduced. The risk that the composite foil material 12 is easily broken during the welding process can be reduced, and problems such as over-welding, through-welding, and temporary welding in the welding process can be effectively avoided, ensuring the welding effect of the laminated foil material 1.

[0088] In step (1), the first foil material 11, the composite foil material 12, and the second foil material 13 are respectively wound around the unwinding rollers. By driving the unwinding rollers to rotate under the drive of the unwinding drive unit, the sequential unwinding of the first foil material 11, the composite foil material 12, and the second foil material 13 can be realized. Here, the unwinding drive unit adopts a motor. Since the first foil material 11, the composite foil material 12, and the second foil material 13 are all thin materials, they do not have high strength and cannot withstand a large tearing force. When welding the first foil material 11, the composite foil material 12, and the second foil material 13, it is necessary to ensure the fixation of the relative positions. Otherwise, cracks will occur after welding, and in severe cases, cutting will occur and continuous production cannot be carried out. Therefore, before welding, the first foil material 11, the composite foil material 12, and the second foil material 13 are sequentially laminated, and the first foil material 11, the composite foil material 12, and the second foil material 13 are conveyed in the same direction. At the same time, by making the conveying speeds of the first foil material 11, the composite foil material 12, and the second foil material 13 consistent during transportation, the speed difference among the three is reduced, thereby ensuring the fixation of the relative positions of the first foil material 11, the composite foil material 12, and the second foil material 13, and further improving the welding quality of the first foil material 11, the composite foil material 12, and the second foil material 13.

[0089] Specifically, the first foil material 11, the composite foil material 12, and the second foil material 13 are all horizontally conveyed to a welding station that welds the first foil material 11 and the second foil material 13 to opposite sides of the composite foil material 12 respectively, thereby reducing the phenomenon of creases and wrinkles during the conveyance of the first foil material 11, the composite foil material 12, and the second foil material 13, effectively ensuring flatness during welding, and further ensuring welding quality.

[0090] In order to realize that the first foil material 11, the composite foil material 12, and the second foil material 13 are all horizontally conveyed to the welding station, they are installed as follows. The unwinding rollers around which the first foil material 11 is wound and the unwinding rollers around which the second foil material 13 is wound are symmetrically installed. The unwinding roller around which the composite foil material 12 is wound is installed between the unwinding roller around which the first foil material 11 is wound and the unwinding roller around which the second foil material 13 is wound in the first direction, and has a gap from the unwinding roller around which the first foil material 11 is wound and the unwinding roller around which the second foil material 13 is wound respectively in the second direction. The first direction and the second direction intersect perpendicularly. Note that the composite foil material 12 is installed parallel to the first foil material 11 and the second foil material 13 respectively, and the composite foil material 12 is located between the first foil material 11 and the second foil material 13. At the same time, the first foil material 11 and the second foil material 13 are symmetrically installed with respect to the composite foil material 12. When the first foil material 11 and the second foil material 13 are unwound respectively, the first foil material 11 and the second foil material 13 can enter the welding station through paths of the same length, reducing the tension difference between the first foil material 11 and the second foil material 13, and ensuring the flatness when the first foil material 11, the composite foil material 12, and the second foil material 13 are laminated.

[0091] Referring to FIG. 8, in step (2), the first foil material 11 and the second foil material 13 are welded to opposite sides of the composite foil material 12 by adopting a continuous welding method. It should be noted that the first foil material 11, the composite foil material 12, and the second foil material 13 are welded during transportation, and continuous welding marks are formed between the first foil material 11 and the composite foil material 12 and between the second foil material 13 and the composite foil material 12. It is not necessary to temporarily stop the first foil material 11, the composite foil material 12, and the second foil material 13 during transportation, the welding time is greatly shortened, and the welding efficiency is improved.

[0092] In order to ensure the accuracy of the relative positions of the first foil material 11, the composite foil material 12, and the second foil material 13, between step (1) and step (2), by pressing the intermediate body of the laminated foil material 1 so that the distance between the first foil material 11, the composite foil material 12, and the second foil material 13 becomes smaller, the first foil material 11 and the second foil material 13 are each brought into close contact with the composite foil material 12, and the step of making relative displacement less likely to occur is further included. For example, before being pressed, the distance between each of the first foil material 11 and the second foil material 13 and the composite foil material 12 is 0.5 - 1 mm, and the distance between the first foil material 11, the second foil material 13, and the composite foil material 12 after pressing is 0 - 0.2 mm.

[0093] The thickness of the first foil material 11 and the second foil material 13 can be selected between 10 - 15 μm, and the thickness of the composite foil material 12 can be selected between 5 - 8 μm. In this embodiment, the thickness of the first foil material 11 and the second foil material 13 is 12 μm, and the thickness of the composite foil material is 6 μm.

[0094] Referring to FIG. 8, in one embodiment, the welding of the first foil material 11, the composite foil material 12, and the second foil material 13 adopts an ultrasonic seam welding method, includes two seam welding heads 3, and the two seam welding heads 3 are respectively installed on both the upper and lower sides of the laminated foil material 1 and are symmetrically installed with respect to the laminated foil material 1. When the first foil material 11 and the second foil material 13 are welded to the opposite two sides of the composite foil material 12 respectively by adopting the ultrasonic welding method, a welding area of 30 - 50 mm is secured in advance, the welding pressure of the ultrasonic welding is 0.2 - 0.5 Mpa, the welding frequency is 20 - 50 Khz, the welding speed is 10 - 15 r / min, the diameter of the ultrasonic welding head is about 100 mm, and the ultrasonic welding head is a circular welding head. For example, the ultrasonic welding head is in the shape of a circular roller.

[0095] Furthermore, after the completion of step (2), the welded first foil material 11, the second foil material 13, and the composite foil material 12 can be wound up, that is, the welded laminated foil material 1 can also be wound up. To realize the winding up of the welded laminated foil material 1, it is installed as follows. A winding roller and a winding driving part are installed, the laminated foil material 1 is wound around the winding roller, and by driving the winding driving part to move the winding roller to rotate, the winding up of the welded laminated foil material 1 can be realized. Before step (3), the wound laminated foil material 1 needs to be cut according to the desired length, and then the laminated foil material 1 needs to be laminated in a set number of layers. The set number of layers can be selected between 15 - 40 layers. In this embodiment, the number of layers of the laminate 21 is 20 layers.

[0096] Referring to FIG. 9, in step (1), when a plurality of laminated foil materials 1 are sequentially welded by adopting the ultrasonic welding method, a second ultrasonic welding head 4 is adopted, the second ultrasonic welding head 4 is square and has no welding teeth. The welding pressure of the ultrasonic welding is 0.2 - 0.5 Mpa, the welding frequency is 30 - 40 Khz, and the welding time is 0.3 - 0.5 s. By sequentially welding a plurality of laminated foil materials 1 by adopting the ultrasonic welding method, the interval between the plurality of laminated foil materials 1 can be shortened, which is beneficial to reducing the consumption of welding energy.

[0097] Referring to FIG. 10, in step (4), when the laminate 21 and the tab 22 are welded by adopting an ultrasonic welding method, the first ultrasonic welding head 5 is adopted. The first ultrasonic welding head 5 may have any shape, and the first ultrasonic welding head 5 adopts a spur welding head. In this embodiment, the first ultrasonic welding head 5 is square. The welding pressure of ultrasonic welding is 0.2 to 0.5 Mpa, the welding frequency is 30 to 40 Khz, and the welding time is 0.3 to 0.5 s. By adopting the ultrasonic welding method to weld the laminate 21 and the tab 22, the welding tensile strength of the tab 22 is increased, the laminate 21 and the tab 22 are brought into contact, and the conductivity is ensured. When the laminate 21 and the tab 22 are welded, the area of the first ultrasonic welding head 5 used for welding is determined according to the area of the welding region where the laminate 21 and the tab 22 are welded, and the area of the first ultrasonic welding head 5 is larger than the area of the welding region where the laminate 21 and the tab 22 are welded. Note that the area of the first ultrasonic welding head 5 is linearly related to the area of the welding region where the laminate 21 and the tab 22 are welded.

[0098] After step (4) is completed, the welding tensile force of the tab assembly 2 is measured. When the welding tensile force is 20 N or more, it is determined as a qualified product that meets the welding requirements.

[0099] Referring to FIGS. 11, 12, and 13, an embodiment of the present invention relates to a tab welding device including an unwinding mechanism 100, a pressing mechanism 200, a first welding mechanism 300, and a second welding mechanism 400. The unwinding mechanism 100 is used to unwind the first foil material 11, the second foil material 13, and the composite foil material 12. The first foil material 11, the composite foil material 12, and the second foil material 13 are sequentially laminated to form an intermediate body of the laminated foil material 1. The pressing mechanism 200 is used to press the intermediate body of the laminated foil material 1. The first welding mechanism 300 is used to weld the first foil material 11 and the second foil material 13 to the opposite two surfaces of the composite foil material 12 respectively. The second welding mechanism 400 is used to weld the laminate to the tab to form a tab assembly. Here, the laminate is formed by laminating the laminated foil material to a set number of layers n (n is 1 or more).

[0100] Referring to FIGS. 11 and 12, the unwinding mechanism 100 includes a first unwinding assembly 110 for unwinding the first foil material 11, a second unwinding assembly 120 for unwinding the second foil material 13, and a third unwinding assembly 130 for unwinding the composite foil material 12. The first unwinding assembly 110, the second unwinding assembly 120, and the third unwinding assembly 130 are used to sequentially laminate the first foil material 11, the composite foil material 12, and the second foil material 13 to form the laminated foil material 1. The first unwinding assembly 110, the second unwinding assembly 120, and the third unwinding assembly 130 all include an unwinding roller and an unwinding drive unit for driving the unwinding roller to rotate. The unwinding drive unit employs a motor. The first unwinding assembly 110 and the second unwinding assembly 120 are symmetrically installed. The third unwinding assembly 130 is installed between the first unwinding assembly 110 and the second unwinding assembly 120 in the first direction. The third unwinding assembly 130 has a gap from the first unwinding assembly 110 and the second unwinding assembly 120 respectively in the second direction, and the first direction and the second direction intersect perpendicularly. By installing in this way, it can be realized that the first foil material 11, the composite foil material 12, and the second foil material 13 are all conveyed in the horizontal direction, the phenomenon of creases and wrinkles during the conveyance of the first foil material 11, the composite foil material 12, and the second foil material 13 can be reduced, the flatness during welding can be effectively ensured, and further the welding quality can be ensured.

[0101] In addition, the composite foil material 12 is installed parallel to the first foil material 11 and the second foil material 13 respectively, and the composite foil material 12 is located between the first foil material 11 and the second foil material 13. At the same time, the first foil material 11 and the second foil material 13 are symmetrically installed with respect to the composite foil material 12. When unwinding the first foil material 11 and the second foil material 13 respectively, the first foil material 11 and the second foil material 13 can enter the welding station through the same-length path, and the tension difference between the first foil material 11 and the second foil material 13 can be reduced. The unwinding tensions of the first unwinding assembly 110 and the second unwinding assembly 120 are 100 - 200 N, and the unwinding tension of the third unwinding assembly 130 is 100 - 200 N.

[0102] In this embodiment, the composite foil material 12 includes a third foil material, a fourth foil material, and a plastic film layer disposed between the third foil material and the fourth foil material, and the third foil material and the fourth foil material are each adhered to the plastic film layer. In other possible embodiments, the third foil material, the plastic film layer, and the fourth foil material are sequentially connected by heat fusion.

[0103] Referring to FIG. 11, the tab welding apparatus 10 includes a synchronous induction mechanism and a control module. The synchronous induction mechanism is used to induce whether the payout rollers of the first payout assembly 110, the second payout assembly 120, and the third payout assembly 130 rotate synchronously. The control module is communicably connected to the synchronous induction mechanism and controllably connected to the payout drive parts of the first payout assembly 110, the second payout assembly 120, and the third payout assembly 130. The control module is used to achieve automatic control, and for example, a PLC may be adopted, or an MCS-51 single-chip microcomputer may be adopted.

[0104] In this embodiment, the synchronous induction mechanism includes a first motor rotation speed detection module, a second motor rotation speed detection module, and a third motor rotation speed detection module. The first motor rotation speed detection module is used to detect the rotation speed of the payout drive part of the first payout assembly 110. The second motor rotation speed detection module is used to detect the rotation speed of the payout drive part of the second payout assembly 120. The third motor rotation speed detection module is used to detect the rotation speed of the payout drive part of the third payout assembly 130. The first motor rotation speed detection module, the second motor rotation speed detection module, and the third motor rotation speed detection module all adopt rotation speed sensors.

[0105] The first motor rotation speed detection module, the second motor rotation speed detection module, and the third motor rotation speed detection module transmit the detected signals to the control module. The control module determines whether the unwinding drive parts of the first unwinding assembly 110, the second unwinding assembly 120, and the third unwinding assembly 130 rotate synchronously and whether the rotation speeds match based on the received signals.

[0106] In other possible embodiments, the first motor rotation speed detection module, the second motor rotation speed detection module, and the third motor rotation speed detection module may all employ a motor rotation speed detection circuit. The first motor rotation speed detection module, the second motor rotation speed detection module, and the third motor rotation speed detection module are electrically connected to the unwinding drive parts of the first unwinding assembly 110, the second unwinding assembly 120, and the third unwinding assembly 130, respectively.

[0107] In other embodiments, the synchronization induction mechanism includes a first unwinding roller rotation speed detection module, a second unwinding roller rotation speed detection module, and a third unwinding roller rotation speed detection module. The first unwinding roller rotation speed detection module is used to detect the rotation speed of the unwinding roller of the first unwinding assembly 110. The second unwinding roller rotation speed detection module is used to detect the rotation speed of the unwinding roller of the second unwinding assembly 120. The third unwinding roller rotation speed detection module is used to detect the rotation speed of the unwinding roller of the third unwinding assembly 130. The first unwinding roller rotation speed detection module, the second unwinding roller rotation speed detection module, and the third unwinding roller rotation speed detection module all employ a rotation speed sensor.

[0108] Referring to FIGS. 11 and 12, the pressing mechanism 200 includes a first pressing roller 210 and a second pressing roller 220 which are installed oppositely, and the first pressing roller 210 and the second pressing roller 220 are used to cooperate with each other to press the laminated foil material 1. The first pressing roller 210 and the second pressing roller 220 are symmetrically installed. A pressing channel for pressing the laminated foil material 1 is formed between the first pressing roller 210 and the second pressing roller 220.

[0109] The pressing mechanism 200 can reduce the distance between the first foil material 11, the composite foil material 12 and the second foil material 13, thereby making the first foil material 11, the composite foil material 12 and the second foil material 13 in close contact with each other, making it difficult to generate relative displacement, ensuring the fixation of the relative positions of the first foil material 11, the composite foil material 12 and the second foil material 13, and further improving the welding quality of the first foil material 11, the composite foil material 12 and the second foil material 13. In one embodiment, before being pressed by the pressing mechanism 200, the distance between each of the first foil material 11 and the second foil material 13 and the composite foil material 12 is 0.5 - 1 mm, and after being pressed by the first pressing roller 210 and the second pressing roller 220, the distance between the first foil material 11, the second foil material 13 and the composite foil material 12 is 0 - 0.2 mm.

[0110] The pressing mechanism 200 further includes a pressing roller driving part for driving the first pressing roller 210 and the second pressing roller 220 to rotate synchronously. The pressing roller driving part employs a motor. The first pressing roller 210 and the second pressing roller 220 employ a metal material. Specifically, the materials of the first pressing roller 210 and the second pressing roller 220 are aluminum, and the surfaces are oxidized.

[0111] Referring to FIGS. 11 and 12, the first welding mechanism 300 employs an ultrasonic welding mechanism. The first welding mechanism 300 includes a driving beam welding head 310, a driven beam welding part 320, a driving beam welding driving part 330 for driving the driving beam welding head 310 to rotate, and a transducer. The transducer is used to drive the driving beam welding head 310 to vibrate along the axial direction of the driving beam welding head 310. By driving the driving beam welding head 310 to vibrate by the transducer, the driving beam welding head 310 ultrasonically welds the laminated foil material 1. The driving beam welding driving part 330 drives the driving beam welding head 310 to rotate and can move the laminated foil material 1 horizontally.

[0112] The driving beam welding head 310 and the driven beam welding part 320 are installed to face each other, and a first welding channel for welding the laminated foil material 1 is formed between the driving beam welding head 310 and the driven beam welding part 320. Specifically, the driven beam welding part 320 includes a driven beam welding head 321 and a driven beam welding driving part 322 for driving the driven beam welding head 321 to move up and down. A first welding channel is formed between the driving beam welding head 310 and the driven beam welding head 321. The driving beam welding head 310 is located above the laminated foil material 1, and the driving beam welding head 310 welds the top surface of the laminated foil material 1. The driven beam welding head 321 is located below the laminated foil material 1, and the driven beam welding head 321 welds the bottom surface of the laminated foil material 1. By the cooperation of the driving beam welding head 310 and the driven beam welding head 321, the first foil material 11 and the second foil material 13 can be respectively welded to the opposite two surfaces of the composite foil material 12, and the welding between the first foil material 11 and the composite foil material 12 and the welding between the second foil material 13 and the composite foil material 12 are performed simultaneously, improving the welding efficiency and quality.

[0113] The driven seam welding drive unit 322 employs an air cylinder. The driven seam welding drive unit 322 can provide an upward acting force to the driven seam welding head 321, whereby the driven seam welding head 321 can apply pressure to the laminated foil material 1, bringing the driven seam welding head 321 into close contact with the laminated foil material 1 and effectively improving the welding quality. Both the driving seam welding head 310 and the driven seam welding head 321 employ circular welding heads, with a welding working surface provided on the outer periphery of the circular welding head, and the contact surface between the circular welding head and the laminated foil material 1 is reduced. In one embodiment, the welding area of the laminated foil material 1 is 30 - 50 mm, the frequency of the first welding mechanism 300 is 20 - 50 Khz, the power is 2500 W, the welding pressure is 0.2 - 0.5 Mpa, and the welding speed is 8 - 12 r / min.

[0114] Referring to FIGS. 11 and 12, the tab welding device 10 further includes a pressure detection mechanism for detecting the welding pressure vertically applied by the first welding mechanism 300 to the laminated foil material 1. The control module is communicably connected to the pressure detection mechanism and controllably connected to the first welding mechanism 300. The pressure detection mechanism employs a pressure sensor.

[0115] Specifically, the pressure detection mechanism is installed on the driven seam welding head 321. The pressure detection mechanism detects the welding pressure applied to the laminated foil material 1 in real time and transmits the data to the control module. For example, when the pressure detection mechanism detects that the welding pressure applied to the laminated foil material 1 is greater than the set value, the control module controls the driven seam welding drive unit 322 to operate, moving the driven seam welding head 321 downward, thereby reducing the welding pressure. In one embodiment, the adjustment range of the welding pressure is 0.2 - 0.8 MPa.

[0116] Referring to FIGS. 11, 12 and 13, the tab welding device 10 is installed corresponding to the second welding mechanism 400, and further includes a tab loading mechanism 700 for transporting the tab 800 to the tab welding station. The tab welding station is located on the bottom surface of the laminated foil material 1. The tab loading mechanism 700 includes a limit assembly 710 and a tab transport assembly 720. The limit assembly 710 has a limit groove capable of accommodating the tab 800, and the inner wall of the limit groove can form a limit for the tab 800 so that it can be accommodated at a predetermined position and shape. The limit groove communicates with the delivery port of the tab transport assembly 720 and is used to transport the tab 800 into the limit groove. The tab transport assembly 720 employs a vibrating disk.

[0117] The second welding mechanism 400 includes a final welding head and a final welding drive unit 420 for driving the final welding head to move up and down. A second welding channel for welding the laminated foil material 1 and the tab 800 is formed between the final welding head and the tab loading mechanism 700. By welding the laminated foil material 1 and the tab 800, the welding tensile strength of the tab 800 is increased, and the conductivity can be ensured by the contact between the laminated foil material 1 and the tab 800. The second welding mechanism 400 employs an ultrasonic welding mechanism. The final welding head employs a square welding head. In one embodiment, the frequency of the second welding mechanism 400 is 30 - 40 Khz, the power is 5500 W, the welding pressure is 0.2 - 0.5 Mpa, and the welding time is 0.3 - 0.5 s.

[0118] Referring to FIGS. 11, 12 and 13, the tab welding device 10 further includes a tab arrival detection mechanism for detecting whether the tab 800 has reached the tab welding station. The tab arrival detection mechanism is communicably connected to the control module, and the control module is controllably connected to the final welding drive unit 420. When the tab arrival detection mechanism detects that the tab 800 has reached the tab welding station, the control module controls the final welding drive unit 420 to operate, moving the final welding head downward so as to weld the laminated foil material 1 and the tab 800.

[0119] Referring to FIG. 11, the tab welding apparatus 10 further includes a cutting mechanism 910, a stacking mechanism 920, a third welding mechanism 930, a scrap winding mechanism 940, a first mounting table 950, and a second mounting table 960.

[0120] The cutting mechanism 910 is used to cut the laminated foil material welded by the first welding mechanism 300. The cutting mechanism is a dicing saw, and is die-cut by a laser or a cutter to partially cut the welded laminated foil material.

[0121] The first mounting table 950 is located below the cutting mechanism 910 and is used to mount the cut laminated foil material. The laminated foil material partially cut by the cutting mechanism 910 falls onto the first mounting table 910.

[0122] The stacking mechanism 920 is used to stack the cut laminated foil material up to a set number of layers n.

[0123] The third welding mechanism 930 is used to sequentially weld the laminated foil material stacked up to n layers by the stacking mechanism to form a laminate. Since the adjacent laminated foil materials of the laminate are welded, the laminate is also called a laminated weld joint.

[0124] The second welding mechanism 400 can weld the laminate formed after being welded by the third welding mechanism 930 to a tab.

[0125] The second mounting table 960 is located below the third welding mechanism 930 and is used to mount the laminated foil material.

[0126] The stacking mechanism 920 includes a suction element for sucking the laminated foil material on the first mounting table 950, and a suction element driving unit for driving the suction element to move so as to move the laminated foil material on the first mounting table 950 onto the second mounting table 960. Preferably, a plurality of suction cups are installed on the suction element, and the suction cups suck the laminated foil material after contacting the surface of the laminated foil material. Preferably, the suction element driving unit is a robot arm.

[0127] After the laminate on the second stage 960 is welded by the third welding mechanism 930, it can be grasped by a human hand or a robot arm and moved to the second welding mechanism 400, and then the welding of the tabs can be started.

[0128] The scrap winding mechanism 940 is used to wind up the scrap formed after the laminated foil material is cut by the cutting mechanism 910. The scrap winding mechanism 940 includes a scrap winding roller and a scrap winding drive unit. The scrap winding drive unit is used to drive the scrap winding roller to rotate, and the scrap formed after the laminated foil material is cut by the cutting mechanism 910 is wound up. The control module controls the scrap winding mechanism 940. In one embodiment, the winding tension of the scrap winding mechanism 940 is 100 - 220 N.

[0129] Each technical feature of the above embodiments can be arbitrarily combined. For the sake of simplicity of description, not all possible combinations of each technical feature of the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, it should be considered within the scope described in this specification.

[0130] The above embodiments only show some embodiments of the present invention, and the description is made more specific and detailed, but it should not be understood that the scope of the invention is limited thereby. For those skilled in the art, some modifications and improvements can be made without departing from the concept of the present invention, and all of these belong to the protection scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the scope of the appended utility model registration claims.

Explanation of Reference Numerals

[0131] 1 Laminated Foil Material 11 First Foil Material 12 Composite Foil Material 13 Second Foil Material 2 Tab Assembly 21 Laminate 22 Tab 3 Seam Welding Head 4 Second Ultrasonic Welding Head 5 First Ultrasonic Welding Head 10 Tab Welding Device 100 Unwinding Mechanism 110 First Unwinding Assembly 120 Second Unwinding Assembly 130 Third Unwinding Assembly 200 Pressing Mechanism 210 First Pressing Roller 220 Second Pressing Roller 300 First Welding Mechanism 310 Driving Seam Welding Head 320 Driven Seam Welding Part 321 Driven Seam Welding Head 322 Driven Seam Welding Driving Part 330 Driving Seam Welding Driving Part 400 Second Welding Mechanism 410 Slide Rail Final Welding Head 420 Final Welding Driving Part 500 Winding Mechanism 700 Tab Loading Mechanism 710 Limit Assembly 720 Tab Transport Assembly 800 Tab 910 Cutting Mechanism 920 Laminating Mechanism 930 Third Welding Mechanism 940 Scrap Winding Mechanism 950 First Mounting Table 960 Second Mounting Table

Claims

1. Step (1) of sequentially unwinding the first foil, the composite foil, and the second foil to sequentially laminate the first foil, the composite foil, and the second foil to form an intermediate of the laminated foil; Step (2) of adopting an ultrasonic welding method to weld the first foil and the second foil to opposite surfaces of the composite foil respectively to obtain a laminated foil; Step (3) of laminating the laminated foil to a set number of layers n or more to form a laminate; Step (4) of adopting an ultrasonic welding method to weld the laminate and a tab to form a tab assembly, characterized in that the tab ultrasonic welding method comprises the above steps.

2. Further, between step (1) and step (2), The tab ultrasonic welding method according to claim 1, characterized by including pressing the intermediate of the laminated foil.

3. The conditions of the ultrasonic welding in step (2) are The welding pressure is 0.2 to 0.5 MPa, The welding frequency is 20 to 50 kHz, The tab ultrasonic welding method according to claim 1, characterized by being one or more selected from the welding speed being 10 to 15 r / min.

4. The conditions of the ultrasonic welding in step (4) are The welding pressure is 0.2 to 0.5 MPa, The welding frequency is 30 to 40 kHz, The tab ultrasonic welding method according to claim 1, characterized by being one or more selected from the welding time being 0.3 to 0.5 s.

5. The first foil and the second foil in step (2) are welded to opposite surfaces of the composite foil respectively by adopting a continuous welding method, characterized in that the tab ultrasonic welding method according to claim 1.

6. The thickness of the first foil material and the second foil material is 10 to 15 μm, and the thickness of the composite foil material is 5 to 8 μm. The tab ultrasonic welding method according to claim 1, characterized in that.

7. Step (4) further includes Determining the area of the first ultrasonic welding head according to the area of the welding region where the laminate and the tab are welded, wherein the area of the first ultrasonic welding head is larger than the area of the welding region where the laminate and the tab are welded. The tab ultrasonic welding method according to claim 2, characterized in that it includes.

8. The first foil material and the second foil material are each independently one selected from the group consisting of aluminum foil, copper foil, and tin foil. The tab ultrasonic welding method according to claim 2, characterized in that.

9. Further including the step of measuring the welding tensile force of the tab assembly and determining it as a qualified product when the welding tensile force is 20 N or more. The tab ultrasonic welding method according to claim 2, characterized in that.

10. Before step (4), further When n is greater than 1, including step (3a) of sequentially welding the n-layer laminated foil materials by adopting an ultrasonic welding method. The tab ultrasonic welding method according to claim 1, characterized in that.

11. The conditions of the ultrasonic welding in step (3a) are The welding pressure is 0.2 to 0.5 Mpa, The welding frequency is 30 to 40 KHz, One or more selected from the welding time being 0.3 to 0.5 s. The tab ultrasonic welding method according to claim 10, characterized in that.

12. The set number of layers n is 15 to 40. The tab ultrasonic welding method according to claim 1, characterized in that.

13. n is equal to 1. The tab ultrasonic welding method according to claim 1, characterized in that.

14. An unwinding mechanism including a first unwinding assembly for unwinding a first foil material, a second unwinding assembly for unwinding a second foil material, and a third unwinding assembly for unwinding a composite foil material, wherein the first unwinding assembly, the second unwinding assembly, and the third unwinding assembly are used to sequentially laminate the first foil material, the composite foil material, and the second foil material to form an intermediate of a laminated foil material; A first welding mechanism for welding the first foil material and the second foil material to opposite surfaces of the composite foil material respectively; A second welding mechanism for welding a laminate to a tab to form a tab assembly, wherein the laminate is formed by laminating the laminated foil material up to a set number of layers n of 1 or more. A tab welding device characterized by including the above.

15. Further including a pressing mechanism, the pressing mechanism includes a first pressing roller and a second pressing roller installed to face each other, and the first pressing roller and the second pressing roller are used to cooperate with each other to press the intermediate of the laminated foil material; The first welding mechanism is installed downstream of the pressing mechanism. The tab welding device according to claim 14, characterized in that.

16. A pressing channel for pressing the laminated foil material is formed between the first pressing roller and the second pressing roller, and the pressing mechanism further includes a pressing roller driving part for driving the first pressing roller and the second pressing roller to rotate synchronously. The tab welding device according to claim 15, characterized in that.

17. Further including a pressure detection mechanism for detecting the welding pressure applied perpendicularly to the laminated foil material by the first welding mechanism. The tab welding device according to claim 14, characterized in that.

18. Further including a synchronous induction mechanism, the first unwinding assembly, the second unwinding assembly, and the third unwinding assembly all include an unwinding roller and an unwinding drive unit for driving the unwinding roller to rotate. The synchronous induction mechanism is used to induce whether the unwinding rollers of the first unwinding assembly, the second unwinding assembly, and the third unwinding assembly rotate synchronously. The tab welding device according to claim 17, characterized in that.

19. Further including a control module communicably connected to the synchronous induction mechanism and the pressure detection mechanism, and controllably connected to the unwinding drive unit and the first welding mechanism. The tab welding device according to claim 18, characterized in that.

20. The first welding mechanism includes a driving seam welding head, a driven seam welding part, and a welding head drive unit for driving the driving seam welding head to rotate. The driving seam welding head and the driven seam welding part are arranged to face each other, and a first welding channel for welding the laminated foil material is formed between the driving seam welding head and the driven seam welding part. The tab welding device according to claim 14, characterized in that.

21. The first unwinding assembly and the second unwinding assembly are symmetrically arranged. The third unwinding assembly is arranged between the first unwinding assembly and the second unwinding assembly in a first direction. The third unwinding assembly has a space from each of the first unwinding assembly and the second unwinding assembly in a second direction. The first direction and the second direction intersect. The tab welding device according to claim 14, characterized in that.

22. Further including a tab loading mechanism installed corresponding to the second welding mechanism for transporting the tab to the tab welding station. The tab welding device according to claim 14, characterized in that.

23. The second welding mechanism includes a final welding head and a final welding drive unit for driving the final welding head to move up and down. A second welding channel for welding the laminated foil material and the tab is formed between the final welding head and the tab loading mechanism. The tab welding device according to claim 19, characterized in that.

24. The tab welding device further includes a tab arrival detection mechanism for detecting whether the tab has reached the tab welding station. The tab arrival detection mechanism is communicably connected to the control module, and the control module is controllably connected to the final welding drive unit. The tab welding device according to claim 23, characterized in that.

25. The tab welding device further includes a winding mechanism for winding the tab assembly welded by the second welding mechanism. The tab welding device according to claim 14, characterized in that.

26. The tab welding device further includes, A cutting mechanism for cutting the laminated foil material welded by the first welding mechanism, A laminating mechanism for laminating the cut laminated foil material up to a set number of layers n, And a third welding mechanism for sequentially welding the laminated foil material laminated up to n layers by the laminating mechanism to form a laminate. The tab welding device according to claim 14, characterized in that.

27. The tab welding device further includes a first mounting table located below the cutting mechanism and a second mounting table located below the third welding mechanism. The first mounting table is used for mounting the cut laminated foil material, The laminating mechanism includes a suction element for sucking the laminated foil material on the first mounting table and a suction element drive unit for driving the suction element to move to move the laminated foil material on the first mounting table to the second mounting table. The tab welding device according to claim 26, characterized in that.

28. The tab welding device according to claim 26, further comprising a scrap winding mechanism for winding scrap formed by cutting the laminated foil material by a cutting mechanism.

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