Bilateral dual-ultrasonic roll welding system for composite current collector

Abstract

A bilateral dual-ultrasonic roll welding system for a composite current collector, comprising a film unwinding mechanism (2), foil unwinding mechanisms, roll pressing and smoothing mechanisms, an ultrasonic roll welding mechanism (5) and a winding mechanism (6). Deviation correction mechanisms and a plurality of guide rollers are respectively arranged between the film unwinding mechanism (2), the foil unwinding mechanisms and the roll pressing and smoothing mechanisms; the film unwinding mechanism (2) and the foil unwinding mechanisms respectively feed the film and the foils to the deviation correction mechanisms for deviation correction and the guide rollers for stretching and flattening, the film and the foils are laminated by a front roll pressing and smoothing mechanism (41), and then the laminated material is welded by the ultrasonic roll welding mechanism (5) to form a composite current collector film which is wound by the winding mechanism (6). The bilateral dual-ultrasonic roll welding system for a composite current collector uses the ultrasonic roll welding mechanism (5) to carry out bilateral welding on the film material so as to form a bilateral double-sided foil-supplemented composite current collector, so that one device can synchronously achieve the working efficiency of two old welding devices, thereby saving the spatial layout of workshops, and achieving the objective of reducing production costs.

Description

A double-sided ultrasonic roller welding system for composite current collectors Technical Field

[0001] The invention relates to the technical field of ultrasonic welding, in particular to a composite current collector bilateral double ultrasonic roller welding system. Background Art

[0002] Composite current collectors are an essential electrode material for lithium-ion batteries, carrying active materials (carrying capacity) and collecting microcurrents (conductivity). However, because the composite current collectors include an insulating film layer made of a polymer material, the tabs of the composite current collectors are unable to transmit the current from the battery cell to the electrode terminals. This necessitates welding foil to the tabs of the composite current collectors to transfer the current from the battery cell.

[0003] The Chinese invention patent application with announcement number CN116765583A discloses an automatic welding system for a multi-layer structure of a pole piece and a tab, which is actually a composite current collector ultrasonic rolling welding system, which includes an A-side foil unwinding mechanism, a composite current collector unwinding mechanism, a B-side foil unwinding mechanism, a coil merging mechanism, an ultrasonic rolling welding mechanism, a weld mark flattening mechanism, an active traction mechanism and a winding mechanism. After the A-side foil outputted by the A-side foil unwinding mechanism, the composite current collector outputted by the composite current collector unwinding mechanism and the B-side foil outputted by the B-side foil unwinding mechanism are converged and aligned in the coil merging mechanism, they are subjected to double-sided rolling welding by the ultrasonic rolling welding mechanism, and the A-side foil and the B-side foil are respectively welded to the A and B sides of the tab end of the composite current collector to form a two-sided foil-patch composite current collector. The weld mark flattening mechanism flattens the weld marks on the two-sided foil-patch composite current collector. The active traction mechanism provides power for the movement of the two-sided foil-patch composite current collector, and the winding mechanism winds up the two-sided foil-patch composite current collector. This solution can achieve welding of the A-side foil and the B-side foil to the A and B sides of the tab end of the composite current collector respectively through the cooperation of an ultrasonic rolling welding mechanism and a coil merging mechanism; the reeling and unreeling mechanism cooperates with the active traction mechanism, the tension control mechanism and the reeling and unreeling correction sensor to control the movement of the coil, so that the welding speed is stable and the position is accurate, thereby improving the welding quality and welding speed.

[0004] The Chinese invention patent application with publication number CN116765688A discloses a current collector tab welding system and welding method based on PLC control, including a PLC programmable controller, a servo controller, a correction control module, a tension control module, a touch screen, a welding machine controller and a welding machine. The PLC programmable controller is connected to the servo controller, the correction control module, the tension control module and the touch screen respectively, the welding machine controller is connected to the touch screen and the welding machine respectively, and the servo controller is connected to the A-side unwinding motor, the B-side unwinding motor, the current collector unwinding motor, the upper welding roller motor, the leveling roller motor, the traction roller motor and the winding motor respectively; this solution realizes the standardized and modular production of current collector tab welding.

[0005] As can be seen from the above, the current collector welding process is very diverse. However, the current welding system generally uses a 300mm wide polymer film substrate in production, while the polymer film substrate production specification on the market is generally 600mm. It needs to be cut before welding production, which can easily slow down production efficiency. If both sides of the substrate can be welded and formed on one device before cutting, production efficiency can be effectively improved. Only one welding device can achieve the simultaneous performance of two old welding devices, which can also save plant space layout and achieve the purpose of reducing production costs.

[0006] Summary of the Invention

[0007] The object of the present invention is to provide a composite current collector bilateral double ultrasonic roller welding system based on the above-mentioned deficiencies in the prior art, which can improve welding efficiency and quality.

[0008] The technical solution adopted by the present invention to solve its technical problems is: a composite current collector bilateral double ultrasonic roller welding system, including a film unwinding mechanism, a foil unwinding mechanism, a roller pressing and smoothing mechanism, an ultrasonic roll welding mechanism and a winding mechanism, characterized in that a correction mechanism and a plurality of guide rollers are respectively arranged between the film unwinding mechanism and the foil unwinding mechanism and the roller pressing and smoothing mechanism, and the film unwinding mechanism and the foil unwinding mechanism respectively correct the film and foil through the correction mechanism and stretch them flat with the guide rollers, and then press them together through the roller pressing and smoothing mechanism, and then the ultrasonic roll welding mechanism performs welding to form a composite current collector film, which is wound up by the winding mechanism.

[0009] Furthermore, the ultrasonic seam welding mechanism includes two ultrasonic seam welding machines relatively arranged on both sides of the membrane material, each of the ultrasonic seam welding machines includes a seam welding chassis and an upper seam welding assembly, a lower seam welding assembly, an upper drive device and a lower drive device installed on the seam welding chassis, the upper seam welding assembly includes an upper seam welding mold, an upper ultrasonic generator, an upper ultrasonic transducer, an upper ultrasonic horn and an upper seam welding motor, the lower seam welding assembly includes a lower seam welding mold, a lower ultrasonic generator, a lower ultrasonic transducer, a lower ultrasonic horn and a lower seam welding motor, the upper ultrasonic generator is connected to the upper seam welding mold through the upper ultrasonic transducer and the upper ultrasonic horn, the lower ultrasonic generator is connected to the upper seam welding mold through the lower ultrasonic transducer and the lower ultrasonic The wave amplitude rod is connected to the lower roll welding mold, the upper roll welding motor and the lower roll welding motor are respectively connected to and drive the upper roll welding mold and the lower roll welding mold to rotate in different directions, the lower roll welding mold is placed directly below the upper roll welding mold, and a welding gap for clamping the composite current collector is provided between the upper roll welding mold and the lower roll welding mold; the roll welding chassis is also equipped with a vertically arranged chassis guide rail, the upper roll welding assembly and the lower roll welding assembly are respectively installed on the chassis guide rail through an upper slide and a lower slide, the upper drive device and the lower drive device are respectively connected and can drive the upper slide and the lower slide to slide up and down along the chassis guide rail, thereby adjusting the welding gap between the upper roll welding mold and the lower roll welding mold to adapt to the welding of composite current collectors of different thicknesses.

[0010] Furthermore, the upper drive device and the lower drive device preferably use cylinders, which have the advantages of small size and cleanliness. They can also be hydraulic cylinders or linear reciprocating mechanisms connected by motor drive.

[0011] Furthermore, the upper and lower slides are also equipped with limit rods, each provided with a limit block that contacts the chassis to limit the maximum travel between the upper and lower slides. A retractable folding plate or telescopic rod is also installed between the upper and lower slides, with the ends of the folding plate or telescopic rod respectively connected to the upper and lower slides. The retracted state of the folding plate or telescopic rod ensures that the minimum distance between the upper and lower slides remains unchanged, thereby ensuring a sufficient safety distance between the upper and lower roll welding molds. The extended state of the folding plate or telescopic rod also ensures that the maximum distance between the upper and lower slides remains unchanged, thereby protecting the travel and providing a double insurance function with the limit rod.

[0012] Furthermore, each of the ultrasonic seam welding machines also includes a seam welding machine base, which is provided with base guide rails arranged on the left and right sides. The chassis is installed on the base guide rails through a bottom slide, and the bottom slide is provided with fastening bolts that fix the bottom slide to the base guide rails. In this way, the distance between the ultrasonic seam welding machine and the two sides of the membrane material can be adjusted to adapt to the welding production of products of different sizes.

[0013] Furthermore, each of the ultrasonic seam welding machines further includes a support welding roller assembly mounted on the front and rear sides of the seam welding machine box, the support welding roller assembly respectively including a support welding mounting plate and an upper support welding roller and a lower support welding roller mounted on the support welding mounting plate, a clamping gap for clamping the composite current collector is provided between the upper support welding roller and the lower support welding roller, and the support welding roller assembly can keep the composite current collector clamped in the clamping gap and the welding gap in a relatively straight state, thereby improving the welding effect. Among them, the upper support welding roller is mounted on the support welding mounting plate so as to be movable up and down by a support welding adjustment slide, and the support welding mounting plate is also equipped with a handle connected to and capable of driving the support welding adjustment slide to move up and down, so that the clamping gap between the upper support roller and the lower support roller can be adjusted to facilitate the matching of composite current collectors of different thicknesses.

[0014] Furthermore, the correction mechanism includes a primary correction mechanism and a secondary correction mechanism, the foil unwinding mechanism includes an A-side foil unwinding mechanism, a B-side foil unwinding mechanism, a C-side foil unwinding mechanism and a D-side foil unwinding mechanism, and the film unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism and the D-side foil unwinding mechanism are respectively provided with the primary correction mechanism for correcting the position of the coil; the roller pressure smoothing mechanism includes a front roller pressure smoothing mechanism and a rear roller pressure smoothing mechanism, and the front roller pressure smoothing mechanism and the rear roller pressure smoothing mechanism are respectively placed on the front and rear sides of the ultrasonic roll welding mechanism, and the film unwinding mechanism, the A-side foil unwinding mechanism, The secondary correction mechanism for correcting the position of the coil is respectively arranged between the B-side foil unwinding mechanism, the C-side foil unwinding mechanism and the D-side foil unwinding mechanism and the front roller pressing and smoothing mechanism. The front roller pressing and smoothing mechanism respectively converges and flattens the coils of the A-side foil unwinding mechanism and the B-side foil unwinding mechanism on one side of the upper and lower surfaces of the coil of the membrane unwinding mechanism. The front roller pressing and smoothing mechanism respectively converges and flattens the coils of the C-side foil unwinding mechanism and the D-side foil unwinding mechanism on the other side of the upper and lower surfaces of the membrane unwinding mechanism. After welding by the ultrasonic rolling welding mechanism, a double-sided double-sided foil-filled composite current collector membrane is formed, and then the weld mark is flattened by the rear roller pressing and smoothing mechanism.

[0015] Furthermore, the first-level correction mechanism includes a first correction slide, a first correction motor and a first correction sensor. The film unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism and the D-side foil unwinding mechanism are respectively installed on the first correction slide. The first correction motor is connected and drives the first correction slide to move along the tangential direction of the coil transmission direction to adjust the unwinding position of the film unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism or the D-side foil unwinding mechanism. The first correction sensor is used to detect the position of the coil of the film unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism and the D-side foil unwinding mechanism. The secondary deflection correction mechanism includes a second deflection correction slide, a second deflection correction motor and a second deflection correction sensor. The second deflection correction slide is equipped with a front guide roller and a rear guide roller for transmitting the coil of the film material unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism or the D-side foil unwinding mechanism. The front guide roller and the rear guide roller are respectively installed on the front side and the rear side of the upper end face of the second deflection correction slide. The second deflection correction sensor is placed below the rear guide roller. The second deflection correction sensor is used to detect whether the coil passing through the rear guide roller is offset; the second deflection correction motor is connected to and drives the second deflection correction slide to move or swing to adjust the transmission position of the coil of the film material unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism and the D-side foil unwinding mechanism. Among them, the first and second correction sensors both use contact displacement sensors or proximity switches. If the coil is offset during transmission, the coil will trigger the contact displacement sensor or proximity switch to determine which coil has offset, which is convenient for maintenance and correction.

[0016] Furthermore, the front roller smoothing mechanism and the rear roller smoothing mechanism both include a smoothing base and an upper pressing roller, a lower pressing roller and two pressing cylinders installed on the smoothing base. A smoothing gap for the coils of the film unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism and the D-side foil unwinding mechanism is provided between the upper pressing roller and the lower pressing roller. Both ends of the upper pressing roller are mounted on the smoothing base so as to be movable up and down through a pressing roller slide. The two pressing cylinders are respectively connected to the pressing roller slide and can drive the upper pressing roller to move up and down, thereby adjusting the size of the smoothing gap to achieve the purpose of merging the coils and flattening the coils.

[0017] Furthermore, the plurality of guide rollers may include a plurality of transmission active rollers and transmission driven rollers, which are arranged between the film material unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism, and the D-side foil unwinding mechanism and the roller pressing and smoothing mechanism, as well as between the roller pressing and smoothing mechanism and the winding mechanism, and the transmission active rollers and transmission driven rollers assist in conveying the coils on the film material unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism, and the D-side foil unwinding mechanism to the roller pressing and smoothing mechanism and the winding mechanism. Among them, the transmission active rollers and the transmission driven rollers are provided with a plurality of anti-slip rods at intervals around the periphery. On the one hand, the anti-slip rods can prevent the coils from falling off the transmission active rollers and the transmission driven rollers. On the other hand, the anti-slip rods can assist in changing the contact angle between the coils and the transmission active rollers or the transmission driven rollers, so that the conveying of the driven rollers and the coils is more stable. The transmission active roller or the transmission driven roller may also be provided with a tension sensor to detect whether each coil slips during the transmission process, thereby ensuring that the transmission speed of each coil is consistent.

[0018] Furthermore, the present invention provides a double-sided double ultrasonic roller welding system for composite current collectors, which also includes a detection mechanism. The detection mechanism includes a controller, a laser speed and length meter, a display, a labeling machine, an ultrasonic dust collector, and several CCD image sensors. The laser speed and length meter is arranged on the rear side of the ultrasonic rolling welding mechanism to measure the transmission speed and length of the double-sided double-sided foil composite current collector coil after welding by the ultrasonic rolling welding mechanism; the CCD image sensor, labeling machine, and ultrasonic dust collector are sequentially arranged between the ultrasonic rolling welding mechanism and the winding mechanism. The sensor is used to photograph the double-sided double-sided foil-patch composite current collector coil after welding, the labeling machine is used to label the double-sided double-sided foil-patch composite current collector coil after welding, and the ultrasonic dust collector is used to remove dust from the double-sided double-sided foil-patch composite current collector coil after welding. The controller is electrically connected to the laser speed and length measuring instrument, display, labeling machine, ultrasonic dust collector and CCD image sensor respectively, and the image data taken by the CCD image sensor is displayed in real time through the display, which is convenient for workers to observe and judge the welding condition of the composite film, discover product defects in time, and correct production equipment.

[0019] Furthermore, the present invention provides a composite current collector double-sided double ultrasonic roller welding system also includes a cutting mechanism, the cutting mechanism includes a splitter, two laser tab cutting machines and at least one group of cutting rollers, the group of cutting rollers is placed on the rear side of the ultrasonic roller welding mechanism to transmit the composite current collector film after welding, and the group of cutting rollers is arranged horizontally, the two laser tab cutting machines are placed directly above the group of cutting rollers, and laser cutting is performed on the tabs on both sides of the composite current collector film respectively, the splitter is placed between the laser tab cutting machine and the winding mechanism, the splitter cuts the composite current collector film into two parts, and then the winding mechanism winds up the composite current collector film.

[0020] Furthermore, the present invention provides a composite current collector bilateral double ultrasonic roller welding system including a box body, a support plate provided in the box body, the foil unwinding mechanism, the roller smoothing mechanism and the detection mechanism are all installed on the support plate, the membrane unwinding mechanism is placed in front of the foil unwinding mechanism, the winding mechanism is placed on the rear side of the roller smoothing mechanism, and the support plate is provided with a hollow portion for the ultrasonic roll welding machine to move. Such a reasonable layout can greatly save the volume and space size of the box body, making the structure more compact; a number of fan filter units (FFU, the full name of which is Fan Filter Unit in English, is a self-powered air supply filter device, a modular terminal air supply device with filtering function) are provided on the top of the box body, which can ensure the safety of operating personnel in the welding operation area and keep the working environment clean and tidy.

[0021] Compared with the existing technology, the beneficial effects of the present invention are as follows: this solution uses two ultrasonic roll welding machines to perform bilateral welding on the membrane material to form a bilateral double-sided foil-patch composite current collector, so that one device can simultaneously achieve the working efficiency of two old-type welding devices, saving factory space layout and achieving the purpose of reducing production costs. This solution adopts a two-level deviation correction in coil transmission, which can correct and prevent the offset of each coil during the transmission process, and is equipped with post-weld detection mechanisms such as CCD image sensors, which makes it convenient for workers to observe and judge the welding condition of the composite membrane, discover product defects in time, correct production equipment, and ensure the final winding and welding quality. The structural layout of this solution is scientific and reasonable, and can improve the production efficiency and quality of the current collector. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG1 is a perspective schematic diagram of the overall structure of Example 1 of the present invention;

[0023] FIG2 is a schematic plan view of the structural arrangement within the housing of Example 1 of the present invention;

[0024] 3a and 3b are schematic perspective views of the structure inside the box of Example 1 of the present invention;

[0025] 4a-4d are schematic structural diagrams of an ultrasonic seam welding machine according to embodiment 1 of the present invention;

[0026] FIG5 is a schematic perspective view of the structure of the secondary deviation-correcting mechanism of Example 1 of the present invention;

[0027] FIG6 is a perspective schematic diagram of the structure of the front roller smoothing mechanism in Example 1 of the present invention;

[0028] FIG7 is a perspective schematic diagram of the structure of the transmission active roller and the transmission driven roller in Example 1 of the present invention;

[0029] FIG8 is a schematic plan view of the structural layout of Example 2 of the present invention. DETAILED DESCRIPTION

[0030] The present invention is further described below with reference to the accompanying drawings. It should be noted that these specific embodiments are merely representative of the present invention, and the specific methods, devices, conditions, materials, etc. exemplified herein are not intended to limit the present invention or the corresponding embodiments. The description of orientation herein is based on Figure 2 as a reference standard.

[0031] Example 1

[0032] A composite current collector bilateral double ultrasonic roller welding system, as shown in Figure 1, includes a closed housing 1. A display 13 and a controller 12 are provided on the left side of the housing 1. The controller 12 is provided with operating buttons and a touch screen. The housing 1 is provided with a support plate, a film unwinding mechanism 2, an ultrasonic roll welding mechanism 5, and a rewinding mechanism 6. The support plate is a vertical support plate that can be mounted on a rear bracket within the housing 1 and used for various functional mechanism modules. A foil unwinding mechanism and a roller-pressing and smoothing mechanism are mounted on the support plate. By rationally arranging the foil unwinding mechanism, roller-pressing and smoothing mechanism, a deviation correction mechanism, and several guide rollers on the support plate, the transport of the film and foil becomes more stable and reliable, and local space in the equipment is saved. The film unwinding mechanism 2 is placed in front of the foil unwinding mechanism, and the rewinding mechanism 6 is placed behind the roller-pressing and smoothing mechanism. A hollow portion is provided on the support plate for the ultrasonic roll welding mechanism 5 to operate. A plurality of fan filter units 11 (FFU) are provided on the top of the box 1. The fan filter units 11 supply air to the box 1, so that a clean welding operation room is formed in the box 1 to avoid pollution such as dust.

[0033] As shown in Figures 2-3b, in this embodiment, the foil unwinding mechanism includes an A-side foil unwinding mechanism 31, a B-side foil unwinding mechanism 32, a C-side foil unwinding mechanism 33, and a D-side foil unwinding mechanism 34. In actual applications, it is also possible to adapt to adding or reducing several side foil unwinding mechanisms. The roller-pressing and smoothing mechanism includes a front roller-pressing and smoothing mechanism 41 and a rear roller-pressing and smoothing mechanism 42, which are respectively placed on the front and rear sides of the ultrasonic seam welding mechanism 5. The film unwinding mechanism 2, the A-side foil unwinding mechanism 31, the B-side foil unwinding mechanism 32, the C-side foil unwinding mechanism 33, and the D-side foil unwinding mechanism 34 are each provided with a correction mechanism and a plurality of guide rollers between the front roller pressing and smoothing mechanism 41. These mechanisms are used to correct the deviation of the film and the upper and lower foils, and to stretch and smooth them by the guide rollers to eliminate the corresponding stresses, before being pressed together by the front roller pressing and smoothing mechanism 41 for welding. This effectively improves welding reliability and yield rate. The film and foil are bent, stretched, and corrected within the very small space of the box, effectively saving working space. Preferably, the film material unwinding mechanism 2, the A-side foil unwinding mechanism 31, the B-side foil unwinding mechanism 32, the C-side foil unwinding mechanism 33 and the D-side foil unwinding mechanism 34 are respectively provided with a primary correction mechanism 21 for correcting the position of the coil; the film material unwinding mechanism 2, the A-side foil unwinding mechanism 31, the B-side foil unwinding mechanism 32, the C-side foil unwinding mechanism 33 and the D-side foil unwinding mechanism 34 and the front roller pressure smoothing mechanism 41 are respectively provided with a secondary correction mechanism 22 for correcting the position of the coil. The coils of the A-side foil unwinding mechanism 31 and the B-side foil unwinding mechanism 32 are respectively converged and flattened on one side of the upper and lower surfaces of the coil of the membrane unwinding mechanism 2, and the front roller pressing and smoothing mechanism 41 converges and flattens the coils of the C-side foil unwinding mechanism 33 and the D-side foil unwinding mechanism 34 on the other side of the upper and lower surfaces of the membrane unwinding mechanism 2. The converged and flattened membrane materials are welded by the ultrasonic rolling welding mechanism 5 to form a double-sided double-sided foil-patch composite current collector membrane, and then the weld marks are flattened by the rear roller pressing and smoothing mechanism, and finally reeled by the reeling mechanism 6.In this embodiment, the film material unwinding mechanism 2 is composed of a film material roll and a film material unwinding active roller driven by a motor, the A side foil material unwinding mechanism 31 is composed of an A side foil material roll and an A side foil material unwinding active roller driven by a motor, the B side foil material unwinding mechanism 32 is composed of a B side foil material roll and a B side foil material unwinding active roller driven by a motor, the C side foil material unwinding mechanism 33 is composed of a C side foil material roll and a C side foil material unwinding active roller driven by a motor, the D side foil material unwinding mechanism 34 is composed of a D side foil material roll and a D side foil material unwinding active roller group driven by a motor. A plurality of transmission active rollers 23 and transmission driven rollers 24 are further arranged between the film material unwinding mechanism 2, the A-side foil material unwinding mechanism 31, the B-side foil material unwinding mechanism 32, the C-side foil material unwinding mechanism 33 and the D-side foil material unwinding mechanism 34 and the front roller pressing and smoothing mechanism 41, as well as between the rear roller pressing and smoothing mechanism 42 and the winding mechanism 6. The transmission active rollers 23 and the transmission driven rollers 24 assist in conveying the coils on the film material roll, the A-side foil material roll, the B-side foil material roll, the C-side foil material roll and the D-side foil material roll to the roller pressing and smoothing mechanism and the winding mechanism 6.

[0034] Among them, the film material unwinding mechanism 2 and the winding mechanism 6 are respectively installed on the brackets inside the feeding side and the discharging side of the box body, and the rest, such as the film material unwinding mechanism 2, the A-side foil material unwinding mechanism 31, the B-side foil material unwinding mechanism 32, the C-side foil material unwinding mechanism 33 and the D-side foil material unwinding mechanism 34, as well as the front roller pressing and smoothing mechanism 41, the rear roller pressing and smoothing mechanism 42, the transmission active roller 23 and the transmission driven roller 24, are all installed on the support plate. In terms of layout, high-power drive equipment is arranged on one side of the support plate, and the roller shaft and the like pass through the other side of the support plate to transmit the film material, which can greatly save equipment space and is conducive to localization, dust removal, maintenance and heat dissipation of the equipment.

[0035] As shown in Figures 4a-4d, the ultrasonic seam welding mechanism 5 includes two ultrasonic seam welders arranged on both sides of the film material. Each of the ultrasonic seam welders includes a seam welding machine box 51, a seam welding machine base 52, and an upper seam welding assembly and a lower seam welding assembly installed on the seam welding machine box 51. The seam welding machine base 52 is provided with a machine base guide rail 521 arranged in the left and right directions. The seam welding machine box 51 is installed on the machine base guide rail 521 through a bottom slide 522. The bottom slide 522 is provided with a fastening bolt 523 that fixes the bottom slide 522 to the machine base guide rail 521, so that the front and rear position of the seam welding machine box can be adjusted. The two ultrasonic seam welders are respectively installed on both sides of the support plate in the box body, and one of the ultrasonic seam welders passes through the hollow portion, which can effectively save installation space.

[0036] The upper roll welding assembly includes an upper roll welding mold 531, an upper ultrasonic generator 532, an upper ultrasonic transducer 533, an upper ultrasonic horn 534 and an upper roll welding motor 535. The lower roll welding assembly includes a lower roll welding mold 541, a lower ultrasonic generator 542, a lower ultrasonic transducer 543, a lower ultrasonic horn 544 and a lower roll welding motor 545. The upper ultrasonic generator 532 is connected to the upper roll welding mold 531 through the upper ultrasonic transducer 533 and the upper ultrasonic horn 534. The lower ultrasonic generator 542 is connected to the lower roll welding mold 541 through the lower ultrasonic transducer 543 and the lower ultrasonic amplitude transformer 544. The upper roll welding motor 535 and the lower roll welding motor 545 are respectively connected to and drive the upper roll welding mold 531 and the lower roll welding mold 541 to rotate in different directions and rotate towards each other. The lower roll welding mold 541 is placed directly below the upper roll welding mold 531. A welding gap for clamping the composite current collector film is provided between the upper roll welding mold 531 and the lower roll welding mold 541. The seam welding chassis 51 is also equipped with an upper drive device 536 and a lower drive device 546. The seam welding chassis 51 is equipped with a vertically arranged seam welding chassis guide rail 513. The upper and lower seam welding assemblies are respectively installed on the seam welding chassis guide rail 513 via an upper slide 514 and a lower slide 515. The upper drive device 536 and the lower drive device 546 are respectively connected and can drive the upper slide 514 and the lower slide 515 to slide up and down along the seam welding chassis guide rail 513, thereby adjusting the welding gap between the upper seam welding mold 531 and the lower seam welding mold 541 to adapt to welding composite current collectors of different thicknesses. Among them, the upper drive device 536 and the lower drive device 546 preferably use a cylinder, which has the advantages of small size and cleanliness. It can also be a hydraulic cylinder or a linear reciprocating mechanism connected by a motor drive.

[0037] Furthermore, limit rods 516 are mounted on the upper slide 514 and the lower slide 515. Each limit rod 516 includes a limit block that contacts the seam welding chassis 51 to limit the maximum travel between the upper slide 514 and the lower slide 515. A retractable folding plate 517 or telescopic rod is mounted between the upper slide 514 and the lower slide 515, with its ends connecting the upper slide 514 and the lower slide 515, respectively. When the folding plate 517 or telescopic rod is retracted, it ensures that the minimum distance between the upper slide 514 and the lower slide 515 remains unchanged, thereby ensuring a sufficient safety distance between the upper and lower seam welding molds 531 and 541. When the folding plate 517 or telescopic rod is extended, it also ensures that the maximum distance between the upper slide 514 and the lower slide 515 remains unchanged, thus protecting the travel and providing a double insurance function with the limit rod 516.

[0038] Furthermore, a plurality of heat dissipation holes 511 are provided on the seam welding chassis 51 , and a heat dissipation fan is installed on the heat dissipation holes 511 to reduce the temperature inside the seam welding chassis 51 .

[0039] Furthermore, a ruler is provided on the bottom slide 522 to facilitate the determination of the displacement size of the seam welding chassis 1 .

[0040] Furthermore, the seam welding machine box 551 is provided with a lifting lug 512 to facilitate lifting to the production line.

[0041] Furthermore, each of the ultrasonic seam welding machines further includes a support welding roller assembly mounted on the front and rear sides of the seam welding machine box 51, the support welding roller assembly including a support welding mounting plate 551 and an upper support welding roller 552 and a lower support welding roller 553 mounted on the support welding mounting plate 551, a clamping gap for clamping the composite current collector is provided between the upper support welding roller 552 and the lower support welding roller 553, and the support welding roller assembly can keep the composite current collector clamped in the clamping gap and the welding gap in a relatively straight state, thereby improving the welding effect. Among them, the upper support welding roller 552 is mounted on the support welding mounting plate 551 so as to be movable up and down by adjusting the slide 554, and the support welding mounting plate 551 is also equipped with a handle 555 connected to and capable of driving the adjusting slide 554 to move up and down, so that the clamping gap between the upper support roller 552 and the lower support roller 553 can be adjusted to facilitate the matching of composite current collectors of different thicknesses.

[0042] Furthermore, the seam welding machine box 51 is also equipped with an air nozzle 561 and a waste suction pipe 562 aimed at the upper seam welding mold and the lower seam welding mold to remove adhesives on the seam welding molds.

[0043] Furthermore, the first-level correcting mechanism 21 includes a first correcting slide, a first correcting motor and a first correcting sensor. The film unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism and the D-side foil unwinding mechanism are respectively installed on the first correcting slide. The first correcting motor is connected and drives the first correcting slide to move along the tangential direction of the coil transmission direction to adjust the unwinding position of the film unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism or the D-side foil unwinding mechanism. The first correcting sensor is used to detect the position of the coil of the film unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism and the D-side foil unwinding mechanism.

[0044] As shown in Figure 5, further, the secondary deflection correction mechanism 22 includes a second deflection correction slide 221, a second deflection correction motor and a second deflection correction sensor 224. The second deflection correction slide is equipped with a front guide roller 222 and a rear guide roller 223 for transmitting the coil of the film unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism or the D-side foil unwinding mechanism. The front guide roller 222 and the rear guide roller 223 are respectively installed on the front and rear sides of the upper end face of the second deflection correction slide 221. The second deflection correction sensor 224 is placed below the rear guide roller 223. The second deflection correction sensor 224 is used to detect whether the coil passing through the rear guide roller 223 is offset; the second deflection correction motor is connected to and drives the second deflection correction slide 221 to move or swing to adjust the transmission position of the coil of the film unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism and the D-side foil unwinding mechanism. Wherein, the first and second deflection correction sensors are both contact displacement sensors or proximity switches. If the coil is offset during the transmission process, the coil will trigger the contact displacement sensor or proximity switch to determine which coil has deviated, which is convenient for maintenance and correction. The second deflection correction slide 221 can also be provided with a limit block 225 that limits the coil position of the film roll, A-side foil roll, B-side foil roll, C-side foil roll and D-side foil roll. A gap is provided between the limit block 225 and the front guide roller 222 and the rear guide roller 223 so that only coils of standard size can pass through, so as to prevent the coil from deviating during the transmission process. In actual applications, the first-level deflection correction mechanism 21 and the second-level deflection correction mechanism 22 can also use the deflection corrector in the existing technology, or can use the intelligent deflection correction equipment commonly used on the market or the infrared coil online deviation detection device.

[0045] As shown in Figure 6, further, the front roller smoothing mechanism 41 and the rear roller smoothing mechanism 42 both include a smoothing base 411 and an upper pressing roller 412, a lower pressing roller 413 and two pressing cylinders 414 installed on the smoothing base 411. A smoothing gap for pressing the film roll, A-side foil roll, B-side foil roll, C-side foil roll and D-side foil roll is provided between the upper pressing roller 412 and the lower pressing roller 413. Both ends of the upper pressing roller 412 are mounted on the smoothing base 411 so as to be movable up and down through slides 415. The two pressing cylinders 414 are respectively connected to the slides 415 and can drive the upper pressing roller 412 to move up and down, thereby adjusting the size of the smoothing gap to achieve the purpose of merging the rolls and flattening the rolls.

[0046] As shown in FIG7 , the plurality of guide rollers may further include a plurality of active transmission rollers 23 and passive transmission rollers 24. The active transmission rollers 23 and passive transmission rollers 24 are provided with a plurality of anti-slip bars 231 at intervals around the periphery. The anti-slip bars 231 can prevent the coil from falling off the active transmission rollers 23 and passive transmission rollers 24. Furthermore, the anti-slip bars 231 can assist in changing the contact angle between the coil and the active transmission rollers 23 or passive transmission rollers 24, thereby making the conveying of the passive rollers and the coil more stable. Furthermore, the active transmission rollers 23 or passive transmission rollers 24 may also be provided with tension sensors to detect whether the coils slip during transmission, thereby ensuring that the transmission speed of each coil is consistent.

[0047] Furthermore, the present invention provides a double-sided double ultrasonic roller welding system for composite current collectors, which also includes a detection mechanism. The detection mechanism includes the controller 12, a laser speed and length meter 14, a display 13, a labeling machine 16, an ultrasonic dust collector 17 and several CCD image sensors 15. The laser speed and length meter 14 is arranged on the rear side of the ultrasonic rolling welding mechanism 5 to measure the transmission speed and length of the double-sided double-sided composite current collector coil after welding by the ultrasonic rolling welding mechanism 5; the CCD image sensor 15, the labeling machine 16 and the ultrasonic dust collector 17 are sequentially arranged between the ultrasonic rolling welding mechanism 5 and the winding mechanism 6. The image sensor 15 is used to photograph the double-sided, double-foil-patched composite current collector coil after welding. The labeling machine 16 is used to label the double-sided, double-foil-patched composite current collector coil after welding. The ultrasonic dust collector 17 is used to remove dust from the double-sided, double-foil-patched composite current collector coil after welding. The controller 12 is electrically connected to the laser speed and length measuring instrument 14, the display 13, the labeling machine 16, the ultrasonic dust collector 17, and the CCD image sensor 15, and displays the image data captured by the CCD image sensor 15 in real time on the display 13, making it convenient for workers to observe and judge the welding condition of the composite membrane, promptly discover product defects, and correct production equipment. The CCD image sensor 15 includes a plurality of first CCD image sensors, a plurality of second CCD image sensors, and a plurality of third CCD image sensors. The plurality of first CCD image sensors are arranged on both sides of the double-sided, double-foil-patched composite current collector coil to monitor the welding condition of both sides of the composite membrane. The second CCD image sensor is arranged below the labeling machine 16 to monitor the labeling status of the labeling machine 16. The third CCD image sensor is used in conjunction with a searchlight instrument to detect the transmittance of the weld of the composite film. If the transmittance of the weld is less than 30%, it means that there is a defect of loose welding at this location.

[0048] This solution uses two ultrasonic roll welding machines to perform bilateral welding on the membrane material, forming a double-sided, double-sided foil-filled composite current collector. This allows one device to simultaneously achieve the work efficiency of two older welding devices, saving factory space layout and achieving the goal of reducing production costs. This solution uses a two-level deviation correction for coil transmission, which can correct and prevent the offset of each coil during transmission. It is also equipped with post-weld detection mechanisms such as CCD image sensors to facilitate workers to observe and judge the welding condition of the composite film, promptly discover product defects, correct production equipment, and ensure the final winding and welding quality. As shown in Table 1 below, in actual application, this solution was tested for pure copper foil and pure aluminum foil, and the welding production efficiency can reach 80 meters / minute. Among them, the width of group A and group B foils are both 3mm. The tension requirement for group A and group B foils during transportation is that the horizontal pulling force of 25mm long is not less than 15N. The physical thickness of group A foil is 0.0185mm, and the actual thickness after welding is 0.019mm. The physical thickness of group B foil is 0.032mm, and the actual thickness after welding is 0.032mm. The error meets the requirements.

[0049] Table 1

[0050] Example 2

[0051] A composite current collector bilateral double ultrasonic roller welding system comprises a box body 1 and a film material unwinding mechanism 2, a foil material unwinding mechanism, a roller pressing and smoothing mechanism, an ultrasonic rolling welding mechanism 5 and a winding mechanism 6 arranged in the box body 1. As shown in Figure 8, the difference between this embodiment and Example 1 lies in the slight change in the arrangement of the transmission rollers and the inclusion of a cutting mechanism. The cutting mechanism includes a splitter 71, two laser tab cutting machines 72, and at least one set of cutting rollers 73. The set of cutting rollers 73 is placed on the rear side of the detection mechanism to transmit the composite current collector film, and the set of cutting rollers 73 is arranged horizontally. The two laser tab cutting machines 72 are placed directly above the set of cutting rollers 73 to laser cut the tabs on both sides of the composite current collector film. The splitter 71 is placed between the laser tab cutting machine 72 and the winding mechanism 6. In this embodiment, the number of the winding mechanisms 6 is two. After the splitter 71 cuts the composite current collector film into two, the two winding mechanisms 6 respectively wind up the cut composite current collector film. This solution integrates the tab laser cutting process and the cutting process, improves the process of automated current collector production, and improves the production efficiency of the current collector.

[0052] The above is only a preferred embodiment of the present invention and should not be used to limit the scope of implementation of the present invention. In other words, any simple equivalent changes and modifications made according to the scope of the patent application and the content of the invention description are still within the scope of the patent of the present invention.

Claims

1. A double-sided double ultrasonic roller welding system for composite current collector, comprising a film unwinding mechanism, a foil unwinding mechanism, a roller pressing and smoothing mechanism, an ultrasonic rolling welding mechanism and a winding mechanism, characterized in that: A deviation correction mechanism and a plurality of guide rollers are respectively arranged between the film material unwinding mechanism and the foil material unwinding mechanism and the roller-pressing and smoothing mechanism. The film material unwinding mechanism and the foil material unwinding mechanism respectively pass the deviation correction adjustment of the deviation correction mechanism and stretch and flatten the film material and the foil material through the guide rollers, and then press them through the roller-pressing and smoothing mechanism, and then weld them through the ultrasonic rolling welding mechanism to form a composite current collector membrane, which is then rolled up by the winding mechanism.

2. A composite current collector bilateral double ultrasonic roll welding system according to claim 1, wherein the ultrasonic roll welding mechanism comprises two ultrasonic roll welding machines relatively arranged on both sides of the membrane material, each of the ultrasonic roll welding machines comprises a roll welding chassis and an upper roll welding assembly, a lower roll welding assembly, an upper drive device and a lower drive device installed on the roll welding chassis, the upper roll welding assembly comprises an upper roll welding mold, an upper ultrasonic generator, an upper ultrasonic transducer, an upper ultrasonic amplitude transformer and an upper roll welding motor, the lower roll welding assembly comprises a lower roll welding mold, a lower ultrasonic generator, a lower ultrasonic transducer, a lower ultrasonic amplitude transformer and a lower roll welding motor, the upper ultrasonic generator is connected to the upper roll welding mold via the upper ultrasonic transducer and the upper ultrasonic amplitude transformer, the lower ultrasonic The sonic wave generator is connected to the lower roll welding mold through the lower ultrasonic transducer and the lower ultrasonic amplitude transformer, the upper roll welding motor and the lower roll welding motor are respectively connected to and drive the upper roll welding mold and the lower roll welding mold to rotate in different directions, the lower roll welding mold is placed directly below the upper roll welding mold, and a welding gap for clamping the composite current collector film is provided between the upper roll welding mold and the lower roll welding mold; the roll welding chassis is also provided with a vertically arranged chassis guide rail, the upper roll welding assembly and the lower roll welding assembly are respectively installed on the chassis guide rail through an upper slide and a lower slide seat, the upper drive device and the lower drive device are respectively connected and can drive the upper slide and the lower slide seat to slide up and down along the chassis guide rail, thereby adjusting the welding gap between the upper roll welding mold and the lower roll welding mold.

3. The composite current collector double-sided double ultrasonic roller welding system according to claim 1, characterized in that: A limit rod is installed on the upper slide and the lower slide, and a limit block that conflicts with the chassis is set on the limit rod. A retractable folding plate or telescopic rod is also installed between the upper slide and the lower slide, and the two ends of the folding plate or telescopic rod are respectively connected to the upper slide and the lower slide.

4. The composite current collector double-sided double ultrasonic roller welding system according to claim 1, characterized in that: Each of the ultrasonic seam welding machines also includes a seam welding machine base, which is provided with base guide rails arranged on the left and right sides. The chassis is installed on the base guide rails through a bottom slide, and the bottom slide is provided with fastening bolts that fix the bottom slide on the base guide rails.

5. The composite current collector double-sided double ultrasonic roller welding system according to claim 1, characterized in that: Each of the ultrasonic roll welding machines also includes a welding roller assembly installed on the front and rear sides of the roll welding machine box, and the welding roller assembly includes a welding mounting plate and an upper welding roller and a lower welding roller installed on the welding mounting plate. The upper welding roller is installed on the welding mounting plate so that it can move up and down through a welding adjustment slide. A handle is installed on the welding mounting plate that is connected to and can drive the welding adjustment slide to move up and down. A clamping gap for clamping the composite current collector membrane is provided between the upper welding roller and the lower welding roller.

6. The composite current collector double-sided double ultrasonic roller welding system according to claim 1, characterized in that: The deflection correction mechanism includes a primary deflection correction mechanism and a secondary deflection correction mechanism, the foil unwinding mechanism includes an A-side foil unwinding mechanism, a B-side foil unwinding mechanism, a C-side foil unwinding mechanism and a D-side foil unwinding mechanism, and the film unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism and the D-side foil unwinding mechanism are respectively provided with the primary deflection correction mechanism for correcting the position of the coil; the rolling and smoothing mechanism includes a front rolling and smoothing mechanism and a rear rolling and smoothing mechanism, and the front rolling and smoothing mechanism and the rear rolling and smoothing mechanism are respectively placed at the front and rear sides of the ultrasonic rolling welding mechanism, and the film unwinding mechanism, the A-side foil unwinding mechanism, the B-side foil unwinding mechanism, the C-side foil unwinding mechanism and the D-side foil unwinding mechanism are respectively provided with the primary deflection correction mechanism for correcting the position of the coil; The secondary deviation correction mechanism for correcting the position of the coil is respectively arranged between the A-side foil unwinding mechanism, the C-side foil unwinding mechanism and the D-side foil unwinding mechanism and the front roller pressing and smoothing mechanism. The front roller pressing and smoothing mechanism respectively converges and flattens the coils of the A-side foil unwinding mechanism and the B-side foil unwinding mechanism on one side of the upper and lower surfaces of the coil of the film material unwinding mechanism. The front roller pressing and smoothing mechanism respectively converges and flattens the coils of the C-side foil unwinding mechanism and the D-side foil unwinding mechanism on the other side of the upper and lower surfaces of the film material unwinding mechanism. After welding by the ultrasonic rolling welding mechanism, a double-sided double-sided foil-filled composite current collector membrane is formed, and then the weld mark is flattened by the rear roller pressing and smoothing mechanism.

7. A composite current collector double-sided double ultrasonic roller welding system according to claim 6, characterized in that: The front roller smoothing mechanism and the rear roller smoothing mechanism both include a smoothing base and an upper pressing roller, a lower pressing roller and a clamping cylinder installed on the smoothing base. Both ends of the upper pressing roller are installed on the smoothing base through a pressing roller slide so that they can move up and down. The clamping cylinder is connected to the pressing roller slide and can drive the upper pressing roller to move up and down. A smoothing gap for clamping the film material unwinding mechanism, the A-side foil material unwinding mechanism, the B-side foil material unwinding mechanism, the C-side foil material unwinding mechanism and the D-side foil material unwinding mechanism is arranged between the upper and lower pressing rollers.

8. The composite current collector double-sided double ultrasonic roller welding system according to claim 1, characterized in that: It also includes a cutting mechanism, which includes a splitter, two laser pole ear cutting machines and at least one group of cutting rollers, wherein the group of cutting rollers is placed on the rear side of the ultrasonic roll welding mechanism to transmit the composite current collector film after welding, and the group of cutting rollers is horizontally arranged, and the two laser pole ear cutting machines are placed directly above the group of cutting rollers to laser cut the pole ears on both sides of the composite current collector film respectively, and the splitter is placed between the laser pole ear cutting machine and the winding mechanism, and after the splitter cuts the composite current collector film into two, the winding mechanism winds up the composite current collector film.

9. A composite current collector double-sided double ultrasonic roller welding system according to claims 1-8, characterized in that: It also includes a detection mechanism, which includes a controller, a laser speed and length meter, a display, a labeling machine, an ultrasonic dust collector and several CCD image sensors. The laser speed and length meter is arranged on the rear side of the ultrasonic rolling welding mechanism, and is used to measure the transmission speed and length of the double-sided double-sided foil-filled composite current collector coil after welding by the ultrasonic rolling welding mechanism; the CCD image sensor, the labeling machine and the ultrasonic dust collector are arranged in sequence between the ultrasonic rolling welding mechanism and the winding mechanism, the CCD image sensor is used to photograph the double-sided double-sided foil-filled composite current collector coil after welding, the labeling machine is used to label the double-sided double-sided foil-filled composite current collector coil after welding, and the ultrasonic dust collector is used to remove dust from the double-sided double-sided foil-filled composite current collector coil after welding. The controller is electrically connected to the laser speed and length meter, the display, the labeling machine, the ultrasonic dust collector and the CCD image sensor respectively, and the picture data photographed by the CCD image sensor is displayed in real time through the display.

10. A composite current collector double-sided double ultrasonic roller welding system according to claims 1-8, characterized in that: It also includes a box body, which is provided with a support plate, the foil unwinding mechanism and the roller smoothing mechanism are installed on the support plate, the film unwinding mechanism is placed in front of the foil unwinding mechanism, and the winding mechanism is placed on the rear of the roller smoothing mechanism, the support plate is provided with a hollow portion for the ultrasonic seam welding machine to move, and a plurality of fan filter units are provided on the top of the box body.

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