Angled Ultrasonic Welding Tip for Cleaner Battery Terminal Joints
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Solution Overview
Problem
Existing ultrasonic welding methods for secondary battery components face challenges with foreign matter generation and limited weldability, particularly when applying linear or transverse methods to metal objects like positive electrode terminals and current collectors, which can lead to internal damage and deformation.
Innovation Solution
An ultrasonic welding apparatus with a modified 'L-shaped' horn and tip configuration, coupled with a suction device, applies ultrasonic waves at an angle of 80° to 100° and efficiently removes foreign matter through linear vibration, supported by an anvil, enhancing weldability and minimizing heat input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser welding is applied to join positive electrode terminal and current collector, then welding speed and energy density are improved, but internal damage to electrode assembly increases due to high heat input and metal foreign matter generation
Solution Approach 1:
The patent replaces laser welding (thermal energy-based mechanical system) with ultrasonic welding (vibration-based mechanical system). The ultrasonic welding device uses high-frequency vibrations to join the positive electrode terminal and current collector, eliminating the need for high heat input that causes internal damage and metal foreign matter generation in laser welding.
Solution Approach 2:
The patent changes the energy input parameters from high-temperature thermal energy (laser) to mechanical vibration energy (ultrasonic). By controlling vibration amplitude, frequency, and applying force, the welding process achieves strong joints without the harmful thermal effects that damage the electrode assembly internally.
2Shape
If linear ultrasonic welding method is applied to metal objects, then deformation is minimized, but foreign matter generation occurs at vibration direction switching points
Solution Approach 1:
The patent extracts and removes the harmful foreign matter generated during ultrasonic welding using a suction device. The suction device is positioned to capture metal particles and foreign matter at the welding zone, preventing contamination and quality issues while maintaining the benefits of linear welding method.
Solution Approach 2:
The suction device acts as an intermediary between the welding zone and the environment, capturing and removing foreign matter before it can cause contamination or quality defects. This mediator approach allows the linear welding method to be used effectively despite foreign matter generation.
3Reliability
If transverse or torsional ultrasonic welding method is applied to metal objects, then weldability is improved, but deformation of the object increases
Solution Approach 1:
The patent employs dynamic control of the ultrasonic welding process by adjusting vibration amplitude, frequency, and applied force parameters. This dynamic approach allows optimization of weldability while minimizing deformation, and enables the system to adapt to different welding conditions and material properties.
Solution Approach 2:
The patent optimizes welding parameters including vibration amplitude, frequency, and applied force to achieve the best balance between weldability and deformation control. By carefully controlling these parameters, the system achieves strong welds with minimal distortion of the workpiece.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus reduces the risk of internal damage and improves weldability by effectively collecting and removing foreign matter, ensuring high-quality welds on secondary battery components like positive electrode terminals and current collectors.
Implementation Method 1
a tip part coupled to the horn part and configured to apply the ultrasonic wave transmitted from the horn part to an object to be welded, and to apply the ultrasonic wave at an angle in a range of 80° to 100° with respect to a direction in which the horn part transmits the ultrasonic wave
Implementation Method 2
a suction device connected to the anvil and configured to remove foreign matter generated from ultrasonic welding performed on the object to be welded
Data Source
AI summary
An ultrasonic welding apparatus includes a housing; a horn part coupled to the housing and configured to transmit an ultrasonic wave in one direction; a tip part coupled to the horn part and configured to apply the ultrasonic wave transmitted from the horn part to an object to be welded, and to apply the ultrasonic wave at an angle of 80° or greater and 100° or less with respect to a direction in which the horn part transmits the ultrasonic wave; an anvil part configured to support the object to be welded; and a suction connected to the anvil part and configured to suck a foreign matter generated resulting from ultrasonic welding, in which the tip part is configured to be driven by linear vibration with respect to the object to be welded, and achieves the effects of easily removing foreign matter and improving welding quality.