Ultrasonic Welding System for Rechargeable Battery Electrode Tab Protection
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Solution Overview
Problem
Conventional ultrasonic welding systems for rechargeable battery modules often damage the electrode tab due to direct application of ultrasonic waves, leading to tearing and reduced durability.
Innovation Solution
An ultrasonic welding system that bonds the electrode lead to the electrode tab without directly applying ultrasonic waves to the tab, using an anvil and horn configuration with a supply device to position and fix the lead, and applying ultrasonic waves between the anvil and horn to generate frictional heat for welding, while a pusher mechanism prevents tab tearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic waves are directly applied to the electrode tab through the horn, then welding efficiency is improved, but the electrode tab is damaged and torn
Solution Approach 1:
The patent introduces an electrode lead as an intermediary component between the horn and the electrode tab. The ultrasonic waves are applied to the electrode lead instead of directly to the electrode tab, and the electrode lead transfers the welding action to the electrode tab. This mediator approach allows efficient welding while protecting the electrode tab from direct ultrasonic exposure that causes damage and tearing.
2Strength
If the horn presses directly on the electrode tab to generate frictional heat, then welding strength is improved, but the bent portion of the stack and electrode tab is damaged
Solution Approach 1:
The electrode lead serves as a mediator that receives the pressing force and ultrasonic vibration from the horn and transfers it to the electrode tab. This indirect application of force through the electrode lead generates sufficient frictional heat for strong welding while avoiding direct compression of the bent portion of the stack and electrode tab, thereby preventing damage to these vulnerable areas.
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
This method reduces damage to the electrode tab, enhances durability, and improves welding strength by minimizing direct ultrasonic wave application and using a pusher mechanism to prevent tab tearing during the welding process.
Implementation Method 1
the horn vibrates and presses the lead terminal and the stack, the lead terminal and the stack may be welded by frictional heat generated between the lead terminal and the stack
Implementation Method 2
welded by frictional heat generated between the lead terminal and the stack
Data Source
AI summary
An ultrasonic welding system for a rechargeable battery for mutually welding and bonding includes: a welding apparatus including an anvil and a horn to perform welding and bonding an electrode tab and an electrode lead extending from an electrode assembly of the rechargeable battery through ultrasonic welding by mutually pressing the electrode tab and the electrode lead supplied between the anvil and the horn; and a supply device moves in a vertical or horizontal direction and supplies the electrode lead between the anvil and the horn.