Battery Pack Coupling Assisting Member Ultrasonic Welding

The patent replaces the mechanical bolt-fixing system with an ultrasonic welding system. The ultrasonic welding apparatus uses high-frequency vibrations to melt and fuse the lead tabs directly to the battery cell terminals, eliminating the need for mechanical fasteners. This substitution removes the weight of bolts and fastening components while creating a more robust welded joint that better resists impact and vibrations compared to mechanical connections.

The patent changes the connection method from mechanical (bolts) to thermal-mechanical (ultrasonic welding). By applying ultrasonic vibration energy, the lead tabs are locally melted and fused to the terminals, creating a metallurgical bond. This parameter change in the connection process eliminates the need for separate fastening components and produces a stronger, more impact-resistant joint with reduced overall weight.

The patent replaces the multi-step mechanical assembly process (positioning bolts, threading, tightening, and securing) with a single-step ultrasonic welding process. The welding apparatus automatically positions and fuses the lead tabs to the terminals through controlled ultrasonic vibration, eliminating the need for multiple manual or automated fastening operations. This simplifies the manufacturing process while ensuring consistent, stable electrical connections.

The patent incorporates preliminary positioning features in the battery cell design, such as recesses or guides that pre-position the lead tabs before welding. This preliminary action ensures proper alignment is achieved automatically during assembly, eliminating the need for complex positioning and adjustment steps that would be required for mechanical fastening, thereby simplifying the overall manufacturing process.

The patent merges the positioning and connection operations into a single ultrasonic welding step. The welding apparatus is designed to automatically position and weld multiple lead tabs simultaneously or in rapid sequence, combining what would otherwise be separate positioning and fastening operations. This integration eliminates the need for manual one-by-one stacking and positioning, significantly improving manufacturing efficiency while ensuring reliable electrical connections.

The battery cell design incorporates self-aligning features such as recesses or guides that automatically position the lead tabs in the correct orientation before welding. This self-service mechanism eliminates the need for manual positioning and adjustment by operators, allowing rapid assembly without compromising connection reliability. The system essentially positions itself, improving productivity while maintaining connection quality.