Ultrasonic Battery Tab Welding With Horn-Anvil Level Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Ultrasonic welding devices for secondary batteries face issues with non-uniform energy transmission due to misalignment of the anvil and horn relative to the overlapping surface of the electrode tab and lead, leading to welding defects.
Innovation Solution
An ultrasonic welding device equipped with an inspection member to assess the horizontal levels of the anvil and horn relative to the overlapping surface, and an angle adjusting member to correct misalignments, ensuring uniform energy application and preventing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the anvil and horn are not disposed horizontally with respect to the overlapping surface, then the welding process can be performed, but welding defects occur due to non-uniform energy transmission
Solution Approach 1:
The patent applies preliminary action by measuring and adjusting the horizontal alignment of the anvil and horn before the welding process begins. The measuring member detects the horizontal values of the overlapping surface, anvil, and horn, and the adjusting member corrects any misalignment prior to welding, ensuring uniform energy transmission and preventing welding defects.
2Reliability
If the horizontal levels of anvil and horn are adjusted to be disposed horizontally with respect to overlapping surface, then uniform welding energy transmission is achieved, but the device complexity increases due to additional inspection and adjustment mechanisms
Solution Approach 1:
The patent replaces complex mechanical alignment procedures with a measuring and adjustment system that uses horizontal value detection. The measuring member optically or mechanically measures horizontal positions, and the adjusting member makes precise corrections, substituting manual alignment operations with an automated measurement-adjustment system that simplifies the overall process despite adding components.
3Device complexity
If manual alignment methods are used for anvil and horn, then the device structure remains simple, but welding defects occur due to inability to ensure uniform horizontal disposition
Solution Approach 1:
The patent implements feedback by using the measuring member to continuously monitor the horizontal alignment of the overlapping surface, anvil, and horn. The measured horizontal values are used to determine whether adjustment is needed, and the adjusting member corrects misalignment based on this feedback, creating a closed-loop system that ensures precise horizontal disposition while maintaining operational simplicity.
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
Ensures uniform welding of the entire overlapping surface by adjusting the anvil and horn angles, thereby improving bonding strength and preventing defects.
Implementation Method 1
a horn configured to weld the overlapping surface disposed on the anvil
Implementation Method 2
an ultrasonic welding device... comprises an anvil provided so that an overlapping surface of an electrode tab and an electrode lead, which are provided in an electrode assembly, are disposed thereon; a horn configured to weld the overlapping surface disposed on the anvil
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention comprises: an anvil provided so that an overlapping surface of an electrode tab and an electrode lead, which are provided in an electrode assembly, are disposed thereon; a horn configured to weld the overlapping surface disposed on the anvil; and an inspection member configured to inspect a horizontal level of an opposing member with respect to the overlapping surface, based on an overlapping surface horizontal value that is a horizontal value of the overlapping surface with respect to a predetermined reference surface and an opposing horizontal value that is a horizontal value of the opposing member, which is one of a welding part of the horn facing the overlapping surface and a disposing part of the anvil, on which the overlapping surface is disposed, with respect to the predetermined reference surface.