Ultrasonic Welding Horn Tip Angles for Battery Tab Joining
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Solution Overview
Problem
Secondary battery electrode tabs are prone to damage and have inconsistent coupling strength during ultrasonic welding, particularly due to differences in material properties between aluminum and copper/nickel tabs.
Innovation Solution
The method involves using ultrasonic horns with protruding tips of varying angles, sizes, and arrangements to optimize the welding process, where aluminum tabs are welded with a focus on minimizing damage and copper/nickel tabs with a focus on enhancing coupling strength by adjusting the positioning direction and number of vibrating contact sides relative to the vibrating direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single ultrasonic welding process is used for both aluminum and copper/nickel tabs, then the manufacturing process is simple, but the electrode tabs are prone to damage and have inconsistent coupling strength
Solution Approach 1:
The patent applies different ultrasonic welding parameters (horn angle, pressing force, welding time) tailored to each tab material's properties. Aluminum tabs use one set of parameters optimized for their softer, more ductile nature, while copper/nickel tabs use different parameters suited for their higher strength and lower ductility, ensuring each material is welded under optimal conditions without damage
Solution Approach 2:
The invention changes multiple welding parameters simultaneously including horn tip angle (e.g., 15° for aluminum vs. 30° for copper), pressing force magnitude, and welding duration to accommodate the different material properties of aluminum versus copper/nickel tabs, thereby achieving consistent coupling strength across different materials
2Strength
If ultrasonic welding is applied to aluminum tabs with high force to ensure coupling strength, then coupling strength is improved, but the aluminum tabs are more prone to damage
Solution Approach 1:
The patent optimizes the horn tip angle to a smaller value (e.g., 15°) for aluminum tabs, which concentrates the ultrasonic energy over a smaller area and reduces the total pressing force required. This parameter change allows achieving adequate coupling strength while applying lower force that prevents damage to the softer aluminum material
3Object-affected harmful factors
If ultrasonic welding is applied to copper/nickel tabs with low force to prevent damage, then tab damage is reduced, but coupling strength is insufficient
Solution Approach 1:
The patent increases the horn tip angle (e.g., to 30°) for copper/nickel tabs, which distributes the ultrasonic energy over a larger contact area. This allows applying higher pressing force without damaging the harder copper/nickel material, thereby achieving sufficient coupling strength for these stronger materials
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 approach reduces damage to aluminum tabs and increases coupling strength between tabs and plates, ensuring a high degree of reliability and performance in secondary battery manufacturing.
Implementation Method 1
ultrasonic-welding a first electrode plate of an electrode assembly and a first electrode tab to each other by using a first horn including a first protruding tip
Implementation Method 2
ultrasonic-welding a second electrode plate of the electrode assembly and a second electrode tab to each other by using a second horn including a second protruding tip
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method of manufacturing a secondary battery includes: ultrasonic-welding a first electrode plate of an electrode assembly and a first electrode tab to each other by using a first horn including a first protruding tip; ultrasonic-welding a second electrode plate of the electrode assembly and a second electrode tab to each other by using a second horn including a second protruding tip, the second protruding tip having a positioning direction different from a positioning direction of the first protruding tip; and preparing the electrode assembly by arranging a separator between the first and second electrode plates.