Ultrasonic Battery Tab Welding with Thickness-Based Pressure Control
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Solution Overview
Problem
Ultrasonic welding devices for secondary batteries often cause deformation and welding defects due to inconsistent pressure application on the overlapping surface of electrode tabs and leads, leading to product defects.
Innovation Solution
An ultrasonic welding device with adjustable anvil and horn pressure based on measured electrode tab and lead thickness, using pressure adjusting devices and height adjusting parts to maintain consistent pressure and prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the overlapping surface is pressed over a set pressure through the anvil and the horn, then welding force is sufficient, but the overlapping surface is deformed to cause product defects and welding defects
Solution Approach 1:
The patent applies dynamics by making the pressing force adjustable rather than fixed. The control unit dynamically adjusts the pressing force applied by the anvil and horn based on real-time thickness measurements of the electrode tab, allowing the system to adapt to variations in material dimensions and prevent deformation while maintaining sufficient welding force.
Solution Approach 2:
The patent changes the parameter of pressing force from a constant set value to a variable parameter that is adjusted according to the measured thickness of the electrode tab. This parameter change allows the system to optimize the balance between welding force and deformation prevention for each specific workpiece.
2Ease of manufacture
If fixed pressure is applied through the anvil and horn, then the welding process is simple, but the overlapping surface deforms causing product defects
Solution Approach 1:
The patent implements feedback by using a thickness measurement device to measure the electrode tab thickness and feeding this information back to the control unit. The control unit then adjusts the pressing force accordingly, creating a closed-loop control system that automatically compensates for dimensional variations and prevents deformation-related defects.
Solution Approach 2:
The system performs self-adjustment by automatically measuring the electrode tab thickness and adjusting the pressing force without requiring manual intervention. The control unit autonomously determines the appropriate pressing force based on the measured dimensions, enabling the system to self-optimize for each welding operation.
3Manufacturing precision
If pressing force is increased to prevent deformation, then manufacturing precision improves, but welding defects occur due to excessive pressure
Solution Approach 1:
The patent changes the pressing force parameter from a fixed high value to a dynamically adjusted value based on measured electrode tab thickness. This allows the system to apply precisely the right amount of pressure needed to prevent deformation without exceeding the threshold that would cause welding defects from excessive pressure.
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 device ensures uniform welding by adjusting pressure according to electrode thickness, preventing deformation and defects, thereby improving the quality of the welded joint.
Implementation Method 1
a horn for applying ultrasonic waves to the overlapping surface disposed on the anvil to weld the overlapping surface
Data Source
AI summary
An ultrasonic welding device for a secondary battery is provided. The ultrasonic welding device is configured to weld an overlapping surface of an electrode tab and an electrode lead in an electrode assembly. The ultrasonic welding device includes an anvil on which the overlapping surface of the electrode tab and the electrode lead are disposed. A horn is configured to apply ultrasonic waves to the overlapping surface of the electrode tab and the electrode lead while pressing the overlapping surface. The overlapping surface is disposed on the anvil. An electrode tab measuring part is configured to measure a thickness of the electrode tab disposed on the overlapping surface. A pressure adjusting device is configured to adjust a pressure applied to the overlapping surface by the anvil and the horn according to the thickness value of the electrode tab. The thickness value is measured by the electrode tab measuring part.