Electrode Tab End-Face Structure for Flat Laser Welding
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Solution Overview
Problem
The traditional ultrasonic welding process for multi-layer electrode tabs damages the surface, leading to poor flatness, which affects subsequent welding with other components and fails to meet the requirements for electrode tab welding.
Innovation Solution
The electrode tab structure is designed with specific end face differences (H1≤H2) and a flat welding tooling with controlled surface roughness (10 μm≤Sa≤85 μm) to ensure high flatness, facilitating stable laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrasonic welding with sharp-tooth structure is used for pre-welding multi-layer electrode tabs, then welding strength is improved, but surface flatness deteriorates
Solution Approach 1:
The patent changes the geometric parameters of the welding head teeth by introducing a rounding radius R (0.1-1mm) at the tooth tips. This parameter modification allows the welding head to maintain sufficient biting force for strong welding while the rounded edges prevent excessive penetration and surface damage, thereby preserving surface flatness for subsequent laser welding operations.
2Productivity
If conventional ultrasonic welding is used, then welding speed is improved, but surface quality deteriorates
Solution Approach 1:
The patent modifies the geometric parameters of the welding head teeth by introducing a rounding radius R (0.1-1mm) at the tooth tips. This parameter modification allows the welding head to maintain sufficient biting force for strong welding while the rounded edges prevent excessive penetration and surface damage, thereby preserving surface flatness for subsequent laser welding operations.
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 stable and efficient welding by preventing laser reflection and reducing wear, while maintaining flatness for mass production and compatibility with other components.
Implementation Method 1
the multi-layer electrode tabs are first pre-welded through ultrasonic welding
Data Source
AI summary
An electrode tab structure and a welding tooling are provided in the present disclosure. The electrode tab structure includes multiple electrode tab units stacked and pre-welded together, and the electrode tab structure includes a first end face and a second end face arranged opposite to each other. The first end face of the electrode tab structure is configured to be abutted against a welding head, and the second end face of the electrode tab structure is configured to be abutted against a welding platform. A difference between a highest point and a lowest point of a metallographic section of the first end face in a first direction being H1, a difference between a highest point and a lowest point of a metallographic section of the second end face in the first direction being H2, and H1≤H2.