Ultrasonic Electrode Tab Welding With Pre-Weld Level Correction
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Solution Overview
Problem
In ultrasonic welding devices for secondary batteries, non-horizontal alignment of the anvil and horn with respect to the overlapping surface of the electrode tab and electrode lead results in uneven welding energy transmission, leading to welding defects.
Innovation Solution
An ultrasonic welding device with an inspection member to ensure horizontal alignment of the anvil and horn, using measuring members to assess alignment angles, and angle adjusting members to correct deviations, ensuring uniform energy application across the overlapping surface.
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 welding energy transmission
Solution Approach 1:
The patent applies preliminary action by providing measuring members that measure the horizontal values of the overlapping surface and opposing member before welding, and an angle adjusting member that adjusts the angle based on the measured values. This preliminary measurement and adjustment prevents welding defects by ensuring proper horizontal alignment before the welding process begins.
Solution Approach 2:
The patent implements feedback by using measuring members to detect the horizontal alignment status of the overlapping surface and opposing member, then using the measured values to control the angle adjusting member. This closed-loop feedback system ensures that the anvil and horn are properly aligned horizontally, preventing welding defects while maintaining manufacturing precision.
2Reliability
If measuring members and angle adjusting members are added to ensure horizontal alignment, then welding quality improves, but device complexity increases
Solution Approach 1:
The patent applies universality by designing the measuring members and angle adjusting member as integrated components of the ultrasonic welding device. The measuring members serve both as detection devices and as basis for control, while the angle adjusting member integrates angle adjustment functionality into the existing welding apparatus. This multi-functionality approach improves welding quality while minimizing the increase in device complexity.
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 solution ensures uniform bonding force across the entire overlapping surface, preventing welding defects and improving overall welding quality.
Implementation Method 1
a horn configured to weld the overlapping surface disposed on the anvil
Data Source
AI summary
An ultrasonic welding device includes an anvil provided so that an overlapping surface of an electrode tab and an electrode lead, which are provided in an electrode assembly, are configured to be 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 configured to face the overlapping surface and a disposing part of the anvil, on which the overlapping surface is configured to be disposed, with respect to the predetermined reference surface.