Electrode Tab Fixing Structure for Damage-Free Ultrasonic Welding
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Solution Overview
Problem
Existing welding apparatuses cause damage and cutting of electrode tabs during the welding process, particularly in stacked type electrode assemblies, due to the application of high-frequency vibration and pressing forces.
Innovation Solution
A welding apparatus with a tab guide and electrode tab fixing portion that maintains a uniform distance between electrode tabs, using a tab guide to form a tab bundle and an electrode tab fixing portion to prevent damage by minimizing bending forces, combined with a welding jig for ultrasonic welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic welding with high-frequency vibration is used to weld electrode tabs, then welding speed and efficiency are improved, but the electrode tabs may be damaged or cut due to shock and vibration
Solution Approach 1:
The electrode tab fixing portion is positioned and configured before the welding process begins. It pre-establishes a stable structure that secures the electrode tabs in place, preventing them from moving or shifting during the ultrasonic welding process. This preliminary positioning action ensures that the tabs remain intact while enabling efficient welding.
Solution Approach 2:
The electrode tab fixing portion acts as a cushioning structure that absorbs and distributes the shock and vibration forces generated during ultrasonic welding. By providing this protective support beforehand, it prevents the electrode tabs from being damaged or cut while maintaining the high-frequency vibration necessary for efficient welding.
2Ease of manufacture
If electrode tabs are gathered by tab guide to form tab bundle, then welding process is simplified, but electrode tabs may be damaged or cut at the gathering portion
Solution Approach 1:
The electrode tab fixing portion serves as an intermediary structure between the tab guide and the electrode tabs. It mediates the gathering process by providing a stable support that allows the tabs to be collected into a bundle without concentrating stress or force at any single point, thereby preventing damage or cutting while maintaining manufacturing simplicity.
3Volume of moving object
If electrode tabs are pressed at steep angle to form tab bundle, then compactness is improved, but the risk of electrode tabs being cut increases
Solution Approach 1:
The electrode tab fixing portion features a curved surface that gradually guides the electrode tabs into a compact bundle. This curved geometry allows the tabs to be pressed at gentler angles, distributing the compressive forces evenly and preventing sudden stress concentrations that could cause cutting, while still achieving the desired compactness for welding.
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
Prevents cutting and damage to electrode tabs by maximizing their length and ensuring a gentle bending process, allowing for efficient and uniform welding without compromising the integrity of the electrode assembly.
Implementation Method 1
The horn 31 and the anvil 32 apply high-frequency vibration generated by an ultrasonic wave having a high frequency of about 20 kHz, and vibration energy is converted into thermal energy between the electrode tabs 11 and an electrode lead
Implementation Method 2
ultrasonic welding using vibration energy may shock the electrode assembly 10, the electrode tabs 11, and the electrode lead
Data Source
AI summary
A welding apparatus may include an electrode tab fixing portion capable of maintaining the distance between and the shape of electrode tabs while minimizing damage to electrode tabs when welding the electrode tabs.