Ultrasonic Electrode Tab Welding with Embossed Protrusions Against Cracking

The patent applies local quality by providing protrusion parts with embossing patterns at specific locations on the anvil and horn. These protrusion parts concentrate the ultrasonic energy and mechanical pressure precisely at the welding interface of the electrode tabs, ensuring adequate welding strength without excessively increasing overall pressure that could cause breakage. The embossing patterns create localized deformation that enhances bonding while preserving the integrity of thin tab structures.

The patent segments the contact surface into multiple protrusion parts with embossing patterns rather than using a single flat contact surface. This segmentation allows the welding force to be distributed across multiple localized points, preventing stress concentration that would lead to cracking while maintaining effective welding at each point. The divided structure of protrusion parts enables controlled deformation without causing overall tab breakage.

The protrusion parts with embossing patterns create localized high-pressure zones precisely where welding is needed, while the surrounding areas experience lower pressure. This localized pressure application achieves strong bonding at the welding interface without subjecting the entire thin tab structure to excessive pressure that would cause breakage or cracking.

The embossing patterns on the protrusion parts prepare the contact surface in advance by creating controlled deformation features. These pre-formed embossments act as cushioning elements that absorb and distribute stress during welding, preventing sudden stress spikes that would cause breakage while ensuring adequate bonding strength.