Electrode Tab Welding Precision via Side Surface Light Scanning
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Solution Overview
Problem
Conventional laser welding methods struggle to precisely align and set the laser irradiation portion for electrode tabs due to similar light reflection characteristics and surface states, leading to inaccurate boundary distinction and biased laser placement.
Innovation Solution
A method involving the irradiation of light to side surfaces of overlapping electrode tabs, scanning the planar shape of steps using reflected light, and setting the welding range within the overlapped portion to ensure accurate alignment and welding only within the defined area, regardless of material reflection or surface similarity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If light is irradiated to upper and lower surfaces of electrode tabs to perform vision inspection, then the inspection process can be completed, but the boundary portion of overlapped electrode tabs cannot be clearly distinguished due to similar light reflection characteristics
Solution Approach 1:
The patent changes the inspection dimension from upper/lower surfaces (2D planar inspection) to side surfaces (lateral profile inspection). By irradiating light to the side surfaces of overlapped electrode tabs, the system can detect the step structure and boundary portions through lateral light reflection differences, enabling clear distinction of overlapping regions that are indistinguishable from top/bottom surface inspection.
2Productivity
If laser welding is performed on electrode tabs, then welding speed and bonding strength are improved, but precise alignment of laser irradiation portion becomes difficult due to inability to clearly identify boundaries
Solution Approach 1:
The patent performs vision inspection of side surfaces before laser welding to pre-identify the boundary portions and overlapped regions of electrode tabs. This preliminary action provides accurate positional information about where the laser should be irradiated, enabling precise alignment without compromising welding speed. The inspection results are used to set the laser irradiation portion accurately.
3Adaptability or versatility
If electrode tabs with similar colors or surface roughness are inspected using conventional light reflection method, then the inspection can be performed, but the boundary formed by step is not clearly distinguished
Solution Approach 1:
The patent focuses inspection on specific local regions - the side surfaces of electrode tabs - rather than attempting to inspect the entire surface. By directing light to the lateral edges and examining the reflected light patterns from these specific locations, the system can detect the step structure and boundary portions even when the overall surface appearance (color, roughness) is similar across different tabs.
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
This approach allows for clear recognition and distinction of electrode tab boundaries, enabling precise laser welding even when tabs are made of the same material or have similar colors or surface roughness, ensuring accurate alignment and efficient welding.
Implementation Method 1
irradiating light to at least two side surfaces among side surfaces of the tab arrangement excluding surfaces on which the electrode tabs overlap and surfaces facing the overlapped surfaces; scanning a planar shape of a step on which the electrode tabs do not overlap each other using light reflected from an end portion of each of the electrode tabs
Data Source
AI summary
The present disclosure provides a method that includes forming a tab arrangement by vertically arranging the electrode tabs whereby at least parts of the electrode tabs overlap each other; irradiating light to at least two side surfaces among side surfaces of the tab arrangement excluding surfaces on which the electrode tabs overlap and surfaces facing the overlapped surfaces; scanning a planar shape of a step on which the electrode tabs do not overlap each other using light reflected from an end portion of each of the electrode tabs; scanning only an overlapped portion of the electrode tabs excluding the step based on the scanned result; setting a welding range within the overlapped portion; and performing welding only within the welding range.