Segmented Mask Jig Layout for Continuous Battery Tab Laser Welding
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Solution Overview
Problem
Existing welding methods for electrode tabs and electrode leads in secondary batteries face issues with poor welding quality due to spatter accumulation on mask jigs, requiring frequent replacements and reducing equipment utilization rates.
Innovation Solution
A welding apparatus with a lower and upper mask jig system, each divided into multiple work regions, allows for sequential use of these regions to extend the replacement period of the mask jigs, improving equipment utilization by alternating the use of partitioned work regions for laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mask jigs are used for laser welding of electrode tabs and electrode leads, then welding quality is maintained, but spatter accumulates on the mask jigs requiring frequent replacements which reduces equipment utilization rates
Solution Approach 1:
The mask jig is divided into multiple work regions (first work region, second work region, etc.) that can be used alternately. When spatter accumulates in one region, the system switches to another region, allowing the used region to be cleaned or replaced independently while welding continues uninterrupted. This segmentation resolves the contradiction by maintaining welding quality through dedicated work regions while improving equipment utilization through continuous operation.
2Manufacturing precision
If mask jigs are frequently replaced due to spatter accumulation, then welding quality is maintained, but equipment utilization rate decreases due to replacement downtime
Solution Approach 1:
Multiple work regions are prepared in advance on the same mask jig, allowing the system to switch to a pre-prepared clean region when spatter accumulation occurs. This preliminary preparation of multiple work regions eliminates the need for immediate mask jig replacement, maintaining welding quality while preventing time loss associated with frequent replacements.
Solution Approach 2:
The multi-region mask jig enables continuous welding operation by allowing seamless switching between work regions. When one region becomes contaminated with spatter, the system immediately transitions to another clean region without interrupting the welding process, thereby maintaining manufacturing precision while eliminating replacement downtime and improving overall equipment utilization.
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 apparatus enhances equipment utilization by extending the replacement period of mask jigs, thereby improving the efficiency and quality of laser welding processes for electrode tabs and electrode leads in secondary batteries.
Implementation Method 1
a laser supply head configured to emit a laser beam to the workpiece fixed while being inserted between the lower mask jig and the upper mask jig
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
The present technology provides a welding apparatus configured to weld a workpiece, the welding apparatus including: a lower base with a lower guide rail; a lower mask jig configured to be moved along the lower guide rail; an upper base including an upper guide rail and provided on the lower base; an upper mask jig configured to be moved along the upper guide rail; and a laser supply head configured to emit a laser beam to the workpiece fixed while being inserted between the lower mask jig and the upper mask jig.