Ultrasonic Tab Welding Pressure Adjustment for Secondary Batteries
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Solution Overview
Problem
Existing ultrasonic welding devices for secondary batteries deform the overlapping surface of electrode tabs and leads, leading to product defects and welding defects due to inconsistent pressure application.
Innovation Solution
An ultrasonic welding device with adjustable anvil and horn pressure based on measured electrode tab and lead thickness, using pressure adjusting devices and height adjusting parts to maintain consistent pressure and prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixed pressure is applied by the anvil and horn to the overlapping surface, then the welding process is simple, but the overlapping surface deforms causing welding defects
Solution Approach 1:
The patent implements dynamic pressure adjustment by equipping the anvil with a first pressure adjusting device and the horn with a second pressure adjusting device. These devices allow the pressing forces to be dynamically adjusted according to the measured thickness of the electrode tab, transforming the static fixed-pressure system into a dynamic adaptive system that prevents overlapping surface deformation while maintaining welding effectiveness.
Solution Approach 2:
The patent changes the pressure parameter adaptively based on the electrode tab thickness. By measuring the thickness first and then adjusting the pressing forces of both the anvil and horn accordingly, the system optimizes the pressure parameter for each specific workpiece, preventing deformation while ensuring proper welding conditions are met.
2Strength
If increased pressure is applied to ensure welding quality, then welding strength improves, but the overlapping surface deforms causing product defects
Solution Approach 1:
The patent implements adaptive pressure parameter adjustment based on electrode tab thickness measurement. By calculating the appropriate pressing forces according to the measured thickness values and adjusting both anvil and horn pressures accordingly, the system achieves optimal welding strength without causing overlapping surface deformation, thus eliminating the harmful effect of excessive pressure.
Solution Approach 2:
The patent introduces a feedback mechanism where the thickness of the electrode tab is measured first, and this measurement information is used to adjust the pressing forces of the anvil and horn. This closed-loop control ensures that the pressure applied is exactly what is needed for welding strength without causing deformation, as the system continuously adapts based on actual workpiece dimensions.
3Manufacturing precision
If separate pressure adjustment for anvil and horn is implemented, then welding precision improves, but device complexity increases
Solution Approach 1:
The patent divides the pressure adjustment function into two independent segments: a first pressure adjusting device for the anvil and a second pressure adjusting device for the horn. Each device can be adjusted independently based on the measured electrode tab thickness, allowing precise control of pressing forces at different locations without requiring a complex integrated adjustment mechanism.
Solution Approach 2:
The patent implements independent parameter adjustment for both anvil and horn pressing forces. By allowing separate adjustment of these two pressure parameters based on thickness measurement feedback, the system achieves high welding precision while keeping each adjustment mechanism relatively simple and modular.
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 deformation and welding defects by uniformly welding the electrode tab and lead surfaces, ensuring consistent pressure application through adjustable horn and anvil pressure adjustment.
Implementation Method 1
a horn configured to apply ultrasonic waves to the overlapping surface of the electrode tab and the electrode lead, which is disposed on the anvil, while pressing the overlapping surface
Implementation Method 2
an electrode tab measuring part configured to measure a thickness of the electrode tab disposed on the overlapping surface
Data Source
AI summary
An ultrasonic welding device for a secondary battery is provided. The ultrasonic welding device is configured to weld an overlapping surface of an electrode tab and an electrode lead in an electrode assembly. The ultrasonic welding device includes an anvil on which the overlapping surface of the electrode tab and the electrode lead are disposed. A horn is configured to apply ultrasonic waves to the overlapping surface of the electrode tab and the electrode lead while pressing the overlapping surface. The overlapping surface is disposed on the anvil. An electrode tab measuring part is configured to measure a thickness of the electrode tab disposed on the overlapping surface. A pressure adjusting device is configured to adjust a pressure applied to the overlapping surface by the anvil and the horn according to the thickness value of the electrode tab. The thickness value is measured by the electrode tab measuring part.