Ultrasonic Welding Horns with Distinct Pressing Patterns
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Solution Overview
Problem
The existing ultrasonic welding devices for rechargeable batteries require separate processes and different conditions for welding positive and negative electrode tabs due to the use of horns with the same structure, leading to increased complexity and welding time, especially in pouch-type batteries where leads are spaced apart.
Innovation Solution
The ultrasonic welding device features horns with distinct pressing patterns for the negative and positive electrode tabs, with different densities and orientations, allowing for simultaneous welding of both tabs using a single device, reducing the need for separate processes and simplifying the manufacturing method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate welding processes are used for positive and negative electrode tabs with different horn structures, then welding quality is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The single horn is segmented into multiple pressing regions with different pressing patterns. The first pressing region has a first pressing pattern for the positive electrode tab, while the second pressing region has a second pressing pattern for the negative electrode tab. This segmentation allows different pressing characteristics to be achieved within a unified horn structure, resolving the contradiction between welding quality and device complexity.
Solution Approach 2:
Different local regions of the horn are designed with distinct pressing patterns tailored to specific electrode materials. The pressing pattern for aluminum electrode tabs differs from that for copper electrode tabs, with parameters such as pressing force distribution, contact area, and pressing sequence optimized for each material type. This local quality approach ensures optimal welding quality for each electrode while maintaining a single horn structure.
2Manufacturing precision
If separate welding processes are used for positive and negative electrode tabs, then welding precision is improved, but welding time increases
Solution Approach 1:
The welding processes for positive and negative electrode tabs are merged into a single simultaneous operation using one horn with multiple pressing regions. The horn applies different pressing patterns to different electrode tabs at the same time, eliminating the need for sequential welding operations. This merging reduces welding time while maintaining precision through material-specific pressing patterns.
Solution Approach 2:
The welding process achieves continuity by performing multiple welding operations simultaneously in one continuous action. While traditional methods require stopping and restarting the welding process for each electrode tab, this invention maintains continuous ultrasonic vibration and pressing, applying different pressing patterns to different tabs without interrupting the welding action, thereby reducing total welding time.
3Reliability
If different welding conditions are configured for positive and negative electrode tabs, then welding quality is improved, but process complexity increases
Solution Approach 1:
The horn is designed as a universal tool that performs multiple welding functions for different electrode materials. By incorporating multiple pressing regions with different pressing patterns into a single horn, the device achieves multi-functionality, allowing it to weld both aluminum and copper electrode tabs with appropriate conditions while simplifying the manufacturing process and reducing the number of tool changes or device configurations needed.
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 enables efficient and streamlined welding of both positive and negative electrode tabs in a single process, reducing manufacturing complexity and time while ensuring effective adhesion without damaging the leads, thereby enhancing the production efficiency of rechargeable batteries.
Implementation Method 1
an ultrasonic vibration module configured to generate ultrasonic vibrations; a horn coupled to the ultrasonic vibration module to transmit the ultrasonic vibrations from the ultrasonic vibration module
Implementation Method 2
a second pressing pattern for pressing a negative electrode tab, wherein the pressing patterns have different densities and orientations
Data Source
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AI summary
An ultrasonic welding device includes a horn coupled to an ultrasonic wave oscillator. The horn performs ultrasonic welding by respectively disposing a negative electrode tab and a positive electrode tab on a negative electrode lead and a positive electrode lead of a rechargeable battery while pressure is applied. The horn includes a negative electrode horn and a positive electrode horn that respectively press the negative electrode tab and the positive electrode tab. The negative and positive electrode horns are integrally provided in a body and have pressing patterns of different shapes.