WO2023173585A1 - 极耳超声波焊接方法 - Google Patents

极耳超声波焊接方法 Download PDF

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Publication number
WO2023173585A1
WO2023173585A1 PCT/CN2022/094895 CN2022094895W WO2023173585A1 WO 2023173585 A1 WO2023173585 A1 WO 2023173585A1 CN 2022094895 W CN2022094895 W CN 2022094895W WO 2023173585 A1 WO2023173585 A1 WO 2023173585A1
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Prior art keywords
foil
welding
ultrasonic welding
laminated
composite
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PCT/CN2022/094895
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English (en)
French (fr)
Inventor
周高阳
李学法
张国平
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江阴纳力新材料科技有限公司
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Priority to PCT/CN2023/082200 priority Critical patent/WO2023174410A1/zh
Publication of WO2023173585A1 publication Critical patent/WO2023173585A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/26—Auxiliary equipment
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/531—Electrode connections inside a battery casing
    • H01M50/534—Electrode connections inside a battery casing characterised by the material of the leads or tabs
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/531—Electrode connections inside a battery casing
    • H01M50/536—Electrode connections inside a battery casing characterised by the method of fixing the leads to the electrodes, e.g. by welding

Definitions

  • the present invention relates to the technical field of battery processing, and in particular to an ultrasonic welding method for tabs.
  • Laser welding is an efficient and precise welding method that uses high-energy-density laser beams as heat sources.
  • the welding process is Thermal conduction type, that is, laser radiation heats the surface of the material, and the surface heat diffuses to the interior through thermal conduction.
  • the generator converts 50/60 Hz current into 15, 20, 30 or 40KHz electrical energy.
  • the converted high-frequency electrical energy is converted again into mechanical motion of the same frequency through the transducer, and then the mechanical motion is transmitted to the welding head through a set of horn devices that can change the amplitude.
  • the welding head transmits the received vibration energy to the joint of the workpiece to be welded. In this area, the vibration energy is converted into heat energy through friction, melting the plastic, thereby forming a welding area.
  • Existing battery electrode foils generally use composite foils, and the structure of composite foils is the bottom layer, the middle layer and the upper layer.
  • the bottom layer and the upper layer are all made of foil, and the middle layer is made of plastic film. Since the strength of the plastic film is low, , and the bottom and upper layers are only 2 ⁇ m-3 ⁇ m, their ductility and tensile strength are too high, and their absorption performance is not strong. Using the above two welding methods can easily cause over-welding, welding through, and excessive power will cause problems such as virtual welding. .
  • An ultrasonic welding method for tabs includes the following steps:
  • the ultrasonic welding method is used to weld the stacked welding parts and the tabs to form the tab assembly.
  • the first foil, the composite foil and the second foil are laminated in sequence and welded together using ultrasonic welding.
  • the ultrasonic welding directly acts on the first foil and the second foil.
  • the foil and the second foil play a role in protecting the composite foil, which can reduce the energy generated by the direct contact of the ultrasonic welding with the composite foil, reduce the risk of the composite foil easily breaking during the welding process, and effectively avoid causing damage to the composite foil during the welding process.
  • the problems of over-welding, welding penetration and false welding can ensure the welding effect of the first foil, composite foil and second foil; and then use ultrasonic welding to weld several laminated foils one after another, which can make several laminated foils
  • the shortening of the spacing between them is beneficial to reducing welding energy consumption; then ultrasonic welding is used to weld the laminated welding parts to the tabs, so that the tensile strength of the tab welding is increased, so that the laminated welding parts are in contact with the tabs to ensure conductive performance.
  • the method before welding the first foil material and the second foil material to the two opposite surfaces of the composite foil material respectively, the method further includes:
  • the first foil, the composite foil and the second foil are sequentially laminated to form an intermediate body of laminated foils and pressed.
  • the distance between the first foil material, the composite foil material and the second foil material can be reduced, thereby making the third foil material
  • the first foil material and the second foil material are closely attached to the composite foil material respectively and are not prone to relative displacement to ensure the accuracy of the relative positions of the first foil material, the composite foil material and the second foil material, thereby improving the first foil material. Welding quality of foils, composite foils and secondary foils.
  • the ultrasonic welding method is used to weld the first foil and the second foil to the two opposite surfaces of the composite foil, including:
  • the welding pressure of the ultrasonic welding is 0.2-0.5Mpa, the welding frequency is 20-50Khz, and the welding speed is 10-15r/min.
  • the ultrasonic welding method is used to weld a plurality of the laminated foil materials in sequence, or the ultrasonic welding method is used to weld the laminated welding parts to the tabs, including;
  • the welding pressure of the ultrasonic welding is 0.2-0.5Mpa, the welding frequency is 30-40Khz, and the welding time is 0.3-0.5s.
  • first foil and the second foil are respectively welded to two opposite surfaces of the composite foil using continuous welding.
  • the first foil material and the second foil material are respectively welded to the two opposite surfaces of the composite foil material using a continuous welding method. That is to say, the first foil, the composite foil and the second foil are welded during the transportation process, and continuous welding marks are formed on the first foil and the composite foil and the second foil and the composite foil. , there is no need to pause the first foil, composite foil and second foil during the transportation process, which greatly shortens the welding time and improves the welding efficiency.
  • the thickness of the first foil material and the second foil material is 10-15 ⁇ m, and the thickness of the composite foil material is 5-8 ⁇ m.
  • the set number of layers is 15-40 layers.
  • the ultrasonic welding method is used to weld the stacked welding parts to the tabs to form the tab assembly, which includes:
  • the material of the first foil material and the second foil material is one of aluminum foil, copper foil, and tin foil.
  • the tab ultrasonic welding method further includes the steps:
  • the welding tension of the tab assembly (2) is tested. When the welding tension is ⁇ 20N, it is determined to be a qualified product.
  • first, the first foil, the composite foil and the second foil are laminated in sequence and welded together using ultrasonic welding.
  • the ultrasonic welding directly acts on the energy of the first foil.
  • the foil material and the second foil material, the first foil material and the second foil material play a role in protecting the composite foil material, which can reduce the energy generated by the direct contact of the ultrasonic welding with the composite foil material, and reduce the easy breakage of the composite foil material during the welding process.
  • ultrasonic welding to weld several laminated foils Stacked welding in sequence can shorten the distance between several laminated foils, which is beneficial to reducing welding energy consumption; then ultrasonic welding is used to weld the laminated welding parts to the tabs, which increases the tensile strength of the tab welding and makes the stack welding The parts are in contact with the tabs to improve the conductive performance.
  • Figure 1 is a flow chart of an ultrasonic welding method for tabs according to an embodiment of the present invention
  • Figure 2 is a welding schematic diagram of the first foil and the second foil respectively welded to the two opposite surfaces of the composite foil according to an embodiment of the present invention.
  • the figure shows the first foil, the composite foil and the second foil.
  • Figure 3 is a welding schematic diagram of several laminated foil materials sequentially stacked and welded according to an embodiment of the present invention.
  • the figure shows the structure of a second ultrasonic welding head used for sequentially stacked welding of several laminated foil materials;
  • FIG. 4 is a welding schematic diagram of the welding of the stacked welding parts and the tab according to an embodiment of the present invention.
  • the figure shows the structure of the first ultrasonic welding head used for welding the stacked welding part and the tab.
  • first and second are used for descriptive purposes only and cannot be understood as indicating or implying relative importance or implicitly indicating the quantity of indicated technical features. Therefore, features defined as “first” and “second” may explicitly or implicitly include at least one of these features.
  • “plurality” means at least two, such as two, three, etc., unless otherwise expressly and specifically limited.
  • connection In the present invention, unless otherwise clearly stated and limited, the terms “installation”, “connection”, “connection”, “fixing” and other terms should be understood in a broad sense. For example, it can be a fixed connection or a detachable connection. , or integrated into one; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be an internal connection between two elements or an interactive relationship between two elements, unless otherwise specified restrictions. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.
  • a first feature being “on” or “below” a second feature may mean that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. touch.
  • the terms “above”, “above” and “above” the first feature is above the second feature may mean that the first feature is directly above or diagonally above the second feature, or simply means that the first feature is higher in level than the second feature.
  • "Below”, “below” and “beneath” the first feature to the second feature may mean that the first feature is directly below or diagonally below the second feature, or simply means that the first feature has a smaller horizontal height than the second feature.
  • an embodiment of the present invention provides an ultrasonic welding method for tabs.
  • This processing method can weld the first foil 11, the composite foil 12 and the second foil 13 together, so as to The laminated foil material 1 is obtained, and several laminated foil materials 1 can be welded together to form a laminated welding part 21 , and the laminated welding part 21 and the tab 22 can also be welded together.
  • the composite foil 12 includes a third foil, a fourth foil and a plastic film layer disposed between the third foil and the fourth foil.
  • the third foil and the fourth foil are respectively bonded to the plastic film layer.
  • the third foil, the plastic film layer and the fourth foil are sequentially connected together by thermal fusion.
  • the thickness of the third foil material and the fourth foil material is 2 ⁇ m-3 ⁇ m.
  • an ultrasonic welding method for tabs includes the following steps:
  • Step 1 Unwind the first foil 11 , the composite foil 12 and the second foil 13 in sequence, and stack the first foil 11 , the composite foil 12 and the second foil 13 in sequence to form an intermediate body of the laminated foil 1 .
  • the material of the first foil material 11 and the second foil material 13 is one of aluminum foil, copper foil, and tin foil.
  • Step 2 Use ultrasonic welding to weld the first foil 11 and the second foil 13 to the two opposite surfaces of the composite foil 12 to obtain the laminated foil 1 .
  • Step 3 Stack the laminated foil materials 1 to a set number of layers, and use ultrasonic welding to weld several laminated foil materials 1 in sequence to form a laminated weldment 21.
  • Step 4 Use ultrasonic welding to weld the stacked welding parts 21 and the tabs 22 to form the tab assembly 2 .
  • the first foil 11, the composite foil 12 and the second foil 13 are welded using ultrasonic welding.
  • Ultrasonic welding uses high-frequency vibration waves to be transmitted to the surfaces of two objects to be welded, and is pressurized. In this case, the surfaces of two objects are rubbed against each other to form fusion between the molecular layers.
  • ultrasonic welding applies energy directly to the first foil material 11 and the second foil material 13.
  • the first foil material 11 and the second foil material 13 play a role in protecting the composite foil material 12, which can reduce the direct contact of ultrasonic welding.
  • the energy generated by the composite foil material 12 reduces the risk of the composite foil material 12 easily breaking during the welding process, effectively avoiding the problems of over-welding, welding penetration and virtual welding during the welding process, and ensuring the welding effect of the laminated foil material 1 .
  • step 1 the first foil material 11, the composite foil material 12 and the second foil material 13 are respectively wound on the unwinding roller. Driven by the unwinding driving part, the unwinding roller is driven to rotate, thereby realizing the first step.
  • the foil 11, the composite foil 12 and the second foil 13 are sequentially unrolled.
  • the unwinding drive part uses a motor. It should be understood that since the first foil 11, the composite foil 12 and the second foil 13 are all thin materials, their strength is not high and they cannot withstand large tearing forces. When welding the first foil 11, the composite foil The relative positions of the material 12 and the second foil 13 need to be fixed, otherwise cracks will appear after welding, and in serious cases, the belt will break and continuous production will be impossible.
  • the first foil 11 , the composite foil 12 and the second foil 13 are laminated in sequence before welding, and the first foil 11 , the composite foil 12 and the second foil 13 are transported in the same direction.
  • the conveying speeds of the first foil 11 , the composite foil 12 and the second foil 13 remain consistent to reduce the speed difference between the three, thereby ensuring that the first foil 11 , the composite foil 12 And the relative position of the second foil 13 is fixed, thereby improving the welding quality of the first foil 11 , the composite foil 12 and the second foil 13 .
  • the first foil material 11 , the composite foil material 12 and the second foil material 13 are all transported in the horizontal direction to a welder who welds the first foil material 11 and the second foil material 13 to the opposite surfaces of the composite foil material 12 respectively. position, it can reduce the phenomenon of folding and wrinkling of the first foil 11, the composite foil 12 and the second foil 13 during the transportation process, effectively ensuring the flatness during welding and further ensuring the welding quality.
  • the unwinding roller around which the first foil material 11 is wound and the unwinding roller around which the second foil material 13 is wound are arranged symmetrically, and the unwinding roller around which the composite foil material 12 is wound is arranged in the first direction. Between the unwinding roller on which the first foil material 11 is wound and the unwinding roller on which the second foil material 13 is wound, the unwinding roller on which the first foil material 11 is wound and the unwinding roller on which the second foil material 13 is wound are respectively connected with each other in the second direction. The unwinding rollers of the two foils 13 are spaced apart. The first direction and the second direction intersect perpendicularly.
  • the composite foil 12 is arranged parallel to the first foil 11 and the second foil 13 respectively, and the composite foil 12 is located between the first foil 11 and the second foil 13. At the same time, the first foil The material 11 and the second foil material 13 are arranged symmetrically with respect to the composite foil material 12 .
  • the first foil material 11 and the second foil material 13 can enter the welding station through the same length path, which can reduce the number of the first foil material 11 and the second foil material 13. The difference in tension between the foils 13 ensures the flatness when the first foil 11, the composite foil 12 and the second foil 13 are stacked.
  • the first foil material 11 and the second foil material 13 are respectively welded to the two opposite surfaces of the composite foil material 12 using continuous welding. It should be understood that the first foil 11 , the composite foil 12 and the second foil 13 are welded during the transportation process, and between the first foil 11 and the composite foil 12 and the second foil 13 and the composite foil Continuous welding marks are formed on the material 12, and there is no need to pause the first foil 11, the composite foil 12 and the second foil 13 during the transportation process, which greatly shortens the welding time and improves the welding efficiency.
  • the composite foil 12 and the second foil 13 before the first foil 11 and the second foil 13 are respectively welded to the two opposite surfaces of the composite foil 12,
  • the intermediate body of the laminated foil 1 formed by the first foil 11 , the composite foil 12 and the second foil 13 is compressed so that the distance between the first foil 11 , the composite foil 12 and the second foil 13 is reduced. Small, so that the first foil material 11 and the second foil material 13 are in close contact with the composite foil material 12 respectively, and relative displacement is unlikely to occur.
  • the distance between the first foil 11 and the second foil 13 and the composite foil 12 is 0.5-1 mm.
  • the first foil 11 and the second foil 13 The distance between the composite foil material 12 and the composite foil material 12 is 0-0.2mm.
  • the thickness of the first foil 11 and the second foil 13 can be selected between 10-15 ⁇ m, and the thickness of the composite foil 12 can be selected between 5-8 ⁇ m. In this embodiment, the thickness of the first foil 11 and the second foil 13 is 12 ⁇ m, and the thickness of the composite foil is 126 ⁇ m.
  • the first foil 11, the composite foil 12 and the second foil 13 are welded using an ultrasonic seam welding method, including two seam welding heads 3, and two seam welding heads 3.
  • the heads 3 are respectively arranged on the upper and lower sides of the laminated foil material 1 and are symmetrically arranged relative to the laminated foil material 1 .
  • the welding pressure of ultrasonic welding is 0.2-0.5Mpa.
  • the frequency is 20-50Khz
  • the welding speed is 10-15r/min
  • the diameter of the ultrasonic welding head is about 100mm
  • the ultrasonic welding head is a round welding head.
  • the ultrasonic welding head is in the shape of a round roller.
  • the welded first foil 11 , the second foil 13 and the composite foil 12 can also be rolled up, that is, the welded laminated foil 1 can be rolled up.
  • the following settings can be made: a winding roller and a winding driving part are provided, the laminated foil 1 is wound on the winding roller, and driven by the winding driving part, The winding roller rotates to wind up the welded laminated foil 1.
  • the rolled laminated foil 1 needs to be cut to the required length, and then the laminated foil 1 is stacked to the set number of layers.
  • the number of layers can be selected from 15 to 40 layers. In this embodiment, the number of layers of the stacked welding parts 21 is 20.
  • a second ultrasonic welding head 4 is used.
  • the second ultrasonic welding head 4 is square and has no welding teeth.
  • the welding pressure of ultrasonic welding is 0.2-0.5Mpa, the welding frequency is 30-40Khz, and the welding time is 0.3-0.5s.
  • the first ultrasonic welding head 5 when ultrasonic welding is used to weld the laminated weldment 21 and the tab 22, the first ultrasonic welding head 5 is used.
  • the first ultrasonic welding head 5 can be of any shape. Head 5 adopts a spur welding head. In this embodiment, the first ultrasonic welding head 5 is square.
  • the welding pressure of ultrasonic welding is 0.2-0.5Mpa, the welding frequency is 30-40Khz, and the welding time is 0.3-0.5s.
  • Ultrasonic welding is used to weld the stacked welding part 21 and the tab 22 to increase the welding tensile strength of the tab 22, so that the stacked welding part 21 is in contact with the tab 22 to ensure conductive performance.
  • the size or length of the first ultrasonic welding head 5 used for welding is determined based on the welding area where the stacked welding parts 21 and the tabs 22 are welded. It should be understood that the size or length of the first ultrasonic welding head 5 has a linear relationship with the welding area where the stacked welding piece 21 and the tab 22 are welded.
  • step 4 test the welding tension of the tab assembly 2.
  • the welding tension is ⁇ 20N, it is determined to be a qualified product and meets the welding requirements.

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Abstract

一种极耳超声波焊接方法，包括以下步骤：依次放卷第一箔材（11）、复合箔材（12）及第二箔材（13），使第一箔材（11）、复合箔材（12）及第二箔材（13）依次层叠形成层叠箔材（1）的中间体，采用超声波焊接方式将第一箔材（11）与第二箔材（13）分别焊接于复合箔材（12）相对的两表面，得到层叠箔材（1）；将层叠箔材（1）层叠至设定层数，并采用超声波焊接方式将若干层叠箔材（1）依次焊接，以形成层叠焊件（21）。该极耳超声波焊接方法首先将第一箔材（11）、复合箔材（12）及第二箔材（13）依次层叠，在焊接时，超声波焊接将能量直接作用于第一箔材（11）与第二箔材（13），能够减少超声波焊接直接接触复合箔材（12）产生的能量，有效避免在焊接过程中造成过焊、焊穿及虚焊的问题，保证焊接效果；然后将若干层叠箔材（1）依次层叠焊接，能够使得若干层叠箔材（1）之间的间距缩短。

Description

极耳超声波焊接方法 技术领域
本发明涉及电池加工技术领域，特别是涉及极耳超声波焊接方法。
背景技术
在锂离子电池极片箔材焊接极耳过程中，传统焊接方式采用的是激光焊接及超声波焊接，而激光焊接是利用高能量密度的激光束作为热源的一种高效精密焊接方法，焊接过程属热传导型，即激光辐射加热材料表面，表面热量通过热传导向内部扩散，通过控制激光脉冲的宽度、能量、峰值功率和重复频率等参数，使材料熔化，形成特定的熔池；超声波焊接是通过超声波发生器将50/60赫兹电流转换成15、20、30或40KHz电能。被转换的高频电能通过换能器再次被转换成为同等频率的机械运动，随后机械运动通过一套可以改变振幅的变幅杆装置传递到焊头。焊头将接收到的振动能量传递到待焊接工件的接合部，在该区域，振动能量被通过摩擦方式转换成热能，将塑料熔化，从而形成焊接区域。
现有的电池极片箔材一般采用复合箔材，而复合箔材的结构依次为底层、中间层及上层，底层及上层均采用箔材，中间层采用塑料薄膜，由于塑料薄膜的强度较低，且底层及上层只有2μm-3μm，本身延展性及拉伸强度过高，吸收性能不强，使用以上两种焊接方式，容易造成过焊，焊穿，功率过小后会造成虚焊等问题。
发明内容
基于此，有必要针对提供一种有效避免在焊接过程中造成过焊、焊穿及虚焊的问题，能够保证焊接效果，保证导电性能的极耳超声波焊接方法。
一种极耳超声波焊接方法，包括以下步骤：
依次放卷第一箔材、复合箔材及第二箔材，使所述第一箔材、所述复合箔材及所述第二箔材依次层叠形成层叠箔材的中间体；
采用超声波焊接方式将所述第一箔材与所述第二箔材分别焊接于所述复合箔材相对的两表面，得到层叠箔材；
将所述层叠箔材层叠至设定层数，并采用所述超声波焊接方式将若干所述层叠箔材依次焊接，以形成层叠焊件；
采用所述超声波焊接方式将所述层叠焊件与极耳焊接，以形成极耳组件。
首先将第一箔材、复合箔材及第二箔材依次层叠，并采用超声波焊接方式焊接在一起，在焊接时，超声波焊接将能量直接作用于第一箔材及第二箔材，第一箔材及第二箔材起到保护复合箔材的作用，能够减少超声波焊接直接接触复合箔材产生的能量，降低了复合箔材在焊接过程中容易断裂的风险，有效避免在焊接过程中造成过焊、焊穿及虚焊的问题，能够保证第一箔材、复合箔材及第二箔材的焊接效果；然后采用超声波焊接方式将若干层叠箔材依次层叠焊接，能够使得若干层叠箔材之间的间距缩短，有利于降低焊接能量消耗；再然后采用超声波焊接方式将层叠焊件与极耳焊接，使极耳焊接抗拉强度增加，使层叠焊件与极耳接触，保证导电性能。
在其中一个实施例中，将所述第一箔材与所述第二箔材分别焊接于所述复合箔材相对的两表面之前，还包括：
将所述第一箔材、所述复合箔材及所述第二箔材依次层叠形成层叠箔材的中间体压紧。
通过将第一箔材、复合箔材及第二箔材形成的层叠箔材的中间体压紧，能够使得第一箔材、复合箔材及第二箔材之间间隔减小，从而使得第一箔材、第二箔材分别与复合箔材之间紧密贴合，不易发生相对位移，以保证第一箔材、复合箔材及第二箔材相对位置的精确度，进而能够提高第一箔材、复合箔材及第二箔材的焊接质量。
在其中一个实施例中，采用所述超声波焊接方式将所述第一箔材与所述第二箔材分别焊接于所述复合箔材相对的两表面，包括：
所述超声波焊接的焊接压力为0.2-0.5Mpa，焊接频率为20-50Khz，焊接速度为10-15r/min。
在其中一个实施例中，采用所述超声波焊接方式将若干所述层叠箔材依次焊接，或，采用所述超声波焊接方式将所述层叠焊件与极耳焊接，包括；
所述超声波焊接的焊接压力为0.2-0.5Mpa，焊接频率为30-40Khz，焊接时间为0.3-0.5s。
在其中一个实施例中，所述第一箔材所述第二箔材分别采用连续焊接方式焊接于所述复合箔材相对的两表面。
第一箔材、第二箔材分别采用连续焊接方式焊接于复合箔材相对的两表面。也就是说，第一箔材、复合箔材及第二箔材在输送过程中即被焊接，并且在第一箔材与复合箔材及第二箔材与复合箔材上形成连续的焊印，无需在输送过程中暂停第一箔材、复合箔材及第二箔材，极大地缩短了焊接时间，提高了焊接效率。
在其中一个实施例中，所述第一箔材及所述第二箔材的厚度为10-15μm，所述复合箔材的厚度5-8μm。
在其中一个实施例中，所述设定层数为15-40层。
在其中一个实施例中，采用所述超声波焊接方式将所述层叠焊件与极耳焊接，以形成极耳组件，包括：
根据所述层叠焊件与所述极耳焊接的焊接区域来确定。
在其中一个实施例中，所述第一箔材及所述第二箔材的材质为铝箔、铜箔、锡箔中的一种。
在其中一个实施例中，所述极耳超声波焊接方法还包括步骤：
测试所述极耳组件(2)的焊接拉力，当所述焊接拉力≥20N时，判定为合格品。
本发明提供的极耳超声波焊接方法，首先将第一箔材、复合箔材及第二箔材依次层叠，并采用超声波焊接方式焊接在一起，在焊接时，超声波焊接将能量直接作用于第一箔材及第二箔材，第一箔材及第二箔材起到保护复合箔材的作用，能够减少超声波焊接直接接触复合箔材产生的能量，降低了复合箔材在焊接过程中容易断裂的风险，有效避免在焊接过程中造成过焊、焊穿及虚焊的问题，能够保证第一箔材、复合箔材及第二箔材的焊接效果；然后采用超声波焊接方式将若干层叠箔材依次层叠焊接，能够使得若干层叠箔材之间的间距缩短，有利于降低焊接能量消耗；再然后采用超声波焊接方式将层叠焊件与极耳焊接，使极耳焊接抗拉强度增加，使层叠焊件与极耳接触，提高导电性能。
附图说明
构成本申请的一部分的附图用来提供对本发明的进一步理解，本发明的示意性实施例及其说明用于解释本发明，并不构成对本发明的不当限定。
为了更清楚地说明本发明实施例中的技术方案，下面将对实施例描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明 的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本发明一实施例所示的极耳超声波焊接方法的流程图；
图2为本发明一实施例所示的第一箔材与第二箔分别焊接于复合箔材相对的两表面的焊接示意图，图中示出了第一箔材、复合箔材及第二箔材焊接所用的滚焊焊头的结构；
图3为本发明一实施例所示的若干层叠箔材依次层叠焊接的焊接示意图，图中示出了若干层叠箔材依次层叠焊接所用的第二超声波焊头的结构；
图4为本发明一实施例所示的层叠焊件与极耳焊接的焊接示意图，图中示出了层叠焊件与极耳焊接所用的第一超声波焊头的结构。
附图标记说明
1、层叠箔材；11、第一箔材；12、复合箔材；13、第二箔材；2、极耳组件；21、层叠焊件；22、极耳；3、滚焊焊头；3、滚焊焊头；4、第二超声波焊头；5、第一超声波焊头。
具体实施方式
为使本发明的上述目的、特征和优点能够更加明显易懂，下面结合附图对本发明的具体实施方式做详细的说明。在下面的描述中阐述了很多具体细节以便于充分理解本发明。但是本发明能够以很多不同于在此描述的其它方式来实施，本领域技术人员可以在不违背本发明内涵的情况下做类似改进，因此本发明不受下面公开的具体实施例的限制。
在本发明的描述中，需要理解的是，术语“中心”、“纵向”、“横向”、“长度”、“宽度”、“厚度”、“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水 平”、“顶”、“底”、“内”、“外”、“顺时针”、“逆时针”、“轴向”、“径向”、“周向”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本发明的限制。
此外，术语“第一”、“第二”仅用于描述目的，而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此，限定有“第一”、“第二”的特征可以明示或者隐含地包括至少一个该特征。在本发明的描述中，“多个”的含义是至少两个，例如两个，三个等，除非另有明确具体的限定。
在本发明中，除非另有明确的规定和限定，术语“安装”、“相连”、“连接”、“固定”等术语应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或成一体；可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通或两个元件的相互作用关系，除非另有明确的限定。对于本领域的普通技术人员而言，可以根据具体情况理解上述术语在本发明中的具体含义。
在本发明中，除非另有明确的规定和限定，第一特征在第二特征“上”或“下”可以是第一和第二特征直接接触，或第一和第二特征通过中间媒介间接接触。而且，第一特征在第二特征“之上”、“上方”和“上面”可是第一特征在第二特征正上方或斜上方，或仅仅表示第一特征水平高度高于第二特征。第一特征在第二特征“之下”、“下方”和“下面”可以是第一特征在第二特征正下方或斜下方，或仅仅表示第一特征水平高度小于第二特征。
需要说明的是，当元件被称为“固定于”或“设置于”另一个元件，它可以直接在另一个元件上或者也可以存在居中的元件。当一个元件被认为是“连接”另一个元件，它可以是直接连接到另一个元件或者可能同时存在居中元件。 本文所使用的术语“垂直的”、“水平的”、“上”、“下”、“左”、“右”以及类似的表述只是为了说明的目的，并不表示是唯一的实施方式。
参见图1及图2所示，本发明的实施例提供了一种极耳超声波焊接方法，该加工方法可将第一箔材11、复合箔材12及第二箔材13焊接在一起，以得到层叠箔材1，并可将若干层叠箔材1焊接在一起，以形成层叠焊件21，还可将层叠焊件21与极耳22焊接在一起。
复合箔材12包括第三箔材、第四箔材及设置于第三箔材与第四箔材之间的塑料薄膜层，第三箔材、第四箔材分别与塑料薄膜层粘接。在其他可行的实施例中，第三箔材、塑料薄膜层及第四箔材依次通过热熔合的方式连接在一起。第三箔材及第四箔材的厚度为2μm-3μm。
参见图1、图2、图3及图4所示，一种极耳超声波焊接方法，包括以下步骤：
步骤1：依次放卷第一箔材11、复合箔材12及第二箔材13，使第一箔材11、复合箔材12及第二箔材13依次层叠形成层叠箔材1的中间体。第一箔材11及第二箔材13的材质为铝箔、铜箔、锡箔中的一种。
步骤2：采用超声波焊接方式将第一箔材11与第二箔材13分别焊接于复合箔材12相对的两表面，得到层叠箔材1。
步骤3：将层叠箔材1层叠至设定层数，并采用超声波焊接方式将若干层叠箔材1依次焊接，以形成层叠焊件21。
步骤4：采用超声波焊接方式将层叠焊件21与极耳22焊接，以形成极耳组件2。
参见图2所示，第一箔材11、复合箔材12及第二箔材13采用超声波焊接方式进行焊接，超声波焊接是利用高频振动波传递到两个需焊接的物体表面， 在加压的情况下，使两个物体表面相互摩擦而形成分子层之间的熔合。在焊接时，超声波焊接将能量直接作用于第一箔材11及第二箔材13，第一箔材11及第二箔材13起到保护复合箔材12的作用，能够减少超声波焊接直接接触复合箔材12产生的能量，降低了复合箔材12在焊接过程中容易断裂的风险，有效避免在焊接过程中造成过焊、焊穿及虚焊的问题，能够保证层叠箔材1的焊接效果。
在步骤1中，第一箔材11、复合箔材12及第二箔材13分别卷绕于放卷辊上，在放卷驱动部的驱动下，带动放卷辊转动，即可实现第一箔材11、复合箔材12及第二箔材13的依次放卷。其中，放卷驱动部采用电机。需要理解的是：由于第一箔材11、复合箔材12及第二箔材13均为薄材，其强度不高且无法承受较大的撕扯力，在焊接第一箔材11、复合箔材12及第二箔材13时需要保证相对位置固定，否则焊接后将会出现裂纹，严重时产生断带无法连续生产。为此，在焊接前将第一箔材11、复合箔材12及第二箔材13依次层叠，且第一箔材11、复合箔材12及第二箔材13沿同一方向输送。同时，在运输过程中第一箔材11、复合箔材12及第二箔材13的输送速度保持一致，以减少三者之间的速度差，从而保证第一箔材11、复合箔材12及第二箔材13相对位置的固定，进而能够提高第一箔材11、复合箔材12及第二箔材13的焊接质量。
具体地，第一箔材11、复合箔材12及第二箔材13均沿水平方向输送至将第一箔材11与第二箔材13分别焊接于复合箔材12相对两表面的焊接工位，能够减少第一箔材11、复合箔材12及第二箔材13在输送过程中出现打折、起皱的现象，有效保证焊接时的平整度，进一步保证焊接质量。
为实现第一箔材11、复合箔材12及第二箔材13均沿水平方向输送至焊接工位，可做如下设置：
将卷绕有第一箔材11的放卷辊、卷绕有第二箔材13的放卷辊对称设置，将卷绕有复合箔材12的放卷辊在第一方向上设置于卷绕有第一箔材11的放卷辊与卷绕有第二箔材13的放卷辊之间，在第二方向上分别与卷绕有第一箔材11的放卷辊及卷绕有第二箔材13的放卷辊具有间隔。第一方向与第二方向垂直相交。需要理解的是：复合箔材12分别与第一箔材11及第二箔材13平行设置，且复合箔材12位于第一箔材11及第二箔材13之间，同时，第一箔材11与第二箔材13相对复合箔材12对称设置。当第一箔材11及第二箔材13分别放卷时，第一箔材11及第二箔材13可以经过相同长度的路径进入焊接工位，能够减少第一箔材11及第二箔材13的张力差，保证第一箔材11、复合箔材12及第二箔材13层叠时的平整度。
参见图2所示，在步骤2中，第一箔材11、第二箔材13分别采用连续焊接方式焊接于复合箔材12相对的两表面。需要理解的是，第一箔材11、复合箔材12及第二箔材13在输送过程中即被焊接，并且在第一箔材11与复合箔材12及第二箔材13与复合箔材12上形成连续的焊印，无需在输送过程中暂停第一箔材11、复合箔材12及第二箔材13，极大地缩短了焊接时间，提高了焊接效率。
为了保证第一箔材11、复合箔材12及第二箔材13相对位置的精确度，在将第一箔材11与第二箔材13分别焊接于复合箔材12相对的两表面之前，将第一箔材11、复合箔材12及第二箔材13形成的层叠箔材1的中间体压紧，使得第一箔材11、复合箔材12及第二箔材13之间间隔减小，从而使得第一箔材11、第二箔材13分别与复合箔材12之间紧密贴合，不易发生相对位移。例如，在未压紧之前，第一箔材11、第二箔材13分别与复合箔材12之间的间隔为0.5-1mm，经压紧后的第一箔材11、第二箔材13及复合箔材12之间的间隔为0-0.2mm。
第一箔材11及第二箔材13的厚度可以在10-15μm之间选取，复合箔材12的厚度可以在5-8μm之间选取。在本实施例中，第一箔材11及第二箔材13的厚度为12μm，复合箔材的厚度为126μm。
参见图2所示，在一个实施例中，第一箔材11、复合箔材12及第二箔材13的焊接采用超声波滚焊焊接方式，包括有两滚焊焊头3，两滚焊焊头3分别设置于层叠箔材1的上下两侧，且相对层叠箔材1对称设置。采用超声波焊接方式将第一箔材11与第二箔材13分别焊接于复合箔材12相对的两表面时，预留有30-50mm焊接区域，超声波焊接的焊接压力为0.2-0.5Mpa，焊接频率为20-50Khz，焊接速度为10-15r/min，超声波焊头的直径约100mm，超声波焊头为圆形焊头。例如，超声波焊头为圆形滚轮状。
进一步地，在步骤2结束之后，还可以将收卷焊接后的第一箔材11、第二箔材13及复合箔材12，即收卷焊接后的层叠箔材1。为实现收卷焊接后的层叠箔材1，可做如下设置：设置有收卷辊及收卷驱动部，层叠箔材1卷绕于收卷辊上，在收卷驱动部的驱动下，带动收卷辊转动，即可实现收卷焊接后的层叠箔材1。在步骤3之前，需将收卷的层叠箔材1按照需要长度进行裁切，然后在将层叠箔材1层叠至设定层数。设定层数可以在15-40层之间选取。在本实施例中，层叠焊件21的层数为20层。
参见图3所示，在步骤3中，采用超声波焊接方式将若干层叠箔材1依次焊接时，采用第二超声波焊头4，第二超声波焊头4为方形，无焊齿。超声波焊接的焊接压力为0.2-0.5Mpa，焊接频率为30-40Khz，焊接时间为0.3-0.5s。采用超声波焊接方式将若干层叠箔材1依次焊接，能够使得若干层叠箔材1之间的间距缩短，有利于降低焊接能量消耗。
参见图4所示，在步骤4中，采用超声波焊接方式将层叠焊件21与极耳22 焊接时，采用第一超声波焊头5，第一超声波焊头5可以是任意形状，第一超声波焊头5采用正齿焊头。在本实施例中，第一超声波焊头5为方形。超声波焊接的焊接压力为0.2-0.5Mpa，焊接频率为30-40Khz，焊接时间为0.3-0.5s。采用超声波焊接方式将层叠焊件21与极耳22焊接，使极耳22焊接抗拉强度增加，使层叠焊件21与极耳22接触，保证导电性能。在焊接层叠焊件21与极耳22时，焊接所用的第一超声波焊头5大小或长度根据层叠焊件21与极耳22焊接的焊接区域来确定。需要理解的是，第一超声波焊头5大小或长度与层叠焊件21与极耳22焊接的焊接区域成线性关系。
在步骤4结束之后，测试极耳组件2的焊接拉力，当焊接拉力≥20N时，判定为合格品，满足焊接要求。
以上所述实施例的各技术特征可以进行任意的组合，为使描述简洁，未对上述实施例中的各个技术特征所有可能的组合都进行描述，然而，只要这些技术特征的组合不存在矛盾，都应当认为是本说明书记载的范围。
以上所述实施例仅表达了本发明的几种实施方式，其描述较为具体和详细，但并不能因此而理解为对发明专利范围的限制。应当指出的是，对于本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变形和改进，这些都属于本发明的保护范围。因此，本发明专利的保护范围应以所附权利要求为准。

Claims (10)

  1. 一种极耳超声波焊接方法，其特征在于，包括以下步骤：
    依次放卷第一箔材(11)、复合箔材(12)及第二箔材(13)，使所述第一箔材(11)、所述复合箔材(12)及所述第二箔材(13)依次层叠形成层叠箔材(1)的中间体；
    采用超声波焊接方式将所述第一箔材(11)与所述第二箔材(13)分别焊接于所述复合箔材(12)相对的两表面，得到层叠箔材(1)；
    将所述层叠箔材(1)层叠至设定层数，并采用所述超声波焊接方式将若干所述层叠箔材(1)依次焊接，以形成层叠焊件(21)；
    采用所述超声波焊接方式将所述层叠焊件(21)与极耳(22)焊接，以形成极耳组件(2)。
  2. 根据权利要求1所述的极耳超声波焊接方法，其特征在于，将所述第一箔材(11)与所述第二箔材(13)分别焊接于所述复合箔材(12)相对的两表面之前，还包括：
    将所述第一箔材(11)、所述复合箔材(12)及所述第二箔材(13)依次层叠形成层叠箔材(1)的中间体压紧。
  3. 根据权利要求1所述的极耳超声波焊接方法，其特征在于，采用所述超声波焊接方式将所述第一箔材(11)与所述第二箔材(13)分别焊接于所述复合箔材(12)相对的两表面，包括：
    所述超声波焊接的焊接压力为0.2-0.5Mpa，焊接频率为20-50Khz，焊接速度为10-15r/min。
  4. 根据权利要求1所述的极耳超声波焊接方法，其特征在于，采用所述超声波焊接方式将若干所述层叠箔材(1)依次焊接，或，采用所述超声波焊接方式将所述层叠焊件(21)与极耳(22)焊接，包括：
    所述超声波焊接的焊接压力为0.2-0.5Mpa，焊接频率为30-40Khz，焊接时间为0.3-0.5s。
  5. 根据权利要求1所述的极耳超声波焊接方法，其特征在于，所述第一箔材(11)、所述第二箔材(13)分别采用连续焊接方式焊接于所述复合箔材(12)相对的两表面。
  6. 根据权利要求1所述的极耳超声波焊接方法，其特征在于，所述第一箔材(11)及所述第二箔材(13)的厚度为10-15μm，所述复合箔材(12)的厚度5-8μm。
  7. 根据权利要求1所述的极耳超声波焊接方法，其特征在于，所述设定层数为15-40层。
  8. 根据权利要求1所述的极耳超声波焊接方法，其特征在于，采用所述超声波焊接方式将所述层叠焊件(21)与极耳(22)焊接，以形成极耳组件(2)，包括：
    根据所述层叠焊件(21)与所述极耳(22)焊接的焊接区域来确定。
  9. 根据权利要求1所述的极耳超声波焊接方法，其特征在于，所述第一箔材(11)及所述第二箔材(13)的材质为铝箔、铜箔、锡箔中的一种。
  10. 根据权利要求1所述的极耳超声波焊接方法，其特征在于，还包括步骤：
    测试所述极耳组件(2)的焊接拉力，当所述焊接拉力≥20N时，判定为合格品。
PCT/CN2022/094895 2022-03-18 2022-05-25 极耳超声波焊接方法 WO2023173585A1 (zh)

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