WO2024022537A1 - 超声焊焊头及超声焊接设备 - Google Patents

超声焊焊头及超声焊接设备 Download PDF

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Publication number
WO2024022537A1
WO2024022537A1 PCT/CN2023/111804 CN2023111804W WO2024022537A1 WO 2024022537 A1 WO2024022537 A1 WO 2024022537A1 CN 2023111804 W CN2023111804 W CN 2023111804W WO 2024022537 A1 WO2024022537 A1 WO 2024022537A1
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WO
WIPO (PCT)
Prior art keywords
welding
plane
ultrasonic
welding head
station
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Application number
PCT/CN2023/111804
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English (en)
French (fr)
Inventor
杨欣
陈利权
苑丁丁
苏斌
吴浩
王�锋
Original Assignee
湖北亿纬动力有限公司
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Application filed by 湖北亿纬动力有限公司 filed Critical 湖北亿纬动力有限公司
Publication of WO2024022537A1 publication Critical patent/WO2024022537A1/zh

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Classifications

    • 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

Definitions

  • This application relates to the technical field of lithium battery manufacturing, for example, to an ultrasonic welding head and ultrasonic welding equipment.
  • Ultrasonic welding is mostly used to weld the tabs and connecting pieces, and the tabs and current collectors.
  • Ultrasonic welding uses high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects rub against each other to form fusion between the molecular layers.
  • Ultrasonic welding equipment in the related art usually includes a welding head and welding teeth provided on the end face of the welding head. Since the welding teeth are directly provided on the end face of the welding head, the force during welding will directly act on the welding head. When the welding power is If it is too large, it will easily cause the welding head to break, and the welded finished product will easily crack. In addition, directly processing the welding teeth on the end face of the welding head will be difficult to process and the processing cost will be high.
  • This application provides an ultrasonic welding head and ultrasonic welding equipment, which can prevent the welding head from breaking when the welding power is too high, ensure the quality of the finished product, and reduce the processing difficulty and cost.
  • an ultrasonic welding head including:
  • the welding head body includes a first connection surface
  • soldering station includes a second connecting surface and a load-bearing surface arranged oppositely, the first connecting surface is connected to the second connecting surface, and the area of the second connecting surface is smaller than that of the first connecting surface. area;
  • Welding teeth are arranged on the bearing surface.
  • the thickness H 1 of the soldering station satisfies: 1.8mm ⁇ H 1 ⁇ 2.5mm.
  • the number of the welding teeth is multiple, and the plurality of welding teeth are arranged in an array on the bearing surface.
  • a plurality of the welding teeth form a rectangular array
  • the length of the rectangular array is L 2
  • the width of the rectangular array is B 2
  • the length of the first connection surface is L 1
  • the The width of the first connecting surface is B 1 , where 1.6mm ⁇ L 1 -L 2 ⁇ 2.4mm and 1.6mm ⁇ B 1 -B 2 ⁇ 2.4mm.
  • the welding teeth include oppositely arranged and concentric welding planes and a fixing plane, the fixing plane is connected to the bearing surface, the welding plane is arranged to be in contact with the parts to be welded, the welding plane The area is smaller than the area of the fixed plane.
  • both the welding plane and the fixing plane are circular, and an arc-shaped surface transition is used between the welding plane and the fixing plane.
  • the area of the welding plane is S 1 and the area of the fixing plane is S 2 , where 4/(95 ⁇ ) ⁇ S 1 /S 2 ⁇ 1/(2 ⁇ ).
  • the welding tooth has a hemispherical structure
  • the diameter D of the fixed plane ranges from 1.2mm to 1.9mm
  • the capping depth H ranges from 0.02mm to 0.1mm
  • the area S 1 of the welding plane ranges from 0.08mm 2 to 0.6mm 2 .
  • both the welding plane and the fixing plane are polygonal, and the transition surface between the welding plane and the fixing plane includes at least one plane.
  • the distance between the centers of two adjacent welding teeth is no more than 2 mm.
  • the soldering station has a cylindrical structure or a platform structure.
  • the soldering station has a cylindrical structure, a prism structure, a truncated cone structure or a prism structure.
  • a rounded transition surface is provided between the top surface and the side surface of the welding station;
  • a rounded transition surface is provided between two adjacent side surfaces and between the top surface and the side surfaces of the welding platform.
  • soldering stations there are multiple soldering stations, a plurality of soldering stations are arranged in an array on the first connection surface, and at least one welding tooth is provided on each soldering station. .
  • the first connection surface is provided on at least one side of the welding head body.
  • embodiments of the present application provide ultrasonic welding equipment, including an ultrasonic generator, a transducer, a horn, and an ultrasonic welding head as described in any of the above solutions.
  • the output end of the ultrasonic generator It is connected to the transducer, and the transducer is connected to the ultrasonic welding head through the horn.
  • Figure 1 is a schematic structural diagram of an ultrasonic welding head provided by an embodiment of the present application.
  • Figure 2 is a schematic side view of an ultrasonic welding head provided by an embodiment of the present application.
  • Figure 3 is a schematic top view of an ultrasonic welding head provided by an embodiment of the present application.
  • FIG. 4 is a partial structural schematic diagram of the ultrasonic welding head provided by the embodiment of the present application.
  • Figure 5 is a schematic diagram 2 of the partial structure of the ultrasonic welding head provided by the embodiment of the present application.
  • Figure 6 is a schematic diagram of the dimensions of the welding head body, welding station and welding teeth in the ultrasonic welding head provided by the embodiment of the present application;
  • FIG. 7 is a schematic structural diagram of a welding tooth provided by an embodiment of the present application.
  • Figure 8 is a schematic structural diagram of the ultrasonic welding equipment provided by the embodiment of the present application.
  • 3-Welding teeth 31-Welding plane; 32-Fixed plane; 33-Arc surface;
  • connection can be a fixed connection, a detachable connection, or an integral body.
  • 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 interaction between two elements.
  • the term “above” or “below” a first feature on a second feature may include direct contact between the first and second features, or may also include the first and second features. Not in direct contact but through additional characteristic contact between them.
  • the terms “above”, “above” and “above” a first feature on a second feature include the first feature being directly above and diagonally above the second feature, or simply mean that the first feature is higher in level than the second feature.
  • “Below”, “under” and “under” the first feature is the second feature includes the first feature being directly below and diagonally below the second feature, or simply means that the first feature is less horizontally than the second feature.
  • FIG. 8 is a schematic structural diagram of the ultrasonic welding equipment.
  • the ultrasonic welding equipment includes an ultrasonic generator 5, a transducer 51, a horn 52 and an ultrasonic welding head, where the ultrasonic wave generates The output end of the device 5 is connected to the transducer 51, and the transducer 51 is connected to the ultrasonic welding head through the horn 52.
  • the ultrasonic generator 5 transmits a signal to the transducer 51, and the transducer 51 controls the action of the ultrasonic welding head through the horn 52, thereby realizing the welding operation of the parts to be welded.
  • FIGS. 1 to 3 show a schematic structural diagram of the ultrasonic welding head provided in this embodiment.
  • Figure 2 shows a schematic side view of the ultrasonic welding head provided in this embodiment.
  • Figure 3 shows a schematic top view of the ultrasonic welding head provided in this embodiment.
  • the ultrasonic welding head includes a connecting part 4 and a welding part.
  • the welding part is connected to the horn 52 through the connecting part 4 .
  • a blind hole is provided at one end of the connecting portion 4 away from the welding portion, and an internal thread is provided in the blind hole.
  • the horn 52 is provided with an external thread that matches the internal thread on the connecting portion.
  • the horn 52 and The connection part is threaded, the connection is tight, and it is easy to disassemble and assemble.
  • the welding part includes a welding head body 1, a welding station 2 and a welding tooth 3.
  • the welding head body 1 includes a first connection surface 11;
  • the welding station 2 includes an oppositely arranged second connection surface 22 and a load-bearing surface 21.
  • the first connection surface 11 and The second connection surfaces 22 are connected, and the area of the second connection surface 22 is smaller than the area of the first connection surface 11 ;
  • the welding teeth 3 are arranged on the bearing surface 21 .
  • one end surface of the welding head body 1 is connected to the connecting portion 4 .
  • the welding teeth 3 are installed on the welding head body 1 through the welding station 2, and the area of the second connection surface 22 of the welding station 2 is smaller than the area of the first connection surface 11 of the welding head body 1.
  • This design can A step-like structure is formed between the welding head body 1 and the welding station 2.
  • the welding station 2 can play a transitional role between the welding head body 1 and the welding teeth 3, so that the welding force does not act directly. on the welding head body 1, thereby preventing the ultrasonic welding head from breaking during the welding process and ensuring the welding quality of the parts to be welded; in addition, since a step-like structure can be formed between the welding head body 1 and the welding station 2, the welding station 2.
  • the welding teeth 3 there is a gap for cutting in or out between the welding head body 1 and the welding station 2, thereby simplifying the processing difficulty and reducing the processing cost.
  • Figure 4 shows a partial structural diagram of the ultrasonic welding head provided in this embodiment.
  • Figure 5 shows a partial structural diagram of the ultrasonic welding head provided in this embodiment.
  • the first connection surface 11 is a rectangular surface
  • the second connection surface 22 is a rectangular surface.
  • the first connection surface 11 and the second connection surface 22 are arranged concentrically, which can ensure the balance of the force on the welding head body 1 .
  • the first connecting surface 11 may be a circular surface
  • the second connecting surface 22 may be a polygon such as a triangle, a rectangle, a pentagon, a hexagon, or the like.
  • the second connecting surface 22 may be a circular surface
  • the first connecting surface 11 may be a polygon such as a triangle, a rectangle, a pentagon, a hexagon, or the like.
  • the soldering station 2 is generally a columnar structure or a table-shaped structure. One end surface of the soldering station 2 forms the above-mentioned second connection surface 22 , and the other end surface forms the above-mentioned bearing surface 21 .
  • the welding station 2 may be a cylindrical structure, a prism structure, a truncated cone structure or a prism structure.
  • the soldering station 2 is a quadrangular prism, one of the two opposite rectangular surfaces of the quadrangular prism forms the above-mentioned second connection surface 22 , and the other forms the above-mentioned bearing surface 21 .
  • the soldering station 2 can also be a quadrangular pyramid structure.
  • the welding station 2 can be a truncated cone structure.
  • a larger circular surface of the truncated cone structure forms the above-mentioned second connection surface 22, and a smaller circular surface of the truncated cone structure forms the above-mentioned bearing surface 21. The same can be done. achieve the above effects.
  • the soldering station 2 may be a cylindrical structure, one of the two opposite circular surfaces of the cylindrical structure forms the above-mentioned second connection surface 22, and the other forms the above-mentioned bearing surface 21.
  • the welding station 2 can also be a triangular prism, a triangular cone, a hexagonal prism, a hexagonal cone, etc., which is not limited in this embodiment.
  • a rounded transition surface is provided between the top surface and the side surface of the welding station 2; when the welding station 2 has a prism structure or a prism structure, a rounded transition surface is provided on the welding station 2.
  • the thickness H 1 of the welding station 2 ranges from 1.8mm to 2.5mm.
  • the thickness H 1 of the soldering station 2 1.9mm, 1.92mm, 2.0mm, 2.1mm, 2.11mm, 2.2mm, 2.3mm or 2.4mm, etc.
  • the forming process of the ultrasonic welding head is: 1) Process the welding head blank and process a cuboid structure on the side of the welding head blank; 2) Process the middle welding station on the end edge of the cuboid structure in step 1).
  • the cuboid structure in step 1) forms a stepped structure, which are the welding head body 1 and the middle welding station; 3) Process the welding teeth 3 on the middle welding table, and the welding station 2 is formed between the welding teeth 3 and the welding head body 1 ; 4) Finish processing the first connection surface 11 of the welding head body 1 and the second connection surface 22 of the welding station 2 to meet the preset accuracy requirements.
  • a first connection surface 11 is provided on at least one side of the welding head body 1 .
  • the welding head body 1 is provided with two first connection surfaces 11 , and the two first connection surfaces 11 are both provided with a welding station 2 and a welding tooth 3 .
  • the welding teeth 3 on one of the welding stations 2 are damaged, the welding teeth 3 on the other welding station 2 can be used to continue the operation, thereby extending the service life of the ultrasonic welding head and saving processing costs.
  • Figure 6 shows a schematic diagram of the dimensions of the welding head body 1, the welding station 2 and the welding teeth 3 in the ultrasonic welding head provided in this embodiment.
  • the number of welding teeth 3 is multiple, and the plurality of welding teeth 3 are arranged in an array on the bearing surface 21 . Multiple welding teeth 3 interact with the parts to be welded at the same time to improve welding efficiency and welding quality.
  • the plurality of welding teeth 3 form a rectangular array, the length of the rectangular array is L 2 , the width of the rectangular array is B 2 , the length of the first connecting surface 11 is L1 , and the width of the first connecting surface 11 is B 1 , among which, 1.6mm ⁇ L1-L2 ⁇ 2.4mm, 1.6mm ⁇ B 1 -B 2 ⁇ 2.4mm.
  • This embodiment does not limit the size of the rectangular array formed by the first connection surface 11, the second connection surface 22 and the plurality of welding teeth 3. It can be customized to the size of the parts to be welded, thereby ensuring the welding quality of the finished product. When ultrasonic welding the welding head, it is necessary to ensure that the center of the welding mark formed on the part to be welded coincides with the center of the second connection surface 22 .
  • the distance between the centers of two adjacent welding teeth 3 is no more than 2 mm, which is beneficial to achieving a strong and stable welding effect.
  • the spacing between two adjacent welding teeth 3 can be 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm, 1mm, 1.1mm, 1.2mm, 1.5mm, 1.6mm, 1.8mm, 2mm .
  • the distance between two adjacent welding teeth 3 is not limited. It can be any value between 0 and 2 mm. It only needs to be convenient for processing on the premise of ensuring stable welding.
  • the number of welding stations 2 is one, and one welding station 2 is provided with a plurality of welding teeth 3 arranged in an array. In other embodiments, the number of welding stations 2 can also be multiple.
  • the plurality of welding stations 2 are arranged in an array on the first connection surface 11.
  • Each welding station 2 is provided with at least one welding tooth 3. In this embodiment, the number of welding teeth 3 provided on each welding station 2 is not limited.
  • FIG 7 shows a schematic structural diagram of the welding tooth 3 provided in this embodiment.
  • the welding tooth 3 includes an oppositely arranged and concentric welding plane 31 and a fixed plane 32.
  • the fixed plane 32 is connected to the bearing surface 21.
  • the welding plane 31 is used to contact the parts to be welded.
  • the welding plane The area of 31 is smaller than the area of fixed plane 32.
  • the welding pressure gradually increases. Under the action of the welding teeth 3, the parts to be welded begin to deform. Setting the area of the welding plane 31 to be smaller than the area of the fixed plane 32 can cause the parts to be welded to deform.
  • the speed is slowed down to avoid the sudden thinning of the parts to be welded around the welding teeth 3 and the occurrence of cracks.
  • both the welding plane 31 and the fixing plane 32 are circular, and an arc-shaped surface 33 is used for transition between the welding plane 31 and the fixing plane 32 .
  • This design can not only eliminate the protective sheet, saving battery manufacturing costs, but also ensure the stability of ultrasonic welding tension and residue, and has strong applicability.
  • the welding tooth 3 has a truncated hemispherical structure or a truncated cone structure.
  • the arc surface 33 may be a convex arc surface or a concave arc surface. This embodiment is not limited to this as long as the welding teeth 3 have sufficient strength to weld the parts to be welded. It has been verified by simulation and experiments that when the welding tooth 3 has a truncated hemispherical structure, the quality of the welded tab is better.
  • the area of the welding plane 31 is S 1 and the area of the fixing plane 32 is S 2 , where 4/(95 ⁇ ) ⁇ S 1 /S 2 ⁇ 1/(2 ⁇ ).
  • the fixed plane 32 has a larger area, which can increase the connection area between the welding teeth 3 and the bearing surface 21 and ensure the stability of the connection; during welding, the welding plane 31 is in direct contact with the parts to be welded, and the area of the welding plane 31 Being smaller can result in greater pressure on the surface area of the parts to be welded that is in contact with the welding plane 31, thereby forming deeper indentations and ensuring welding quality.
  • the welding tooth 3 is a hemispherical structure with a cut top
  • a hemispherical structure with a diameter D can be processed on the welding station 2 first, and then the top cutting operation is performed on the side of the hemispherical structure away from the welding station 2. , thereby forming a welding plane 31 on this side.
  • the top cutting depth H2 is 0.02mm ⁇ 0.1mm
  • the area S1 of the welding plane 31 ranges from 0.08mm2 ⁇ 0.6mm2 .
  • D 1.82mm
  • the cutting depth is 0.05mm
  • S 1 0.28mm 2 .
  • the following table exemplarily lists the diameter D, the cutting depth and the area S 1 of the welding plane 31 of the fixed plane 32 of the welding tooth 3.
  • the above dimensions of the welding tooth 3 are not limited to the examples in the following table. The operator can Make adjustments according to actual conditions.
  • both the welding plane 31 and the fixing plane 32 are polygonal, and the transition surface between the welding plane 31 and the fixing plane 32 includes at least one plane.
  • the welding plane 31 and the fixing plane 32 may be a triangle, a rectangle, a pentagon, a hexagon, etc., which are not limited in this embodiment.
  • this embodiment does not limit the sizes of the welding plane 31 and the fixing plane 32, and the operator can adjust them according to the actual welding scene.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

一种超声焊焊头及超声焊接设备。该超声焊焊头包括焊头本体（1）、焊台（2）和焊齿（3），焊头本体（1）包括第一连接面（11）；焊台（2）包括相对设置的第二连接面（22）和承载面（21），第一连接面（11）与第二连接面（22）相连接，第二连接面（22）的面积小于第一连接面（11）的面积；焊齿（3）设置于承载面（21）上。

Description

超声焊焊头及超声焊接设备
本申请要求在2023年06月30日提交中国专利局、申请号为202321701631.7的中国专利申请的优先权，该申请的全部内容通过引用结合在本申请中。
技术领域
本申请涉及锂电池制造技术领域，例如涉及一种超声焊焊头及超声焊接设备。
 背景技术
在锂离子电池加工过程中，极耳与连接片、极耳与集流体的焊接大多采用超声波焊接。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。相关技术中的超声焊接设备通常包括焊头及在焊头的端面上设置的焊齿，由于焊齿直接设置在焊头的端面，焊接时的作用力会直接作用在焊头上，当焊接功率过大时容易导致焊头发生断裂，且焊接完的成品容易发生开裂；此外，在焊头的端面上直接加工焊齿，其加工难度较大，加工成本较高。
 发明内容
本申请提供了一种超声焊焊头及超声焊接设备，可以防止焊接功率过大时导致的焊头断裂，可以保证成品质量，降低加工难度及加工成本。
第一方面，本申请实施例提供了一种超声焊焊头，包括：
焊头本体，所述焊头本体包括第一连接面；
焊台，所述焊台包括相对设置的第二连接面和承载面，所述第一连接面与所述第二连接面相连接，所述第二连接面的面积小于所述第一连接面的面积；
焊齿，设置于所述承载面上。
在一实施例中，所述焊台的厚度H 1满足：1.8mm≤H 1≤2.5mm。
在一实施例中，所述焊齿的数量为多个，多个所述焊齿呈阵列排布于所述承载面上。
在一实施例中，多个所述焊齿形成矩形阵列，所述矩形阵列的长度为L 2，所述矩形阵列的宽度为B 2，所述第一连接面的长度为L 1，所述第一连接面的宽度为B 1，其中，1.6mm≤L 1-L 2≤2.4mm，1.6mm≤B 1-B 2≤2.4mm。
在一实施例中，所述焊齿包括相对设置且同心的焊接平面和固定平面，所述固定平面与所述承载面相连接，所述焊接平面设置为与待焊接件相接触，所述焊接平面的面积小于所述固定平面的面积。
在一实施例中，所述焊接平面和所述固定平面均为圆形，且所述焊接平面和所述固定平面之间采用弧形面过渡。
在一实施例中，所述焊接平面的面积为S 1，所述固定平面的面积为S 2，其中，4/（95π）≤S 1/S 2≤1/（2π）。
在一实施例中，所述焊齿为切顶半球形结构，所述固定平面的直径D的范围为1.2mm~1.9mm；所述切顶深度H 2的范围为0.02mm~0.1mm，所述焊接平面的面积S 1的范围为0.08mm 2~0.6mm 2。
在一实施例中，所述焊接平面和所述固定平面均为多边形，所述焊接平面和所述固定平面之间的过渡面至少包括一个平面。
在一实施例中，相邻两个所述焊齿的中心之间的间距不大于2mm。
在一实施例中，所述焊台为柱体结构或者台体结构。
在一实施例中，所述焊台为圆柱结构、棱柱结构、圆台结构或者棱台结构。
在一实施例中，在所述焊台为圆柱结构或者圆台结构的情况下，所述焊台的顶面和侧面之间设置有圆角过渡面；
在所述焊台为棱柱结构或者棱台结构的情况下，所述焊台上相邻两个侧面之间以及顶面和侧面之间均设置有圆角过渡面。
在一实施例中，所述焊台的数量为多个，多个所述焊台呈阵列排布于所述第一连接面上，每个所述焊台上设置有至少一个所述焊齿。
在一实施例中，所述焊头本体的至少一侧设置有所述第一连接面。
第二方面，本申请实施例提供了一种超声焊接设备，包括超声波发生器、换能器、变幅杆和如以上任一方案所述的超声焊焊头，所述超声波发生器的输出端与所述换能器相连接，所述换能器通过所述变幅杆与所述超声焊焊头相连接。
 附图说明
图1是本申请实施例提供的超声焊焊头的结构示意图；
图2是本申请实施例提供的超声焊焊头的侧视示意图；
图3是本申请实施例提供的超声焊焊头的俯视示意图；
图4是本申请实施例提供的超声焊焊头的局部结构示意图一；
图5是本申请实施例提供的超声焊焊头的局部结构示意图二；
图6是本申请实施例提供的超声焊焊头中焊头本体、焊台及焊齿的尺寸示意图；
图7是本申请实施例提供的焊齿的结构示意图；
图8是本申请实施例提供的超声焊接设备的结构示意图。
其中：
1-焊头本体；11-第一连接面；
2-焊台；21-承载面；22-第二连接面；
3-焊齿；31-焊接平面；32-固定平面；33-弧形面；
4-连接部；
5-超声发生器；51-换能器；52-变幅杆。
 实施方式
在本申请的描述中，除非另有明确的规定和限定，术语“相连”、“连接”、“固定”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。
在本申请中，除非另有明确的规定和限定，第一特征在第二特征之“上”或之“下”可以包括第一和第二特征直接接触，也可以包括第一和第二特征不是直接接触而是通过它们之间的另外的特征接触。而且，第一特征在第二特征“之上”、“上方”和“上面”包括第一特征在第二特征正上方和斜上方，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”包括第一特征在第二特征正下方和斜下方，或仅仅表示第一特征水平高度小于第二特征。
在本实施例的描述中，术语“上”、“下”、“左”、“右”等方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述和简化操作，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申请的限制。此外，术语“第一”、“第二”仅仅用于在描述上加以区分，并没有特殊的含义。
本实施例提供了一种超声焊接设备，图8是超声焊接设备的结构示意图，该超声焊接设备包括超声波发生器5、换能器51、变幅杆52和超声焊焊头，其中，超声波发生器5的输出端与换能器51相连接，换能器51通过变幅杆52与超声焊焊头相连接。使用时，超声波发生器5传递信号给换能器51，换能器51通过变幅杆52控制超声焊焊头动作，从而实现对待焊接件的焊接操作，通过应用上述超声焊焊头，可以保证焊接过程的顺畅性及成品的焊接质量，并防止在焊接过程中设备发生损坏。
图1示出了本实施例提供的超声焊焊头的结构示意图。图2示出了本实施例提供的超声焊焊头的侧视示意图。图3示出了本实施例提供的超声焊焊头的俯视示意图。如图1-图3所示，超声焊焊头包括连接部4和焊接部，焊接部通过连接部4连接于变幅杆52上。可选地，连接部4远离焊接部的一端设置有盲孔，盲孔内设置有内螺纹，变幅杆52上设置有与连接部上的内螺纹相配合的外螺纹，变幅杆52和连接部螺纹连接，连接紧固，方便拆装。
焊接部包括焊头本体1、焊台2和焊齿3，焊头本体1包括第一连接面11；焊台2包括相对设置的第二连接面22和承载面21，第一连接面11与第二连接面22相连接，第二连接面22的面积小于第一连接面11的面积；焊齿3设置于承载面21上。其中，焊头本体1的一端面连接连接部4。在本实施例中，焊齿3通过焊台2安装于焊头本体1上，且焊台2的第二连接面22的面积小于焊头本体1的第一连接面11的面积，该设计能够使焊头本体1与焊台2之间形成台阶状结构，在焊接时，焊台2能够在焊头本体1和焊齿3之间起到过渡的作用，使焊接的作用力不会直接作用于焊头本体1上，从而防止焊接过程中超声焊焊头发生断裂，并保证待焊接件的焊接质量；此外，由于焊头本体1与焊台2之间能形成台阶状结构，在焊台2上加工焊齿3时，焊头本体1与焊台2之间存在进刀或者退刀的间隙，从而简化加工难度，降低加工成本。
图4示出了本实施例提供的超声焊焊头的局部结构示意图一。图5示出了本实施例提供的超声焊焊头的局部结构示意图二。如图3-图5所示，在本实施例中，第一连接面11为矩形面，第二连接面22为矩形面。可选地，第一连接面11与第二连接面22同心设置，可以保证焊头本体1上受力的平衡性。在另一实施例中，第一连接面11可以是圆形面，第二连接面22为三角形、矩形、五边形、六边形等多边形。在又一实施例中，第二连接面22可以是圆形面，第一连接面11可以是三角形、矩形、五边形、六边形等多边形。
焊台2大体上为柱状结构或者台状结构，焊台2的其中一个端面形成上述第二连接面22，另一个端面形成上述承载面21。示例性地，焊台2可以为圆柱结构、棱柱结构、圆台结构或者棱台结构。在一个实施例中，焊台2为四棱柱，四棱柱相对的两个矩形面中的一个形成上述第二连接面22，另一个形成上述承载面21。在第二个实施例中，焊台2还可以为四棱台结构，四棱台较大的一个端面形成上述第二连接面22，四棱台较小的一个端面形成上述承载面21，同样能够实现上述效果。在第三个实施例中，焊台2可以是圆台结构，圆台结构较大的一个圆形面形成上述第二连接面22，圆台结构较小的一个圆形面形成上述承载面21，同样能够实现上述效果。在第四个实施例中，焊台2可以是圆柱结构，圆柱结构相对的两个圆形面中的一个形成上述第二连接面22，另一个形成上述承载面21。当然，焊台2还可以是三棱柱、三棱台、六棱柱、六棱台等，本实施例对此不作限定。
可选地，当焊台2为圆柱结构或者圆台结构时，焊台2的顶面和侧面之间设置有圆角过渡面；当焊台2为棱柱结构或者棱台结构时，焊台2上相邻两个侧面之间以及顶面和侧面之间均设置有圆角过渡面。通过设置圆角过渡面，可以降低焊接过程中对待焊接件的损伤，保证成品质量。
为了保证在加工该超声焊焊头时，焊头本体1与焊台2之间能形成足够的进刀或者退刀的间隙，焊台2的厚度H 1的范围为1.8mm~2.5mm。示例性地，焊台2的厚度H 1=1.9mm、1.92mm、2.0mm、2.1mm、2.11mm、2.2mm、2.3mm或者2.4mm等。
该超声焊焊头的成型过程为：1）加工焊头毛坯，在焊头毛坯的侧面上加工一长方体结构；2）在步骤1）中的长方体结构的端面边缘加工中间焊台，此时，步骤1）中的长方体结构形成一台阶状结构，分别为焊头本体1和中间焊台；3）在中间焊台上加工焊齿3，焊齿3与焊头本体1之间形成焊台2；4）对焊头本体1的第一连接面11及焊台2的第二连接面22进行精加工，以满足预设的精度要求。
焊头本体1的至少一侧设置有第一连接面11。在本实施例中，焊头本体1上设置有两个第一连接面11，两个第一连接面11上均设置有焊台2和焊齿3。当其中一个焊台2上的焊齿3发生损坏后，可以使用另一个焊台2上的焊齿3继续作业，从而延长该超声焊焊头的使用寿命，节约加工成本。
图6示出了本实施例提供的超声焊焊头中焊头本体1、焊台2及焊齿3的尺寸示意图。如图4和图6所示，焊齿3的数量为多个，多个焊齿3呈阵列排布于承载面21上。多个焊齿3同时与待焊接件发生相互作用，提高焊接效率及焊接质量。可选地，多个焊齿3形成矩形阵列，该矩形阵列的长度为L 2，矩形阵列的宽度为B 2，第一连接面11的长度为L1，第一连接面11的宽度为B 1，其中，1.6mm≤L1-L2≤2.4mm，1.6mm≤B 1-B 2≤2.4mm。可选地，在本实施例中，L 1=18.75mm，L 1=16.75mm；B 1=8mm，B 2=6mm。本实施例对第一连接面11、第二连接面22及多个焊齿3形成的矩形阵列的尺寸不作限定，其可以待焊接件的尺寸进行定制，从而保证成品的焊接质量，在加工该超声焊焊头时，需要保证待焊接件上形成的焊印中心与第二连接面22的中心重合。
可选地，相邻两个焊齿3的中心之间的间距不大于2mm，有利于实现牢固且稳定的焊接效果。示例性地，相邻两个焊齿3之间的间距可以为0.5mm、0.6mm、0.7mm、0.8mm、0.9mm、1mm、1.1mm、1.2mm、1.5mm、1.6mm、1.8mm、2mm。本实施例对相邻两个焊齿3之间的间距不作限定，其可以是0~2mm之间的任意数值，在保证稳定焊接的前提下，方便加工即可。
在本实施例中，焊台2的数量为一个，一个焊台2上设置有多个呈阵列排布的焊齿3。在其他实施例中，焊台2的数量还可以为多个，多个焊台2呈阵列排布于第一连接面11上，每个焊台2上设置有至少一个焊齿3，本实施例对每个焊台2上设置的焊齿3的数量不作限定。
图7示出了本实施例提供的焊齿3的结构示意图。如图6和图7所示，焊齿3包括相对设置且同心的焊接平面31和固定平面32，固定平面32与承载面21相连接，焊接平面31用于与待焊接件相接触，焊接平面31的面积小于固定平面32的面积。在焊接的过程中，焊接的压力逐渐增强，在焊齿3的作用下，待焊接件开始发生形变，而将焊接平面31的面积设置为小于固定平面32的面积，可以使待焊接件发生形变的速度变缓，避免焊齿3周围的待焊接件突然变薄产生裂缝。
在本实施例中，焊接平面31和固定平面32均为圆形，且焊接平面31和固定平面32之间采用弧形面33过渡。该设计既可以取消保护片，节约电池制造成本，又可以保证超声焊接拉力和残留的稳定性，适用性较强。示例性地，焊齿3为切顶半球结构或者圆台结构。其中，弧形面33可以是外凸弧形面，也可以是内凹弧形面，本实施例对此均不作限定，只要能够保证焊齿3具有足够的强度对待焊接件进行焊接即可。经模拟仿真及试验验证，焊齿3为切顶半球形结构时，其焊接后的极耳质量更好。
可选地，焊接平面31的面积为S 1，固定平面32的面积为S 2，其中，4/(95π)≤S 1/S 2≤1/(2π)。其中，固定平面32的面积较大，可以增加焊齿3与承载面21之间的连接面积，保证连接的稳定性；在焊接时，焊接平面31与待焊接件直接接触，焊接平面31的面积较小可以使待焊接件上与焊接平面31相接触的表面区域压强较大，从而形成更深的压痕，保证焊接质量。
由于焊齿3为切顶半球形结构，在加工焊齿3时，可以先在焊台2上加工直径D的半球形结构，再在该半球形结构远离焊台2的一侧进行切顶操作，从而在该侧形成焊接平面31。可选地，1.2mm≤D≤1.9mm，切顶深度H 2为0.02mm~0.1mm，焊接平面31的面积S 1的范围为0.08mm 2~0.6mm 2。示例性地，D=1.82mm，切顶深度为0.05mm，S 1=0.28mm 2。在加工焊齿3时，首先在焊台2上加工直径D的半球形结构，然后再在该半球形结构远离焊台2的一侧进行切顶操作，如图7所示的虚线半球即为从上述半球形结构上切下来的小半球，该小半球的半径即为切顶深度H 2。
下表示例性地列出了焊齿3的固定平面32的直径D、切顶深度及焊接平面31的面积S 1，当然，焊齿3的上述各项尺寸不限于下表示例，操作人员可以根据实际情况进行调整。
在其他实施例中，焊接平面31和固定平面32均为多边形，焊接平面31和固定平面32之间的过渡面至少包括一个平面。示例性地，焊接平面31和固定平面32可以是三角形、矩形、五边形、六边形等，本实施例对此不作限定。另外，本实施例对焊接平面31和固定平面32的尺寸也不作限定，操作人员可以根据实际焊接场景进行调整。

Claims (16)

  1. 一种超声焊焊头，包括：
    焊头本体（1），所述焊头本体（1）包括第一连接面（11）；
    焊台（2），所述焊台（2）包括相对设置的第二连接面（22）和承载面（21），所述第一连接面（11）与所述第二连接面（22）相连接，所述第二连接面（22）的面积小于所述第一连接面（11）的面积；
    焊齿（3），设置于所述承载面（21）上。
  2. 根据权利要求1所述的超声焊焊头，其中，所述焊台（2）的厚度H 1满足：1.8mm≤H 1≤2.5mm。
  3. 根据权利要求1所述的超声焊焊头，其中，所述焊齿（3）的数量为多个，多个所述焊齿（3）呈阵列排布于所述承载面（21）上。
  4. 根据权利要求3所述的超声焊焊头，其中，多个所述焊齿（3）形成矩形阵列，所述矩形阵列的长度为L 2，所述矩形阵列的宽度为B 2，所述第一连接面（11）的长度为L 1，所述第一连接面（11）的宽度为B 1，其中，1.6mm≤L 1-L 2≤2.4mm，1.6mm≤B 1-B 2≤2.4mm。
  5. 根据权利要求1所述的超声焊焊头，其中，所述焊齿（3）包括相对设置且同心的焊接平面（31）和固定平面（32），所述固定平面（32）与所述承载面（21）相连接，所述焊接平面（31）设置为与待焊接件相接触，所述焊接平面（31）的面积小于所述固定平面（32）的面积。
  6. 根据权利要求5所述的超声焊焊头，其中，所述焊接平面（31）和所述固定平面（32）均为圆形，且所述焊接平面（31）和所述固定平面（32）之间采用弧形面（33）过渡。
  7. 根据权利要求6所述的超声焊焊头，其中，所述焊接平面（31）的面积为S 1，所述固定平面（32）的面积为S 2，其中，4/（95π）≤S 1/S 2≤1/（2π）。
  8. 根据权利要求6所述的超声焊焊头，其中，所述焊齿（3）为切顶半球形结构，所述固定平面（32）的直径D的范围为1.2mm~1.9mm；所述切顶深度H 2的范围为0.02mm~0.1mm，所述焊接平面（31）的面积S 1的范围为0.08 mm 2~0.6 mm 2。
  9. 根据权利要求5所述的超声焊焊头，其中，所述焊接平面（31）和所述固定平面（32）均为多边形，所述焊接平面（31）和所述固定平面（32）之间的过渡面至少包括一个平面。
  10. 根据权利要求1所述的超声焊焊头，其中，相邻两个所述焊齿（3）的中心之间的间距不大于2mm。
  11. 根据权利要求1所述的超声焊焊头，其中，所述焊台（2）为柱体结构或者台体结构。
  12. 根据权利要求11所述的超声焊焊头，其中，所述焊台（2）为圆柱结构、棱柱结构、圆台结构或者棱台结构。
  13. 根据权利要求12所述的超声焊焊头，其中，在所述焊台（2）为圆柱结构或者圆台结构的情况下，所述焊台（2）的顶面和侧面之间设置有圆角过渡面；
    在所述焊台（2）为棱柱结构或者棱台结构的情况下，所述焊台（2）上相邻两个侧面之间以及顶面和侧面之间均设置有圆角过渡面。
  14. 根据权利要求1所述的超声焊焊头，其中，所述焊台（2）的数量为多个，多个所述焊台（2）呈阵列排布于所述第一连接面（11）上，每个所述焊台（2）上设置有至少一个所述焊齿（3）。
  15. 根据权利要求1-14中任一项所述的超声焊焊头，其中，所述焊头本体（1）的至少一侧设置有所述第一连接面（11）。
  16. 一种超声焊接设备，包括超声波发生器5、换能器51、变幅杆52和如权利要求1-15中任一项所述的超声焊焊头，所述超声波发生器5的输出端与所述换能器51相连接，所述换能器51通过所述变幅杆52与所述超声焊焊头相连接。
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