Abstract
The ultrasonic metal welding has been used extensively in many fields because it can weld thin layers of highly conductive and dissimilar materials with high reliability. In particular, one-wave length horns with four welding tips on both sides of the horn are widely used for welding positive and negative electrodes and tabs of rechargeable lithium ion batteries. As the vibrational amplitude of each tip is known to be non-uniform, this causes some problems in welding performance. In this study, the one-wave length horn which has four welding tips on both sides of the horn is newly designed to improve amplitude uniformity of each tip. The design of experiment technique is employed to determine the optimum configuration of the horn. The modal analysis and harmonic response analysis are repeatedly conducted to obtain the uniform amplitude of horn tips, and stress distribution in the horn is analyzed finally. It is shown that the uniformity of amplitude can be improved by making appropriate grooves on both sides of the conventional horn.
Highlights
With the recent expansion of mobile devices, such as smart phones, tablets and PCs, and the development of electric cars, many researches are being carried out actively on their key component, the secondary cell battery
The design of experiment technique is employed to determine the optimum configuration of the horn
The modal and harmonic response analysis are performed to obtain the uniform amplitude of designed horn tips, and the stress distribution in the horn is analyzed
Summary
With the recent expansion of mobile devices, such as smart phones, tablets and PCs, and the development of electric cars, many researches are being carried out actively on their key component, the secondary cell battery. Ultrasonic metal welding has been used for efficient welding of multi-layer tabs. For welding of multiple foil-layers onto a single tab, there is not much research available This topic should be studied in detail. The differences in amplitude between the tips should be minimized for efficient ultrasonic metal welding. The one-wave length horn which has four welding tips is newly designed to improve vibrational uniformity on each tip of the horn. The modal and harmonic response analysis are performed to obtain the uniform amplitude of designed horn tips, and the stress distribution in the horn is analyzed . Several different modifications in the shape of conventional horn are tried, and analyzed by using ANSYS tool
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