Ultrasonic welding winder machine for cylindrical batteries

A method for ultrasonically welding a metal ribbon (25) to a metal sheet (16) with an ultrasonic welding machine (10), the method being useful to manufacture a cylindrical battery, the method comprising the steps of:

• (I) providing an ultrasonic welding machine having a stack assembly, which comprises:
• (a) an ultrasonic stack assembly (22) having a horn (54), the horn (54) configured to include a pair of ends between which are one or more upstanding welding studs (80, 84, 88, 90, 94, 98) configured to ultrasonically weld the metal ribbon to the metal sheet;
• and
• (b) a holder assembly (23) comprising
• (i) an upside down U-shaped upper bracket assembly (60) having downwardly extending legs (116);
• (ii) a U-shaped lower bracket assembly (62) having upwardly extending legs (112) and downwardly extending legs (114);
• (iii) a generally T-shaped middle holder (64) having a generally downwardly extending vertical leg (118);
• (iv) a strain gage assembly (66), which experiences a compressive force of an ultrasonic welding, located between the generally downwardly extending vertical leg (118) of the generally T-shaped middle holder (64) and upwardly extending legs (112) of the U-shaped lower bracket assembly (62);
• (v) a pair of bearing assemblies (65A, 65B) which are located between the downwardly extending legs of the upside down U-shaped upper bracket assembly (60), and both the generally T-shaped middle holder (64) and the U-shaped lower bracket assembly (62);
• (vi) an adjustable screw (76) which extends generally vertically adjacent to the generally T-shaped middle holder (64) and into the U-shaped lower bracket assembly (62);
• (vii) four brackets (55A, 55B, 55C, and 55D) which extend from the downwardly extending legs (114) of the U-shaped lower bracket assembly (62) and which each respectively house set screw assemblies (57A, 57B, 57C, and 57D) for holding the horn (54);
• (viii) a first laterally extending arm and bolt assembly (63A and 63C) and a second laterally extending arm and bolt assembly (63B and 63D), wherein the first and second laterally extending arm and bolt assemblies (“63A and 63C” and “63B and 63D”) allow limited vertical motion of the holder assembly (23) while maintaining a parallel orientation of the horn (54) relative to an anvil (20), wherein a first end of the laterally extending arm and bolt assemblies (“63A and 63C” and “63B and 63D”) extends through the generally T-shaped middle holder (64) and a second end of the laterally extending arm and bolt assemblies (“63A and 63C” and “63B and 63D”) extends through the U-shaped lower bracket assembly (62) to secure the U-shaped lower bracket assembly (62) and the generally T-shaped middle holder (64) in position;
• whereby the one or more upstanding welding studs (80, 84, 88, 90, 94, 98) conformingly mate with the metal ribbon as the metal ribbon is being welded to the metal sheet;
• (II) feeding the metal ribbon from a coil (26) of the metal ribbon to adjacency with the metal sheet;
• (III) moving the one or more upstanding welding studs (80, 84, 88, 90, 94, 98) of the horn (54) adjacent to the metal ribbon;
• (IV) actuating the horn (54) whereby the metal ribbon is ultrasonically welded to the metal sheet;
• and
• (V) actuating a cutter assembly (48) to cut the metal ribbon adjacent to the ultrasonically welded metal ribbon and metal sheet.

A holder assembly (23) for holding an ultrasonic welding horn (54) adaptable for use in an ultrasonic tab welder, which comprises:

• (i) an upside down U-shaped upper bracket assembly (60) having downwardly extending legs (116);
• (ii) a U-shaped lower bracket assembly (62) having upwardly extending legs (112) and downwardly extending legs (114);
• (iii) a generally T-shaped middle holder (64) having a generally downwardly extending vertical leg (118);
• (iv) a strain gage assembly (66), which experiences a compressive force of an ultrasonic welding, located between the generally downwardly extending vertical leg (118) of the generally T-shaped middle holder (64) and the upwardly extending legs (112) of the U-shaped lower bracket assembly (62);
• (v) a pair of bearing assemblies (65A, 65B) which are located between the downwardly extending legs of the upside down U-shaped upper bracket assembly (60), and both the generally T-shaped middle holder (64) and the U-shaped lower bracket assembly (62);
• (vi) an adjustable screw (76) which extends generally vertically adjacent to the generally T-shaped middle holder (64) and into the U-shaped lower bracket assembly (62);
• (vii) four brackets (55A, 55B, 55C, and 55D) which extend from the downwardly extending legs (114) of the U-shaped lower bracket assembly (62) and which each respectively house set screw assemblies (57A, 57B, 57C, and 57D) for holding the horn (54);
• and,
• (viii) a first laterally extending arm and bolt assembly (63A and 63C) and a second laterally extending arm and bolt assembly (63B and 63D), wherein the first and second laterally extending arm and bolt assemblies (“63A and 63C” and “63B and 63D”) allow limited vertical motion of the holder assembly (23) while maintaining a parallel orientation of the horn (54) relative to an anvil (20), wherein a first end of the laterally extending arm and bolt assemblies (“63A and 63C” and “63B and 63D”) extends through the generally T-shaped middle holder (64) and a second end of the laterally extending arm and bolt assemblies (“63A and 63C” and “63B and 63D”) extends through the U-shaped lower bracket assembly (62) to secure the U-shaped lower bracket assembly (62) and the generally T-shaped middle holder (64) in position,
• whereby the one or more upstanding welding studs (80, 84, 88, 90, 94, 98) conformingly mate with material to be ultrasonically welded prior to initiation of ultrasonic welding.