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In recent years, with the development of electronic technology, 5G technology and artificial intelligence, global electronic products tend to be intelligent, light and thin, wireless interconnection, entertainment, etc., with TWS (True Wireless Bluetooth) headphones, smart watches, smart speakers, etc. Create a new round of electronic consumer demand for the representative products. Among them, the TWS headset is undoubtedly the most concerned consumer electronic product in recent years.
1. The new headset uses button batteries
TWS headsets are generally composed of a main control chip, a battery, a flexible circuit board, and an audio controller, and the battery cost accounts for about 10% to 20%. Take AirpodsPro as an example. It contains 3 batteries in total: two earphones and one in the charging compartment. The battery in the earphone is a new rechargeable button battery. Compared with other electronic products, the button battery in the TWS headset is a new rechargeable type, and its processing technology is more difficult than traditional disposable button batteries, so the value is higher.
New rechargeable button batteries are widely used in consumer electronics, computers and peripherals, communications, automotive, medical, household, Internet of Things (IoT) and other fields because of their compact and energy storage functions. Button batteries are often called button batteries, which refer to small single cylindrical batteries with a diameter greater than their height. Button batteries are divided into disposable (non-rechargeable) and rechargeable. Disposable (non-rechargeable) button batteries usually start with the "CR" logo, and rechargeable batteries usually start with "LIR", "ML" or " "VL" logo is the main. In addition to the first two English logos, there are 4 digits on the battery. The first two digits are the diameter of the battery (in mm), and the last two digits are the height of the battery (in mm and divided by 10). For example, the logo "CR2032" It means that the diameter of this button battery is 20mm and the height is 3.2mm.
Most of the button batteries on various inexpensive electronic products that are common in people's daily life are traditional disposable (non-rechargeable) ones, which are low in price and simple in processing technology. Nowadays, in order to meet consumers' demands for high endurance, high safety and individualization of electronic products, major battery manufacturers have begun to gradually manufacture new rechargeable button batteries with higher energy density, diverse specifications and diverse materials. Because of this, the processing difficulty and technology of the new button battery are constantly upgrading, and the traditional processing technology has touched the pain point of the new button battery processing technology upgrade.
2. Application of laser welding in button batteries
The traditional button battery processing technology uses the thermal effect of resistance to heat fusion the solder tabs and the battery case to form resistance welding. Although this welding technology is convenient and low-cost, its shortcomings are obvious. For example, it can only be used for welding of a single material, the weld marks are not beautiful, the size of the weld joints is inaccurate, and it is easy to oxidize and turn black. The factors that affect the operation of equipment and personnel are relatively large, and it is easy to cause safety problems such as falling off of solder tabs and drop of battery voltage of solder feet. Therefore, resistance welding is no longer suitable for processing new button batteries with high-quality requirements.
The new button battery is generally applied to the circuit board in the process of processing, and the pins need to be soldered on the surface. According to the needs of different circuit boards, there are often various forms of welding pins. At the same time, the welding feet of the new button battery are more complicated, and the resistance welding process is not very professional. The existing resistance welding technology cannot meet the high quality of the new button battery. For welding requirements, many button battery manufacturers have turned their attention to laser welding technology.
Laser welding technology can meet the diversity of button battery processing technologies, such as welding of dissimilar materials (stainless steel, aluminum alloy, nickel, etc.), irregular welding traces, excellent welding appearance, firm welds, more detailed welding points, and More precise positioning of the welding area, etc. Not only that, laser welding can also make the product consistency high and reduce the damage to the battery, avoiding the waste of raw materials.
3. Solution
As a supplier of precision laser welding equipment and automation solutions, Huiyao Laser has successfully upgraded the button battery welding process from traditional resistance welding to today's laser welding by virtue of years of practical experience in button battery laser welding process. Because of its higher energy density, laser welding can easily reach the material absorption threshold (especially high-reflection materials, which have more obvious advantages), and can achieve a variety of welding trace patterns. Such as sine line shape, spiral line shape, spiral point shape, etc. In addition, the principle of laser welding is different from the traditional welding principle based on large molten pools. It is more similar to the inlaid welding effect and can obtain higher weld strength, especially in the welding of dissimilar materials, which can reduce the brittle compound. generate.
In order to cope with the rapid development of electronic products and the increasing demand for the new button battery market, Huiyao Laser has already developed double-station tab welding stations for button batteries, automatic welding stations for button battery nickel sheets, and button battery steel shells and nickel. It also provides various button battery pin welding proofing, laser and automatic welding equipment solutions for many button battery companies.
◆HY button battery equipment·Nickel sheet automatic welding station
Is used for the welding of the front and back tabs of button batteries. The process includes: battery feeding, tab loading, tab welding, visual inspection, voltage detection, NG blanking and finished product offline. The production capacity/efficiency can reach 1000/H.
◆HY button battery equipment·Steel shell and nickel sheet welding station
The equipment can realize automatic loading and unloading, automatic welding, automatic post-welding inspection, NG discharge, etc., and can meet the needs of welding with different welding materials and different material thicknesses. If the material of the lug is nickel, the steel shell is stainless steel, the thickness of the lug is 0.15mm, and the thickness of the steel shell is 0.15 or 0.2mm, it can meet multiple welding points at the same time and the welding point is extremely small, the point distance is extremely small, and the pulling force ≥30N and other welding requirements.
In addition to the above button battery equipment, the button battery automatic welding assembly line can realize automatic feeding, automatic inspection and sorting, and the automatic production function of button battery welding, assembly, bonding and automatic electrical inspection through the robot and laser equipment , To achieve high-quality, large-scale and flexible production of button batteries.
According to Counterpoint research report statistics, global TWS headset shipments are expected to double in 2020 compared to 2019, and will increase to 700 million in 2022. Now that button batteries are gradually becoming the standard equipment of TWS, the future application of laser processing technology is worth looking forward to.
At present, ultra-thin mobile phones have become the mainstream. The original stainless steel main frame is gradually replaced by the whole aluminum plate for CNC processing. This aluminum main frame is not easy to deform, light in weight, and easy to anode. Processing and other advantages, but because the middle plate is not easy to be CNC processed, laser welding is used to weld the outer frame and the middle plate, which solves the problem that CNC cannot process. For aluminum, it has excellent welding performance, high energy, and more stable processing performance in high-power welding aluminum.
