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In recent years, with the development of electronic technology, 5G technology and artificial intelligence, global electronic products tend to develop in the direction of intelligence, thinness, wireless interconnection, entertainment, etc. Products represented by TWS (true wireless Bluetooth) earphones, smart watches, smart speakers, etc. have created a new round of demand for electronic consumption. TWS headset is undoubtedly the most popular consumer electronics product in recent years.

TWS headset is generally composed of main control chip, battery, flexible circuit board and audio controller, among which the cost of battery accounts for about 10%~20%. Take the Airpods Pro as an example, it contains three batteries: two earphones and one in the charging bin. The batteries in the earphones are new rechargeable button batteries. Compared with other electronic products, the button battery in TWS headset is a new type of rechargeable battery, and its processing technology is more difficult than the traditional disposable button battery, so its value is higher.

Because of its compact and energy storage function, the new rechargeable button battery has also been widely used in consumer electronics, computers and peripherals, communications, vehicular, medical, household, IOT and other fields.

Popular science of button battery

Button battery is often called button battery, which refers to a small single cylindrical battery with a diameter greater than the height. Button batteries are divided into disposable (non rechargeable) and rechargeable ones. The disposable (non rechargeable) button batteries usually start with the "CR" logo, while the rechargeable ones are mainly marked with the "LIR", "ML" or "VL" logo.

In addition to the first two English signs, there are four digits on the battery. The first two digits are the diameter of the battery (unit: mm), and the last two digits are the height of the battery (unit: mm and divided by 10). For example, the sign "CR2032" represents that the diameter of the button battery is 20 mm, and the height is 3.2 mm.

Most of the button batteries used in various affordable electronic products in our daily life are traditional disposable (non rechargeable) batteries, which are cheap and simple in processing. Today, in order to meet consumers' demand for high endurance, high safety and personalization of electronic products, major battery manufacturers have gradually begun to manufacture new rechargeable button batteries with higher energy density, various specifications and materials. Because of this, the processing difficulty and technology of the new button battery are also constantly upgrading. The traditional processing technology has touched the pain point of the upgrading of the new button battery processing technology.

The traditional button battery processing technology is resistance welding, which uses the thermal effect of resistance to heat fuse the solder and battery shell to form welding. Although this welding technology is convenient and low cost, its disadvantages are also obvious. For example, it can only be used for welding of a single material, the weld mark is not beautiful, the size of the solder joint is not accurate, and it is easy to oxidize and blacken, and the sharp edge is large. In the process of operation, there are many factors that affect the operation of equipment and personnel, and it is easy to have the safety problems such as the falling of the solder lug, the voltage drop of the solder foot battery, and so on. Therefore, resistance welding is no longer applicable to the processing of new button batteries with high quality requirements.

The new button battery is generally applied to the circuit board in the processing process, and the pins need to be welded on its surface. According to the needs of different circuit boards, the forms of welding pins are often various. At the same time, the solder legs of new button batteries are relatively complex, and the resistance welding process is not professional. In view of the existing resistance welding technology can not meet the high-quality welding requirements of new button batteries, many button battery manufacturers turn their attention to laser welding technology.

Laser welding technology can meet the diversity of button battery processing technology, such as welding of dissimilar materials (stainless steel, aluminum alloy, nickel, etc.), irregular welding track, excellent welding appearance, firm weld, more detailed welding points, and more accurate positioning welding area. Not only that, laser welding can also make the product more consistent and reduce the damage to the battery and avoid the waste of raw materials. In 2015, Uniwin Laser has been involved in the laser welding processing of button batteries and has continued to this day.

Button battery laser welding application solution

Lianying Laser is one of the main suppliers of precision laser welding equipment and automation solutions with international leading level. With many years of practical experience in button battery laser welding process, Uniwin Laser has upgraded the button battery welding process from traditional resistance welding to current laser welding. Its technological advantages are shown in the figure below:

1. With higher energy density, it is easier to reach the material absorption threshold (especially for high anti-material, the advantage is more obvious);

2. It can realize various welding trajectory graphics. Such as sine line, spiral line, spiral point, etc;

3. Smaller welding spot, larger weld depth to width ratio, larger contact area and greater weld strength and tension can be obtained under the same size of welding spot;

4. High power density. Its welding principle is different from the traditional welding principle based on large molten pool, and is more similar to the mosaic welding effect, which can obtain higher weld strength, especially in the welding of dissimilar materials, which can reduce the formation of brittle compounds.

In order to cope with the new button battery market with the rapid development of electronic products and the increasing demand, Uniwin Laser has already successively developed the button battery two-position pole ear welding station, the button battery nickel plate automatic welding station, the button battery electricity inspection and labeling machine, the button battery steel shell and nickel plate welding equipment, and also provided various kinds of button battery pin welding and proofing for many enterprises producing button batteries Laser and automatic welding equipment scheme, etc. The following are some cases of Lianying laser button battery production and processing:

UW button battery equipment · double-station pole lug welding station

The equipment can realize the functions of loading and unloading of electric core, automatic switching of two stations, welding of positive and negative pole lugs at the same station, laser ranging adjustment of welding focal length, weldable points, straight lines, circles, squares or any plane figure composed of arcs. It has high welding accuracy, good consistency, no damage to the base material, strong tensile force and high yield.

UW button battery equipment · electricity testing and labeling machine

The device can realize the functions of battery voltage and resistance detection and single-sided adhesive tape pasting, and can be compatible with the battery specifications of different manufacturers. The capacity/efficiency is 100/1min (varies according to the size of the battery).

UW button battery equipment · nickel sheet automatic welding station

This equipment is used for the welding of the front and back pole lugs of the button battery. The processes include: battery charging, pole lug charging, pole lug welding, visual detection, voltage detection, NG blanking and finished product offline. The capacity/efficiency reaches 1000/h.

UW button battery equipment · steel shell and nickel plate welding station

The equipment can realize automatic loading and unloading, automatic welding, automatic post-welding detection, NG discharging, etc., and can meet the welding of different welding materials and different material thicknesses. For example, the electrode lug material is nickel, the steel shell is stainless steel, the thickness of the electrode lug is 0.15 mm, the thickness of the steel shell is 0.15 or 0.2 mm, and the welding requirements of multiple welding points with very small welding points, very small point spacing, and the drawing force ≥ 30 N are met at the same time.

In addition to the above button battery equipment, Uniwin Laser has an automatic button battery welding and assembly line, which can realize automatic feeding, automatic detection and sorting, and the full automatic production functions of button battery welding, assembly, fitting and full automatic electrical detection through the combination of manipulator and laser equipment, which can achieve high-quality, large-scale and flexible production of button batteries. The button battery equipment of the company adopts modular design and professional design, with strong compatibility, high efficiency, low cost and short customization cycle, which can realize rapid delivery.

Lianying Laser 3C Electronics Division has been deeply involved in the 3C electronics field for many years, has a high-level laser welding technology research and development team and advanced research and development platform, has accumulated a huge welding process parameter library, and has been committed to building laser welding as the leading, supporting the whole line of automatic production equipment, and providing customers with high-quality product production solutions.

At present, the 3C electronics business unit of Uniwin Laser is involved in the consumer electronics industry, optical communication industry, plastic welding, tin welding and other fields. The application scope of the consumer electronics industry includes mobile phone batteries, button batteries, mobile phone fingerprint modules, etc., which can respond quickly and achieve efficient production according to customers' various needs.

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