CA2383843C - Metal sheet perforating disk roll, metal sheet perforating device and metal sheet perforating method which use the disk roll, and perforated metal sheet produced by using the disk roll - Google Patents
Metal sheet perforating disk roll, metal sheet perforating device and metal sheet perforating method which use the disk roll, and perforated metal sheet produced by using the disk roll Download PDFInfo
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- CA2383843C CA2383843C CA002383843A CA2383843A CA2383843C CA 2383843 C CA2383843 C CA 2383843C CA 002383843 A CA002383843 A CA 002383843A CA 2383843 A CA2383843 A CA 2383843A CA 2383843 C CA2383843 C CA 2383843C
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- metal sheet
- perforating
- roll
- shape
- disk roll
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
- B21D28/12—Punching using rotatable carriers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
- B26F1/02—Perforating by punching, e.g. with relatively-reciprocating punch and bed
- B26F1/06—Perforating by punching, e.g. with relatively-reciprocating punch and bed with punching tools moving with the work
- B26F1/10—Roller type punches
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D28/00—Shaping by press-cutting; Perforating
- B21D28/24—Perforating, i.e. punching holes
- B21D28/36—Perforating, i.e. punching holes using rotatable work or tool holders
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
- B26F1/02—Perforating by punching, e.g. with relatively-reciprocating punch and bed
- B26F1/14—Punching tools; Punching dies
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Forests & Forestry (AREA)
- Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)
- Cell Electrode Carriers And Collectors (AREA)
Abstract
A metal sheet drilling disk roll used to successively drill holes in alo ng band-shaped metal sheet or metal foil, a metal sheet drilling device using the roll, a metal sheet drilling method, and a drilled metal sheet manufactured using the metal sheet drilling device and metal sheet drilling methods, the metal sheet drilling disk roll (1) comprising a plurality of drilling edge parts formed, in the state of being projected to the outer radial direction and at intervals in circumferential direction, on the outer peripheral surface of the disk roll with a specified thickness, wherein a flat edge part shape on the outer peripheral surface of a drilling edge part (2) is formed in a geometrical shape surrounded by one closed line, and a side edge part shape of the drilling edge part (2) as viewed from the side is formed in a recessed shape so that edge height at its both circumferential end parts is higher than at the other parts and that edge height is lowered gradually toward the center part from the both circumferential end parts.
Description
Description Technical Field This invention relates to a metal sheet perforating disk roll for making holes successively in a long belt-like metal sheet or metal foil, a metal sheet perforating device and a metal sheet perforating method which use the same roll, and a perforated metal sheet produced by using these metal sheet perforating device and metal sheet perforating method.
Background Art In recent years, the demand for a perforated metal sheet in which a multiplicity of holes are made so that the perforated metal sheet is used as a base for a secondary battery electrode has increased. The perforated metal sheet for a secondary battery electrode base is wound with an active material deposited on a surface thereof, and loaded into a battery case. The holes are made in the metal sheet for the purpose of giving an anchoring effect to the active material to promote the adhesion thereof to the metal sheet, and also filling the holes with the active material. In order to increase the capacity of a battery, it is necessary to load the largest possible quantity of active material into the battery case, so that the thinnest possible metal sheet is demanded as a metal sheet to be perforated and used for an electrode base.
Background Art In recent years, the demand for a perforated metal sheet in which a multiplicity of holes are made so that the perforated metal sheet is used as a base for a secondary battery electrode has increased. The perforated metal sheet for a secondary battery electrode base is wound with an active material deposited on a surface thereof, and loaded into a battery case. The holes are made in the metal sheet for the purpose of giving an anchoring effect to the active material to promote the adhesion thereof to the metal sheet, and also filling the holes with the active material. In order to increase the capacity of a battery, it is necessary to load the largest possible quantity of active material into the battery case, so that the thinnest possible metal sheet is demanded as a metal sheet to be perforated and used for an electrode base.
A method of perforating a metal sheet by using a dieing out press has heretofore been generally used as a perforated metal sheet manufacturing method. However, in a perforating method using a press, a metal sheet to be perforated is necessarily fed intermittently, and necessarily stopped when the metal sheet is pressed.
Moreover, it was very difficult to improve the productivity of perforated metal sheets by increasing a perforating speed while exerting a great force on the press.
Japanese Patent Laid-Open No. 133936/1985 discloses a method of continuously manufacturing perforated metal sheets by rotating a perforating roller having a multiplicity of projections as a method of improving the productivity of perforated metal sheets by increasing a perforating speed. The manufacturing of this metal sheet is done in the following manner. Namely, first, a metal sheet is passed continuously between a roller provided with a multiplicity of saw-tooth-like projections on an outer circumferential surface thereof and a receiving roller, and holes are thereby perforated by the projections with burrs raised at the same time. The perforated metal sheet advances continuously, and the burrs impinge upon an end of a scratch jig provided ahead of the perforated metal sheet, the burrs being thereby folded back. The metal sheet further advances continuously, and is fed to a rolling roller provided ahead thereof. The metal sheet is then rolled, and the folded-back portions thereof eat into the metal sheet, so that a burrless perforated metal sheet is formed. When this perforated metal sheet manufacturing method is used, carrying out a continuous perforating operation becomes possible, and a perforating speed increases to enable the improvement of the productivity of perforated metal sheets to be attained.
However, this method of continuously manufacturing a perforated metal sheet by rotating the above-mentioned projection-carrying perforating roller still had problems to be solved.
Namely, the thickness of the burr-folded-back portions becomes nearly two times that of the original metal sheet. When this metal sheet is used as a perforated metal sheet for a secondary battery electrode base, the volume of the metal sheet itself increases when the metal sheet with an active material deposited on a surface thereof and wound is loaded into a battery case, and the quantity of the active material loaded into the battery jar therefore decreases correspondingly, so that this method is not preferable to increase the capacity of the battery.
When the thickness of the folded-back portions is set equal to that of the other portion of the metal sheet by increasing a rolling force, the folded-back portions only are rolled extremely and elongated since the thickness of these portions is nearly two times as large as that of the other portion of the metal sheet.
Therefore, the distance between the holes made by a perforating operation increases to cause the density of the holes to decrease. When a metal sheet having such holes is used as a perforated metal sheet for a secondary battery base, the anchoring effect becomes insufficient, and the quantity of the active material packed in the holes decreases, so that such a perforated metal sheet is not preferable.
The present invention has been made in view of the above-mentioned circumstances, and provides a metal sheet perforating disk roll capable of perforating a multiplicity of uniform holes successively in a long belt-like metal sheet, especially, very thin metal foil used as a secondary battery electrode base while keeping the thickness of the metal sheet uniform; a metal sheet perforating device and a metal sheet perforating method which use the disk roll; and a perforated metal sheet produced by using the metal sheet perforating device and metal sheet perforating method.
Disclosure of the Invention One aspect of the present invention is to provide a metal sheet perforating disk roll formed with a plurality of perforating blades provided on an outer circumferential surface thereof in a circumferentially spaced manner and in a radially projecting state, the shape in plan of each perforating blade on the outer circumferential surface of the disk roll is set to a geometric shape surrounded by one closed line, the shape in side elevation of side surfaces of the perforating blade being set concave so that the height of both of circumferential end portions of the blade becomes larger than that of the other portion thereof with the height of the blade becoming gradually smaller from the two circumferential end portions thereof toward a central portion thereof, characterized in that:
the shape in side elevation of side surfaces of the perforating blade is set so that the height of a preceding circumferential end portion thereof with respect to the rotational direction of the disk roll becomes smaller than that of a posterior circumferential end portion thereof with respect to the same direction.
Brief Description of the Drawings Fig. 1 is a schematic diagram showing an example of the condition of a metal sheet being perforated by using a metal sheet driving disk roll according to the present invention;
Fig. 2 is a perspective view showing an example of the shape of perforating blades provided in a projecting state on an outer circumferential surface of the metal sheet driving disk roll according to the present invention;
Fig. 3 is a schematic diagram showing another example of the condition of a metal sheet being perforated by using the metal sheet perforating disk roll according to the present invention;
Fig. 4 is a schematic diagram showing a mode of perforating a metal sheet in a metal sheet perforating operation using the metal sheet perforating disk roll according to the present invention;
Fig. 5 is a schematic diagram showing an example of a perforating unit of the metal sheet perforating device according to the present invention;
Fig. 6 is a schematic diagram showing an example of the metal sheet perforating device according to the present invention;
Fig. 7 is a schematic diagram showing another example of the perforating unit of the metal perforating device according to the present invention;
Fig. 8 is a schematic diagram showing another example of the metal sheet perforating device according to the present invention; and Fig. 9 is a schematic diagram showing still another example of the metal sheet perforating device according to the present invention.
Best Mode for Carrying Out the Invention The present invention will now be described in detail with reference to the drawings.
A metal sheet perforating disk roll according to the present invention is provided so as to make a multiplicity of holes in a metal sheet or metal foil of around 0.02 to 0.2 mm in thickness.
As shown in Fig. 1, the disk roll 1 is provided on an outer circumferential surface thereof with a plurality of perforating blades 2 in a circumferentially spaced manner and in a radially outwardly projecting state.
The shape in plan of each perforating blade on the outer circumferential surface of the disk roll, i.e. a cross-sectional shape of a perforated hole is set to a geometrical shape surrounded by one closed line. In this embodiment, this shape is set rectangular.
As shown in Figs. 1 and 2, the shape in side elevation of each perforating blade 2 is set concave so that the height of front and rear edges 21, 22 thereof constituting both circumferential end portions of the perforating blade becomes larger than that of the other portions thereof with the height of the perforating blade becoming gradually smaller from the front and rear edges 21, 22 toward a central portion thereof.
As shown in Fig. 2, the perforating blade 2 is formed so that both side edges 23 thereof, which correspond to the portions of both-side closed lines opposed to each other in the circumferential direction of the disk roll 1, project lower than an imaginary straight line 24 connecting together the front and rear edges 21, 22 which correspond to the portions of both-side closed lines which are opposed to each other in the direction of the thickness of the disk roll 1.
The shape in plan of the perforating blade 2, i.e.
the cross-sectional shape of the perforated hole can also be set to a substantially rectangular shape with its four corner portions rounded besides an accurate rectangular shape having the front edge 21, rear edge 22 and side edge 23 as shown in Fig. 2.
The front and rear edges 21 and 22 constituting the two circumferential end portions on the outer circumferential surface of the disk roll 1 of the perforating blade 2 can be formed so that the height of the front edge 21 thereof, a circumferentially preceding end portion which eats into the metal sheet or metal foil (which will hereinafter be referred to generically as a metal sheet) 10 first in accordance with the rotation of the disk roll 1 as shown in Fig. 3 is smaller than that of the rear edge 22 thereof, a circumferentially posterior end portion which is thereafter eats into the metal sheet 10. Since the shape in side elevation of the driving blade 2 is set in this manner, the front edge 21 and rear edge 22 can be made so that these edges eat into the metal sheet 10 at once as shown in Fig. 3.
The shape in plan of the perforating blade 2 can also be formed to other shapes, for example, desired geometric shapes, such as an elongated circular shape, an elliptic shape, a right circular shape, a rhomboidal shape, or a substantially rhomboidal shape with its four corner portions rounded, etc. in accordance with the property of the metal sheet instead of setting the shape to the above-mentioned rectangular shape and a substantially rectangular shape.
The construction of the metal sheet perforating device according to the present invention will now be described with reference to Fig. 6.
As shown in the drawing, the metal sheet perforating device includes a perforating unit 20, upper and lower pinch rolls 6a, 6b provided on the front side and rear side of the perforating unit 20 as tensile force application means, and tensile force application units 30 having 17a, 17b. On the other hand, the perforating unit 20 is formed by providing on the outer circumferential surfaces of the upper and lower rolls 11, 12 with perforating blades 2 in a circumferentially spaced manner.
As shown in Fig. 9, upper and lower bridle rolls 16a, 16b and 17a, 17b may also be used as the tensile force application means.
In the metal sheet perforating device having the above-described construction, the perforating portion 2 can have the construction shown, for example, in Fig. 5.
Namely, as shown in Fig. 5, a pair of disk rolls 3 the radius of each of which is set shorter than a distance between the center of the metal sheet perforating disk roll 1 and the lowest portion (lowest portion of the side edge 23) of the edge of the perforating blade 2 by at least a length corresponding to the thickness of the metal sheet 10 are connected coaxially as upper side guide rolls to both sides of the metal sheet driving disk roll 1 to form an upper roll unit 11.
A disk roll the thickness of which is slightly larger than that of a disk of the metal sheet perforating disk roll 1 is provided as a guide roll 4, and a pair of disc rolls 5 the radius of each of which is set larger than that of the guide roll 4 by at least a length corresponding to the sum of the thickness of the metal sheet 10 and a difference between an amount of projection of the highest portion (front edge 21 or rear edge 22) of the perforating blade 2 and that of projection of the lowest portion (side edge 23) thereof being connected to both sides of the guide roll coaxially to form a lower roll unit 12.
The above-mentioned upper roll unit 11 and lower roll unit 12 are engaged with each other, the perforating unit 20 being thereby formed.
Another example of the perforating unit 20 of the metal sheet perforating device according to the present invention will be shown in Fig. 7. As shown in the drawing, the perforating unit 20 is formed by the metal sheet perforating disk roll 1 and guide roll 4 arranged in a vertically symmetric manner with respect to the center of the metal sheet 10. The guide roll 4 having a thickness slightly larger than that of the disk of the metal sheet perforating disk roll 1 is provided on the portions of the outer circumferential surface thereof which are opposed to the plural perforating blades 2 formed so as to project in the radially outward direction with a plurality of recesses 42 each of which has a cross-sectional shape identical with the shape in plan (i.e. the shape of a cross section of a perforated hole) of the perforating blade 2.
The guide roll 4 of an elastic material, such as rubber can also be formed of a disk having a flat outer circumferential surface without forming a recessed portion 42 having a cross section identical with that of the perforated hole as mentioned above. In this case, the perforating blade 2 provided on the metal sheet perforating disk roll 1 eats into the outer circumferential portion of the upper roll unit 12 during a perforating operation, and the outer circumferential portion of the guide roll 4 is elastically deformed in accordance with the shape of the perforating blade 2.
However, when the hole perforating operation finishes to cause the perforating blade 2 to be disengaged from the guide roll 4, the shape of the perforating blade 2 is restored to that of a disk having the original flat outer circumferential surface.
In order to make a plurality of rows of holes in the metal sheet 10 so that the holes are parallel spaced in the widthwise direction, a metal sheet perforating device can also be formed by connecting a plurality of sets of upper rolls 11 and lower rolls 12, which constitute the above-mentioned perforating unit 20, to each other coaxially in the axial direction of each roll shaft as shown in Fig. 8.
The perforating blade 2 in the present invention is formed on the outer circumferential surface of the disk roll 1 in a radially outwardly projecting state so as to be spaced at regular intervals in the circumferential direction as shown in Fig. 1. When the disk roll 1 is rotated, the metal sheet 10 provided with unperforated hole portions at regular intervals is subjected to p'erforating. It is also possible to provide some of adjacent perforating blades 2 at intervals larger than those of the other thereof instead of providing the perforating blades on the outer circumferential surface of the metal sheet at regular intervals in the circumferential direction thereof. Namely, it is possible to form a disk roll 1 having no perforating blades 2 on a part of the outer circumferential surface thereof, and perforate the metal sheet 10 by rotating the resultant disk roll so that the metal sheet has in the lengthwise direction thereof unperforated hole portions spaced at predetermined intervals larger than those of the other perforated portions. Thus, it becomes possible to provide unperforated portions at regular intervals larger than those of the other unperforated portions, and cut the metal sheet 10 at the greatly spaced unperforated portion thereof. Especially, when the sheet perforating device formed as mentioned above, by connecting a plurality of sets of the upper roll 11 and lower roll 12, which constitute the perforating unit 20, to each other coaxially in the axial direction of each roll, is used to perforate holes in the metal sheet 10 in a staggered manner in the widthwise direction thereof, an object portion of the metal sheet 10 can be cut irrespective of the presence of the staggeringly arranged perforated portions on the metal sheet. When the metal sheet 10 is used as a core of a battery, it is possible to provide unperforated portions, the intervals of which are larger than those of other portions, at predetermined intervals so that the distance between perforated portions agrees with the length of the core needed for one battery. This enables the metal sheet 10 to be cut without causing both of lengthwise end portions thereof to fall on perforated portions. Such intervals of the unperforated portions that are larger than those of the other unperforated portions can be changed arbitrarily by selecting the diameter of the disk roll.
A method of making a multiplicity of holes successively in a metal sheet 10 by using the metal sheet perforating disk roll 1 according to the present invention and the metal sheet perforating device according to the present invention will now be described with a case where the shape in plan (cross-sectional shape of a perforated hole) of a perforating blade 2 of the metal sheet perforating disk roll 1 is rectangular taken as an example will now be described with reference to Fig. 4.
According to the present invention, a metal sheet of around 0.02 to 0.2 mm in thickness, and, especially, extremely thin metal foil of not larger than 0.1 mm in thickness is perforated.
As described above, the metal sheet perforating device according to the present invention includes as shown in Fig. 6 a perforating unit 20, a pair of pinch rolls 6a and 6b provided ahead of the perforating unit 20, and a tensile force application units 30 formed of a pair of pinch rolls 7a and 7b provided at the back of the perforating unit 20. As mentioned above, the pinch rolls may be replaced with upper and lower bridle rolls as shown in Fig. 9.
In order to perforate the metal sheet 10, first, a tensile force is applied to the portion of the metal sheet 10 which is between the pinch rolls 6a and 6b and 7a and 7b which constitute tensile force application means. The metal sheet 10 is passed continuously between the upper and lower rolls 6a, 6b and upper and lower rolls 7a, 7b which constitute the perforating unit 20 and tensile force application unit 30 with the tensile force applied condition maintained.
When the metal sheet 10 with a tensile force applied thereto is brought into contact with the metal sheet perforating disk roll 1, the upper roll 11 of the perforating unit, first, a front edge 21 of a perforating blade 2 and a part of a side edge 23 extending from the f ront edge 21 eat into the metal sheet 10 as shown in Fig. 4 i) to cause a break to occur.
When the metal sheet perforating disk roll 1 is further rotated, the mentioned part of the side edge 23 extending from the front edge 21 of the perforating blade 2 further eats into the metal sheet as shown in Fig. 4 ii), and the break stretches with the rear edge 22 of the perforating blade 2 and the part of the side edge 23 which extends from the rear edge 22 eating into the metal sheet 10 to cause a break to occur.
When the metal sheet perforating disk roll 1 is further rotated, the mentioned part of the side edge 23 extending from the front edge 21 of the perforating blade 2 further eats into the metal sheet as shown in Fig. 4 iii), and the break stretches with the mentioned part of the side edge 23 which extends from the rear edge 22 of the perforating blade 2 further eating into the metal sheet to cause the break to stretch. The break in the side edge 23 thus comes to stretch from both sides, i.e., from the front edge 21 and rear edge 22.
When the metal sheet disk roll 1 is further rotated, the break in the side edge 23 extending from both the front edge 21 and rear edge 22 are joined together as shown in Fig. 4 iv), and a hole of a rectangular shape is formed in the metal sheet 10.
When the metal sheet disk roll 1 is further rotated, a subsequent perforating blade 2 eats into the metal sheet 10, and a rectangular hole is formed in the same manner as mentioned above.
When the metal sheet perforating disk roll 1 is thus rotated, rectangular holes can be formed successively in the metal sheet 10 in a spaced manner.
When in this case the height of the front edge 21 forming a preceding circumferential end portion which eats into the metal sheet 10 first in accordance with the rotation of the disk roll 1 is set lower than that of the rear edge 22 forming a posterior circumferential end portion which thereafter eats into the metal sheet 10 as shown in Fig. 3, it becomes possible to have the front edge 21 and rear edge 22 eaten into the metal sheet 10 at once, and make rectangular holes in the metal sheet 10 more accurately and reliably.
In the case where a metal sheet perforating operation is carried out in practice with a tensile force not applied to the metal sheet 10, which is made of, especially, metal foil of an extremely small thickness of not larger than 0.1 mm, the rigidity of the metal sheet lowers even when the height of the portions constituting intermediate portions between the front edge 21 and rear edge 22 is set lower than those of the front and rear edges 21, 22 as shown in Fig. 2, i.e., even when a metal sheet perforating disk roll 1 in which the portion of the blade corresponding to the side edge 23 projects lower than an imaginary straight line connecting together the apexes of the portions of the blade which correspond to the front edge 21 and rear edge 22 is used. As a result, it becomes difficult to have the portions of the blade which correspond to the front edge 21 and rear edge 22 eat into the metal sheet, and make accurately shaped holes successively. Therefore, it is preferable to give a tensile force to the metal sheet 10 when metal foil of extremely small thickness of not larger than 0.1 mm is perforated.
When a method of moving the metal sheet 10 so that the metal sheet winds round a part of the outer circumference of the guide roll 2 (lower roll 12) as shown in Fig. 9, and perforating the metal sheet with the metal sheet 10 brought into close contact with the lower roll 12 is used, metal foil of an extremely small thickness of not larger than 0.1 mm can be perforated more reliably. In this case, the upper and lower bridle rolls 16a and 16b and 17a and 17b, which serve as tensile force application means, and upper roll 11 and lower roll 12 are provided in the positional relation which permits the metal sheet to advance along a part of the outer circumference of the guide roll 2 (lower roll 12), and not in the positional relation shown in Fig. 9, i.e., not in the positional relation in which the metal sheet 10 is moved linearly between the perforating unit 20 and tensile force application units 30 as shown in Fig. 6.
Fig. 5 and Fig. 7 show a case where holes are formed in one row in a metal sheet 10. As shown in Fig. 8, it is possible to form a metal sheet perforating device by arranging a plurality of sets of lower rolls 12 and upper rolls 11, which constitute a metal sheet perforating unit, coaxially in the axial direction of the rolls, and make in a metal sheet 10 a plurality of widthwise arranged rows of substantially rectangular holes successively in a lengthwise spaced manner. When in this case the intervals of perforating blades 2 of adjacent metal sheet perforating disk rolls 1 are mutually regulated, making holes in an arbitrary arrangement, such as a staggered arrangement and a latticed arrangement and the like can be done.
The perforated metal sheet having a multiplicity of holes according to the present invention can be made by using the above-mentioned metal sheet perforating device having a metal sheet perforating disk roll 1, and the above-mentioned metal sheet perforating method. The perforated metal sheet having a multiplicity of holes according to the present invention can be formed by making uniform holes successively and accurately in, especially, metal foil of an extremely small thickness of not larger than 0.1 mm. Since such a perforated metal sheet does not have projecting portions, such as folded-back portions and the like, the metal sheet is suitable for a base for a secondary battery electrode.
(Embodiment) 30 sets of metal sheet perforating disk rolls (upper rolls) were prepared each of which was formed of a disk of alloy tool steel (SKS1) of 1 mm in thickness and 80 mm in diameter and provided on its outer circumferential surface with 60 perforating blades so that the blades were spaced at 1.59 mm intervals and projected in the radially outward direction, each of which blades had a rectangular perforating section of 2.6 mm in circumferential length and 1 mm in width.
Each of the perforating blades was formed in a projecting manner so that the height (maximum height) of rectangular front edge and rear edge projecting at front and rear portions of the blade with respect to the direction of the thickness of the disk roll became 1 mm with the height (minimum height) of the centers of side edges projecting at left and right portions of the blade with respect to the circumferential direction 0.5 mm so as to vary the height of the front edge - the centers of the side edges - the rear edge continuously and arcuately.
31 sets of disk rolls (upper side guide rolls) of 80 mm in diameter formed of alloy tool steel (SKS1) of 1 mm in thickness were prepared. The metal sheet perforating disk rolls and side guide rolls were arranged alternately and coaxially so that the rolls at both ends became side guide rolls with the distance between each side guide roll and each metal sheet perforating disk roll becoming 0.05 mm, by inserting spaces therebetween and thereby regulating the distance, to form upper rolls.
On the other hand, 30 sets of disk rolls (guide rolls) of 80 mm in diameter were prepared from alloy tool steel (SKS1) of 1.1 mm in thickness. Also, 31 sets of disk rolls (lower side guide rolls) of 81 mm in diameter were prepared from alloy tool steel (SKS1) of 1 mm in thickness. The guide rolls and side guide rolls were arranged alternately and coaxially so that the rolls at both ends became side guide rolls, to form lower rolls.
The upper rolls and lower rolls thus prepared were engaged with each other to form a perforating unit. The perforating blades of adjacent upper rolls were lined so as to stagger the blades thereof by a half pitch in the circumferential direction so that the holes formed after a perforating operation were arranged in a staggered manner.
Moreover, a pair of bridle rolls were provided at each of the front and rear sides of this perforating unit in such positional relation that permitted a metal sheet to advance so as to wind round a part of the outer circumference of the lower roll of the perforating unit as shown in Fig. 9, to form tensile force application units. The rotational speed of the front bridle roll was set slightly higher than that of the rear bridle roll so that a tensile force be applied at all times to the portion of the metal sheet which is between the two bridle rolls. Thus, the metal sheet perforating device was formed.
A long belt-like nickel plated steel foil of 0.035 mm in thickness and 65 mm in width was then perforated by using the above-mentioned metal sheet perforating device.
The rotational speeds of the bridle roll in front of the tensile force application unit, bridle roll at the back thereof and upper and lower rolls of the perforating unit were set respectively so that the steel foil advances at a speed of 1 m/sec. The rotational speeds of the bridle rollers were set so that 2 kgf tensile force was exerted on the portion of the metal sheet which was between the front bridle roll and rear bridle roll. Thus, rectangular holes of 2.6 mm in length and 1 mm in width were made successively at 1.59 mm intervals in the lengthwise direction, and nickel plated steel foil having 30 rows of holes made in a staggered manner at 1.1 mm intervals in the widthwise direction thererof was obtained.
Industrial Applicability The present invention relates to a metal sheet perforating device and a metal sheet perforating method which use a metal sheet driving disc roll provided on an outer circumferential surface thereof with a plurality of perforating blades arranged in a circumferentially spaced manner and in a radially projecting state. Using the metal sheet perforating device and metal sheet perforating method according to the present invention has enabled a multiplicity of uniform holes of a constant depth to be made successively in a long belt-like metal sheet, especially, long belt-like metal foil used for a base for a secondary battery electrode.
Moreover, it was very difficult to improve the productivity of perforated metal sheets by increasing a perforating speed while exerting a great force on the press.
Japanese Patent Laid-Open No. 133936/1985 discloses a method of continuously manufacturing perforated metal sheets by rotating a perforating roller having a multiplicity of projections as a method of improving the productivity of perforated metal sheets by increasing a perforating speed. The manufacturing of this metal sheet is done in the following manner. Namely, first, a metal sheet is passed continuously between a roller provided with a multiplicity of saw-tooth-like projections on an outer circumferential surface thereof and a receiving roller, and holes are thereby perforated by the projections with burrs raised at the same time. The perforated metal sheet advances continuously, and the burrs impinge upon an end of a scratch jig provided ahead of the perforated metal sheet, the burrs being thereby folded back. The metal sheet further advances continuously, and is fed to a rolling roller provided ahead thereof. The metal sheet is then rolled, and the folded-back portions thereof eat into the metal sheet, so that a burrless perforated metal sheet is formed. When this perforated metal sheet manufacturing method is used, carrying out a continuous perforating operation becomes possible, and a perforating speed increases to enable the improvement of the productivity of perforated metal sheets to be attained.
However, this method of continuously manufacturing a perforated metal sheet by rotating the above-mentioned projection-carrying perforating roller still had problems to be solved.
Namely, the thickness of the burr-folded-back portions becomes nearly two times that of the original metal sheet. When this metal sheet is used as a perforated metal sheet for a secondary battery electrode base, the volume of the metal sheet itself increases when the metal sheet with an active material deposited on a surface thereof and wound is loaded into a battery case, and the quantity of the active material loaded into the battery jar therefore decreases correspondingly, so that this method is not preferable to increase the capacity of the battery.
When the thickness of the folded-back portions is set equal to that of the other portion of the metal sheet by increasing a rolling force, the folded-back portions only are rolled extremely and elongated since the thickness of these portions is nearly two times as large as that of the other portion of the metal sheet.
Therefore, the distance between the holes made by a perforating operation increases to cause the density of the holes to decrease. When a metal sheet having such holes is used as a perforated metal sheet for a secondary battery base, the anchoring effect becomes insufficient, and the quantity of the active material packed in the holes decreases, so that such a perforated metal sheet is not preferable.
The present invention has been made in view of the above-mentioned circumstances, and provides a metal sheet perforating disk roll capable of perforating a multiplicity of uniform holes successively in a long belt-like metal sheet, especially, very thin metal foil used as a secondary battery electrode base while keeping the thickness of the metal sheet uniform; a metal sheet perforating device and a metal sheet perforating method which use the disk roll; and a perforated metal sheet produced by using the metal sheet perforating device and metal sheet perforating method.
Disclosure of the Invention One aspect of the present invention is to provide a metal sheet perforating disk roll formed with a plurality of perforating blades provided on an outer circumferential surface thereof in a circumferentially spaced manner and in a radially projecting state, the shape in plan of each perforating blade on the outer circumferential surface of the disk roll is set to a geometric shape surrounded by one closed line, the shape in side elevation of side surfaces of the perforating blade being set concave so that the height of both of circumferential end portions of the blade becomes larger than that of the other portion thereof with the height of the blade becoming gradually smaller from the two circumferential end portions thereof toward a central portion thereof, characterized in that:
the shape in side elevation of side surfaces of the perforating blade is set so that the height of a preceding circumferential end portion thereof with respect to the rotational direction of the disk roll becomes smaller than that of a posterior circumferential end portion thereof with respect to the same direction.
Brief Description of the Drawings Fig. 1 is a schematic diagram showing an example of the condition of a metal sheet being perforated by using a metal sheet driving disk roll according to the present invention;
Fig. 2 is a perspective view showing an example of the shape of perforating blades provided in a projecting state on an outer circumferential surface of the metal sheet driving disk roll according to the present invention;
Fig. 3 is a schematic diagram showing another example of the condition of a metal sheet being perforated by using the metal sheet perforating disk roll according to the present invention;
Fig. 4 is a schematic diagram showing a mode of perforating a metal sheet in a metal sheet perforating operation using the metal sheet perforating disk roll according to the present invention;
Fig. 5 is a schematic diagram showing an example of a perforating unit of the metal sheet perforating device according to the present invention;
Fig. 6 is a schematic diagram showing an example of the metal sheet perforating device according to the present invention;
Fig. 7 is a schematic diagram showing another example of the perforating unit of the metal perforating device according to the present invention;
Fig. 8 is a schematic diagram showing another example of the metal sheet perforating device according to the present invention; and Fig. 9 is a schematic diagram showing still another example of the metal sheet perforating device according to the present invention.
Best Mode for Carrying Out the Invention The present invention will now be described in detail with reference to the drawings.
A metal sheet perforating disk roll according to the present invention is provided so as to make a multiplicity of holes in a metal sheet or metal foil of around 0.02 to 0.2 mm in thickness.
As shown in Fig. 1, the disk roll 1 is provided on an outer circumferential surface thereof with a plurality of perforating blades 2 in a circumferentially spaced manner and in a radially outwardly projecting state.
The shape in plan of each perforating blade on the outer circumferential surface of the disk roll, i.e. a cross-sectional shape of a perforated hole is set to a geometrical shape surrounded by one closed line. In this embodiment, this shape is set rectangular.
As shown in Figs. 1 and 2, the shape in side elevation of each perforating blade 2 is set concave so that the height of front and rear edges 21, 22 thereof constituting both circumferential end portions of the perforating blade becomes larger than that of the other portions thereof with the height of the perforating blade becoming gradually smaller from the front and rear edges 21, 22 toward a central portion thereof.
As shown in Fig. 2, the perforating blade 2 is formed so that both side edges 23 thereof, which correspond to the portions of both-side closed lines opposed to each other in the circumferential direction of the disk roll 1, project lower than an imaginary straight line 24 connecting together the front and rear edges 21, 22 which correspond to the portions of both-side closed lines which are opposed to each other in the direction of the thickness of the disk roll 1.
The shape in plan of the perforating blade 2, i.e.
the cross-sectional shape of the perforated hole can also be set to a substantially rectangular shape with its four corner portions rounded besides an accurate rectangular shape having the front edge 21, rear edge 22 and side edge 23 as shown in Fig. 2.
The front and rear edges 21 and 22 constituting the two circumferential end portions on the outer circumferential surface of the disk roll 1 of the perforating blade 2 can be formed so that the height of the front edge 21 thereof, a circumferentially preceding end portion which eats into the metal sheet or metal foil (which will hereinafter be referred to generically as a metal sheet) 10 first in accordance with the rotation of the disk roll 1 as shown in Fig. 3 is smaller than that of the rear edge 22 thereof, a circumferentially posterior end portion which is thereafter eats into the metal sheet 10. Since the shape in side elevation of the driving blade 2 is set in this manner, the front edge 21 and rear edge 22 can be made so that these edges eat into the metal sheet 10 at once as shown in Fig. 3.
The shape in plan of the perforating blade 2 can also be formed to other shapes, for example, desired geometric shapes, such as an elongated circular shape, an elliptic shape, a right circular shape, a rhomboidal shape, or a substantially rhomboidal shape with its four corner portions rounded, etc. in accordance with the property of the metal sheet instead of setting the shape to the above-mentioned rectangular shape and a substantially rectangular shape.
The construction of the metal sheet perforating device according to the present invention will now be described with reference to Fig. 6.
As shown in the drawing, the metal sheet perforating device includes a perforating unit 20, upper and lower pinch rolls 6a, 6b provided on the front side and rear side of the perforating unit 20 as tensile force application means, and tensile force application units 30 having 17a, 17b. On the other hand, the perforating unit 20 is formed by providing on the outer circumferential surfaces of the upper and lower rolls 11, 12 with perforating blades 2 in a circumferentially spaced manner.
As shown in Fig. 9, upper and lower bridle rolls 16a, 16b and 17a, 17b may also be used as the tensile force application means.
In the metal sheet perforating device having the above-described construction, the perforating portion 2 can have the construction shown, for example, in Fig. 5.
Namely, as shown in Fig. 5, a pair of disk rolls 3 the radius of each of which is set shorter than a distance between the center of the metal sheet perforating disk roll 1 and the lowest portion (lowest portion of the side edge 23) of the edge of the perforating blade 2 by at least a length corresponding to the thickness of the metal sheet 10 are connected coaxially as upper side guide rolls to both sides of the metal sheet driving disk roll 1 to form an upper roll unit 11.
A disk roll the thickness of which is slightly larger than that of a disk of the metal sheet perforating disk roll 1 is provided as a guide roll 4, and a pair of disc rolls 5 the radius of each of which is set larger than that of the guide roll 4 by at least a length corresponding to the sum of the thickness of the metal sheet 10 and a difference between an amount of projection of the highest portion (front edge 21 or rear edge 22) of the perforating blade 2 and that of projection of the lowest portion (side edge 23) thereof being connected to both sides of the guide roll coaxially to form a lower roll unit 12.
The above-mentioned upper roll unit 11 and lower roll unit 12 are engaged with each other, the perforating unit 20 being thereby formed.
Another example of the perforating unit 20 of the metal sheet perforating device according to the present invention will be shown in Fig. 7. As shown in the drawing, the perforating unit 20 is formed by the metal sheet perforating disk roll 1 and guide roll 4 arranged in a vertically symmetric manner with respect to the center of the metal sheet 10. The guide roll 4 having a thickness slightly larger than that of the disk of the metal sheet perforating disk roll 1 is provided on the portions of the outer circumferential surface thereof which are opposed to the plural perforating blades 2 formed so as to project in the radially outward direction with a plurality of recesses 42 each of which has a cross-sectional shape identical with the shape in plan (i.e. the shape of a cross section of a perforated hole) of the perforating blade 2.
The guide roll 4 of an elastic material, such as rubber can also be formed of a disk having a flat outer circumferential surface without forming a recessed portion 42 having a cross section identical with that of the perforated hole as mentioned above. In this case, the perforating blade 2 provided on the metal sheet perforating disk roll 1 eats into the outer circumferential portion of the upper roll unit 12 during a perforating operation, and the outer circumferential portion of the guide roll 4 is elastically deformed in accordance with the shape of the perforating blade 2.
However, when the hole perforating operation finishes to cause the perforating blade 2 to be disengaged from the guide roll 4, the shape of the perforating blade 2 is restored to that of a disk having the original flat outer circumferential surface.
In order to make a plurality of rows of holes in the metal sheet 10 so that the holes are parallel spaced in the widthwise direction, a metal sheet perforating device can also be formed by connecting a plurality of sets of upper rolls 11 and lower rolls 12, which constitute the above-mentioned perforating unit 20, to each other coaxially in the axial direction of each roll shaft as shown in Fig. 8.
The perforating blade 2 in the present invention is formed on the outer circumferential surface of the disk roll 1 in a radially outwardly projecting state so as to be spaced at regular intervals in the circumferential direction as shown in Fig. 1. When the disk roll 1 is rotated, the metal sheet 10 provided with unperforated hole portions at regular intervals is subjected to p'erforating. It is also possible to provide some of adjacent perforating blades 2 at intervals larger than those of the other thereof instead of providing the perforating blades on the outer circumferential surface of the metal sheet at regular intervals in the circumferential direction thereof. Namely, it is possible to form a disk roll 1 having no perforating blades 2 on a part of the outer circumferential surface thereof, and perforate the metal sheet 10 by rotating the resultant disk roll so that the metal sheet has in the lengthwise direction thereof unperforated hole portions spaced at predetermined intervals larger than those of the other perforated portions. Thus, it becomes possible to provide unperforated portions at regular intervals larger than those of the other unperforated portions, and cut the metal sheet 10 at the greatly spaced unperforated portion thereof. Especially, when the sheet perforating device formed as mentioned above, by connecting a plurality of sets of the upper roll 11 and lower roll 12, which constitute the perforating unit 20, to each other coaxially in the axial direction of each roll, is used to perforate holes in the metal sheet 10 in a staggered manner in the widthwise direction thereof, an object portion of the metal sheet 10 can be cut irrespective of the presence of the staggeringly arranged perforated portions on the metal sheet. When the metal sheet 10 is used as a core of a battery, it is possible to provide unperforated portions, the intervals of which are larger than those of other portions, at predetermined intervals so that the distance between perforated portions agrees with the length of the core needed for one battery. This enables the metal sheet 10 to be cut without causing both of lengthwise end portions thereof to fall on perforated portions. Such intervals of the unperforated portions that are larger than those of the other unperforated portions can be changed arbitrarily by selecting the diameter of the disk roll.
A method of making a multiplicity of holes successively in a metal sheet 10 by using the metal sheet perforating disk roll 1 according to the present invention and the metal sheet perforating device according to the present invention will now be described with a case where the shape in plan (cross-sectional shape of a perforated hole) of a perforating blade 2 of the metal sheet perforating disk roll 1 is rectangular taken as an example will now be described with reference to Fig. 4.
According to the present invention, a metal sheet of around 0.02 to 0.2 mm in thickness, and, especially, extremely thin metal foil of not larger than 0.1 mm in thickness is perforated.
As described above, the metal sheet perforating device according to the present invention includes as shown in Fig. 6 a perforating unit 20, a pair of pinch rolls 6a and 6b provided ahead of the perforating unit 20, and a tensile force application units 30 formed of a pair of pinch rolls 7a and 7b provided at the back of the perforating unit 20. As mentioned above, the pinch rolls may be replaced with upper and lower bridle rolls as shown in Fig. 9.
In order to perforate the metal sheet 10, first, a tensile force is applied to the portion of the metal sheet 10 which is between the pinch rolls 6a and 6b and 7a and 7b which constitute tensile force application means. The metal sheet 10 is passed continuously between the upper and lower rolls 6a, 6b and upper and lower rolls 7a, 7b which constitute the perforating unit 20 and tensile force application unit 30 with the tensile force applied condition maintained.
When the metal sheet 10 with a tensile force applied thereto is brought into contact with the metal sheet perforating disk roll 1, the upper roll 11 of the perforating unit, first, a front edge 21 of a perforating blade 2 and a part of a side edge 23 extending from the f ront edge 21 eat into the metal sheet 10 as shown in Fig. 4 i) to cause a break to occur.
When the metal sheet perforating disk roll 1 is further rotated, the mentioned part of the side edge 23 extending from the front edge 21 of the perforating blade 2 further eats into the metal sheet as shown in Fig. 4 ii), and the break stretches with the rear edge 22 of the perforating blade 2 and the part of the side edge 23 which extends from the rear edge 22 eating into the metal sheet 10 to cause a break to occur.
When the metal sheet perforating disk roll 1 is further rotated, the mentioned part of the side edge 23 extending from the front edge 21 of the perforating blade 2 further eats into the metal sheet as shown in Fig. 4 iii), and the break stretches with the mentioned part of the side edge 23 which extends from the rear edge 22 of the perforating blade 2 further eating into the metal sheet to cause the break to stretch. The break in the side edge 23 thus comes to stretch from both sides, i.e., from the front edge 21 and rear edge 22.
When the metal sheet disk roll 1 is further rotated, the break in the side edge 23 extending from both the front edge 21 and rear edge 22 are joined together as shown in Fig. 4 iv), and a hole of a rectangular shape is formed in the metal sheet 10.
When the metal sheet disk roll 1 is further rotated, a subsequent perforating blade 2 eats into the metal sheet 10, and a rectangular hole is formed in the same manner as mentioned above.
When the metal sheet perforating disk roll 1 is thus rotated, rectangular holes can be formed successively in the metal sheet 10 in a spaced manner.
When in this case the height of the front edge 21 forming a preceding circumferential end portion which eats into the metal sheet 10 first in accordance with the rotation of the disk roll 1 is set lower than that of the rear edge 22 forming a posterior circumferential end portion which thereafter eats into the metal sheet 10 as shown in Fig. 3, it becomes possible to have the front edge 21 and rear edge 22 eaten into the metal sheet 10 at once, and make rectangular holes in the metal sheet 10 more accurately and reliably.
In the case where a metal sheet perforating operation is carried out in practice with a tensile force not applied to the metal sheet 10, which is made of, especially, metal foil of an extremely small thickness of not larger than 0.1 mm, the rigidity of the metal sheet lowers even when the height of the portions constituting intermediate portions between the front edge 21 and rear edge 22 is set lower than those of the front and rear edges 21, 22 as shown in Fig. 2, i.e., even when a metal sheet perforating disk roll 1 in which the portion of the blade corresponding to the side edge 23 projects lower than an imaginary straight line connecting together the apexes of the portions of the blade which correspond to the front edge 21 and rear edge 22 is used. As a result, it becomes difficult to have the portions of the blade which correspond to the front edge 21 and rear edge 22 eat into the metal sheet, and make accurately shaped holes successively. Therefore, it is preferable to give a tensile force to the metal sheet 10 when metal foil of extremely small thickness of not larger than 0.1 mm is perforated.
When a method of moving the metal sheet 10 so that the metal sheet winds round a part of the outer circumference of the guide roll 2 (lower roll 12) as shown in Fig. 9, and perforating the metal sheet with the metal sheet 10 brought into close contact with the lower roll 12 is used, metal foil of an extremely small thickness of not larger than 0.1 mm can be perforated more reliably. In this case, the upper and lower bridle rolls 16a and 16b and 17a and 17b, which serve as tensile force application means, and upper roll 11 and lower roll 12 are provided in the positional relation which permits the metal sheet to advance along a part of the outer circumference of the guide roll 2 (lower roll 12), and not in the positional relation shown in Fig. 9, i.e., not in the positional relation in which the metal sheet 10 is moved linearly between the perforating unit 20 and tensile force application units 30 as shown in Fig. 6.
Fig. 5 and Fig. 7 show a case where holes are formed in one row in a metal sheet 10. As shown in Fig. 8, it is possible to form a metal sheet perforating device by arranging a plurality of sets of lower rolls 12 and upper rolls 11, which constitute a metal sheet perforating unit, coaxially in the axial direction of the rolls, and make in a metal sheet 10 a plurality of widthwise arranged rows of substantially rectangular holes successively in a lengthwise spaced manner. When in this case the intervals of perforating blades 2 of adjacent metal sheet perforating disk rolls 1 are mutually regulated, making holes in an arbitrary arrangement, such as a staggered arrangement and a latticed arrangement and the like can be done.
The perforated metal sheet having a multiplicity of holes according to the present invention can be made by using the above-mentioned metal sheet perforating device having a metal sheet perforating disk roll 1, and the above-mentioned metal sheet perforating method. The perforated metal sheet having a multiplicity of holes according to the present invention can be formed by making uniform holes successively and accurately in, especially, metal foil of an extremely small thickness of not larger than 0.1 mm. Since such a perforated metal sheet does not have projecting portions, such as folded-back portions and the like, the metal sheet is suitable for a base for a secondary battery electrode.
(Embodiment) 30 sets of metal sheet perforating disk rolls (upper rolls) were prepared each of which was formed of a disk of alloy tool steel (SKS1) of 1 mm in thickness and 80 mm in diameter and provided on its outer circumferential surface with 60 perforating blades so that the blades were spaced at 1.59 mm intervals and projected in the radially outward direction, each of which blades had a rectangular perforating section of 2.6 mm in circumferential length and 1 mm in width.
Each of the perforating blades was formed in a projecting manner so that the height (maximum height) of rectangular front edge and rear edge projecting at front and rear portions of the blade with respect to the direction of the thickness of the disk roll became 1 mm with the height (minimum height) of the centers of side edges projecting at left and right portions of the blade with respect to the circumferential direction 0.5 mm so as to vary the height of the front edge - the centers of the side edges - the rear edge continuously and arcuately.
31 sets of disk rolls (upper side guide rolls) of 80 mm in diameter formed of alloy tool steel (SKS1) of 1 mm in thickness were prepared. The metal sheet perforating disk rolls and side guide rolls were arranged alternately and coaxially so that the rolls at both ends became side guide rolls with the distance between each side guide roll and each metal sheet perforating disk roll becoming 0.05 mm, by inserting spaces therebetween and thereby regulating the distance, to form upper rolls.
On the other hand, 30 sets of disk rolls (guide rolls) of 80 mm in diameter were prepared from alloy tool steel (SKS1) of 1.1 mm in thickness. Also, 31 sets of disk rolls (lower side guide rolls) of 81 mm in diameter were prepared from alloy tool steel (SKS1) of 1 mm in thickness. The guide rolls and side guide rolls were arranged alternately and coaxially so that the rolls at both ends became side guide rolls, to form lower rolls.
The upper rolls and lower rolls thus prepared were engaged with each other to form a perforating unit. The perforating blades of adjacent upper rolls were lined so as to stagger the blades thereof by a half pitch in the circumferential direction so that the holes formed after a perforating operation were arranged in a staggered manner.
Moreover, a pair of bridle rolls were provided at each of the front and rear sides of this perforating unit in such positional relation that permitted a metal sheet to advance so as to wind round a part of the outer circumference of the lower roll of the perforating unit as shown in Fig. 9, to form tensile force application units. The rotational speed of the front bridle roll was set slightly higher than that of the rear bridle roll so that a tensile force be applied at all times to the portion of the metal sheet which is between the two bridle rolls. Thus, the metal sheet perforating device was formed.
A long belt-like nickel plated steel foil of 0.035 mm in thickness and 65 mm in width was then perforated by using the above-mentioned metal sheet perforating device.
The rotational speeds of the bridle roll in front of the tensile force application unit, bridle roll at the back thereof and upper and lower rolls of the perforating unit were set respectively so that the steel foil advances at a speed of 1 m/sec. The rotational speeds of the bridle rollers were set so that 2 kgf tensile force was exerted on the portion of the metal sheet which was between the front bridle roll and rear bridle roll. Thus, rectangular holes of 2.6 mm in length and 1 mm in width were made successively at 1.59 mm intervals in the lengthwise direction, and nickel plated steel foil having 30 rows of holes made in a staggered manner at 1.1 mm intervals in the widthwise direction thererof was obtained.
Industrial Applicability The present invention relates to a metal sheet perforating device and a metal sheet perforating method which use a metal sheet driving disc roll provided on an outer circumferential surface thereof with a plurality of perforating blades arranged in a circumferentially spaced manner and in a radially projecting state. Using the metal sheet perforating device and metal sheet perforating method according to the present invention has enabled a multiplicity of uniform holes of a constant depth to be made successively in a long belt-like metal sheet, especially, long belt-like metal foil used for a base for a secondary battery electrode.
Claims (9)
1. A metal sheet perforating disk roll formed with a plurality of perforating blades provided on an outer circumferential surface thereof in a circumferentially spaced manner and in a radially projecting state, the shape in plan of each perforating blade on the outer circumferential surface of the disk roll is set to a geometric shape surrounded by one closed line, the shape in side elevation of side surfaces of the perforating blade being set concave so that the height of both of circumferential end portions of the blade becomes larger than that of the other portion thereof with the height of the blade becoming gradually smaller from the two circumferential end portions thereof toward a central portion thereof, characterized in that:
the shape in side elevation of side surfaces of the perforating blade is set so that the height of a preceding circumferential end portion thereof with respect to the rotational direction of the disk roll becomes smaller than that of a posterior circumferential end portion thereof with respect to the same direction.
the shape in side elevation of side surfaces of the perforating blade is set so that the height of a preceding circumferential end portion thereof with respect to the rotational direction of the disk roll becomes smaller than that of a posterior circumferential end portion thereof with respect to the same direction.
2. The metal sheet perforating disk roll according to Claim 1, wherein the shape in plan of the perforating blade is set to a rectangular shape or a substantially rectangular shape with four corner portions thereof rounded.
3. The metal sheet perforating disk roll according to Claim 1, wherein the shape in plan of the perforating blade is set to one of an elongated circular shape, an elliptic shape, a right circular shape, a rhomboidal shape and a substantially rhomboidal shape with four corner portions thereof rounded.
4. The metal sheet perforating device for making a plurality of holes in a metal sheet or metal foil, characterized by:
the metal sheet perforating disk roll according to one of Claims 1 to 3 disposed as an upper side roll, and a pair of upper side guide rolls connected coaxially to both sides of the upper roll, each having a radius which is set smaller than the length measured from the center of the metal sheet driving disk roll to the lowest portion of the perforating blade, by at least a size corresponding to the thickness of the metal sheet or metal foil to form an upper roll unit, a disk roll disposed as a guide roll, the thickness of which is slightly larger than that of the metal sheet driving disk roll, and a pair of lower side guide rolls connected coaxially to both sides of the guide roll, each having a radius which is set larger than that of the disk roll by a length corresponding to the sum of the thickness of the metal sheet or metal foil and a difference between an amount of projection of the highest portion of the perforating blade and that of projection of the lowest portion thereof, to form a lower roll unit, the upper roll unit and lower roll unit engaging with each other to form portions being perforated in the metal sheet while passing the metal sheet or metal foil beneath the perforating roll disk, and tensile force application units formed of means for applying a tensile force to the metal sheet or metal foil disposed on the front and rear sides of the portions being perforated.
the metal sheet perforating disk roll according to one of Claims 1 to 3 disposed as an upper side roll, and a pair of upper side guide rolls connected coaxially to both sides of the upper roll, each having a radius which is set smaller than the length measured from the center of the metal sheet driving disk roll to the lowest portion of the perforating blade, by at least a size corresponding to the thickness of the metal sheet or metal foil to form an upper roll unit, a disk roll disposed as a guide roll, the thickness of which is slightly larger than that of the metal sheet driving disk roll, and a pair of lower side guide rolls connected coaxially to both sides of the guide roll, each having a radius which is set larger than that of the disk roll by a length corresponding to the sum of the thickness of the metal sheet or metal foil and a difference between an amount of projection of the highest portion of the perforating blade and that of projection of the lowest portion thereof, to form a lower roll unit, the upper roll unit and lower roll unit engaging with each other to form portions being perforated in the metal sheet while passing the metal sheet or metal foil beneath the perforating roll disk, and tensile force application units formed of means for applying a tensile force to the metal sheet or metal foil disposed on the front and rear sides of the portions being perforated.
5. The metal sheet perforating device according to Claim 4, wherein a plurality of sets of the upper roll units and lower roll units which constitute the perforating unit are connected together coaxially, whereby a plurality of rows of holes are perforated in the metal sheet or metal foil.
6. The metal sheet perforating device according to Claim 4 or 5, wherein the upper roll unit, lower roll unit and tensile force application means are provided in such positional relation that permits the metal sheet or metal foil to advance along a part of an outer circumference of the guide roll so that the metal sheet or metal foil is perforated as the metal sheet winds round the guide roll.
7. The metal sheet perforating device according to Claim 4 or 5, wherein the tensile force application means are formed of upper and lower pinch rolls adapted to hold the metal sheet or metal foil therebetween.
8. The metal sheet perforating device according to Claim 4 or 6, wherein the tensile force application means comprises a pair of upper and lower bridle rolls.
9. The metal sheet perforating method for perforating a metal sheet or metal foil characterized by using the metal sheet perforating device defined in one of Claims 4 to 8, wherein:
the metal sheet or metal foil is passed through the two tensile force application units provided on the front and rear sides of the perforating unit, the upper and lower roll units which constitute the perforating unit being rotated as a tensile force is applied to the metal sheet or metal foil by the tensile force application means, each of which constitutes the tensile force application unit respectively, the metal sheet or metal foil being thereby perforated continuously.
the metal sheet or metal foil is passed through the two tensile force application units provided on the front and rear sides of the perforating unit, the upper and lower roll units which constitute the perforating unit being rotated as a tensile force is applied to the metal sheet or metal foil by the tensile force application means, each of which constitutes the tensile force application unit respectively, the metal sheet or metal foil being thereby perforated continuously.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/JP1999/004799 WO2001017710A1 (en) | 1999-09-03 | 1999-09-03 | Metal sheet drilling disk roll, metal sheet drilling device using the roll, metal sheet drilling method, and drilled metal sheet |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2383843A1 CA2383843A1 (en) | 2001-03-15 |
| CA2383843C true CA2383843C (en) | 2007-05-29 |
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| CA002383843A Expired - Fee Related CA2383843C (en) | 1999-09-03 | 1999-09-03 | Metal sheet perforating disk roll, metal sheet perforating device and metal sheet perforating method which use the disk roll, and perforated metal sheet produced by using the disk roll |
Country Status (7)
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| EP (1) | EP1219364B1 (en) |
| KR (1) | KR100604681B1 (en) |
| CN (1) | CN1163325C (en) |
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| CA (1) | CA2383843C (en) |
| DE (1) | DE69924038T2 (en) |
| WO (1) | WO2001017710A1 (en) |
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| JP4836351B2 (en) * | 2001-05-17 | 2011-12-14 | パナソニック株式会社 | Electrode plate for alkaline storage battery and alkaline storage battery using the same |
| EP1273365A1 (en) * | 2001-07-06 | 2003-01-08 | Recherche Et Developpement Du Groupe Cockerill Sambre | Rotary cutting tool for continuous perforating of profiles |
| JP5421087B2 (en) * | 2009-12-10 | 2014-02-19 | 大同工業株式会社 | Punch unit |
| JP2014036977A (en) * | 2012-08-15 | 2014-02-27 | Toyo Kohan Co Ltd | Metallic plate boring device |
| JP6116828B2 (en) * | 2012-08-15 | 2017-04-19 | 東洋鋼鈑株式会社 | Disc roll for punching metal plate and metal plate punching device |
| JP6406794B2 (en) * | 2012-08-15 | 2018-10-17 | 東洋鋼鈑株式会社 | Metal plate punching device |
| JP6307285B2 (en) * | 2014-01-22 | 2018-04-04 | 株式会社三井ハイテック | Punching method of iron core pieces |
| CN105140542A (en) * | 2015-08-28 | 2015-12-09 | 张家港讴德电池技术有限公司 | Grid lowering interface resistance and preparation method thereof |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE823694C (en) * | 1948-10-02 | 1951-12-06 | Bosch Gmbh Robert | Punching tool |
| US3209630A (en) * | 1961-12-22 | 1965-10-05 | Ibm | Rotary punching device |
| DE1778094C3 (en) * | 1968-03-28 | 1978-12-07 | Fraenkische Isolierrohr- & Metallwaren-Werke, Gebr. Kirchner, 8729 Koenigsberg | Device for continuous perforation of the wall of thin-walled folded tubes |
| US3543554A (en) * | 1968-11-25 | 1970-12-01 | Gen Motors Corp | Apparatus for punching and forming articles from sheet stock |
| JPS5268851A (en) * | 1975-12-05 | 1977-06-08 | Tanazawa Hakkosha Kk | Punching roller device |
| DE9017365U1 (en) * | 1990-12-22 | 1992-01-30 | Westaflexwerk Gmbh & Co Kg, 4830 Guetersloh, De |
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- 1999-09-03 CA CA002383843A patent/CA2383843C/en not_active Expired - Fee Related
- 1999-09-03 EP EP99940658A patent/EP1219364B1/en not_active Expired - Lifetime
- 1999-09-03 KR KR1020027002736A patent/KR100604681B1/en active IP Right Grant
- 1999-09-03 AU AU54488/99A patent/AU5448899A/en not_active Abandoned
- 1999-09-03 WO PCT/JP1999/004799 patent/WO2001017710A1/en active IP Right Grant
- 1999-09-03 DE DE69924038T patent/DE69924038T2/en not_active Expired - Lifetime
- 1999-09-03 CN CNB99816884XA patent/CN1163325C/en not_active Expired - Fee Related
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| DE69924038D1 (en) | 2005-04-07 |
| DE69924038T2 (en) | 2006-04-13 |
| CA2383843A1 (en) | 2001-03-15 |
| EP1219364A1 (en) | 2002-07-03 |
| AU5448899A (en) | 2001-04-10 |
| CN1163325C (en) | 2004-08-25 |
| EP1219364A4 (en) | 2003-05-28 |
| EP1219364B1 (en) | 2005-03-02 |
| KR20020030102A (en) | 2002-04-22 |
| WO2001017710A1 (en) | 2001-03-15 |
| KR100604681B1 (en) | 2006-07-26 |
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