JP2009119499A - Method for producing lead component for lead storage battery - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a lead component for lead storage battery by which the temperature variation of split dies is small and the defects in the casting hardly occur. <P>SOLUTION: On a bottom plate 21, a pair of the split dies 31 for casting a product part 32, and a cover 41 having a sprue 42 are placed successively, and molten lead alloy 15 is poured and supplied into the lower part of the split dies 31 from the sprue 42, and is solidified and released, thereby producing the lead component for lead storage battery. Here, a cartridge heater 36, which has a low exothermic part 38 at the top end part and a high exothermic part 39 at the root part, is used, and two pieces of the cartridge heaters 36 are inserted into the hole parts 37 for the heater of the split dies 31 so that the low exothermic parts 38 are made nearer thereto. Then, the lead component for lead storage battery is produced while strongly heating both end poprtions in the longitudinal direction of the split dies 31. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a lead component for a lead storage battery.

  Lead-acid batteries are inexpensive and highly reliable batteries, and are used in various applications such as automobile batteries and uninterruptible power supplies. Among these lead storage batteries, control valve type lead storage batteries are characterized by the fact that they do not require refilling water, and therefore demand is increasing for applications such as uninterruptible power supplies.

  A comparatively large control valve type lead-acid battery for an uninterruptible power supply used conventionally has an internal structure as shown in FIG. And these comparatively large control valve type lead acid batteries, as shown in FIG. 7, group-weld the pole column parts 18 and the ears 9 of each electrode plate, insert them into the battery case 4, 5 was manufactured (for example, refer to Patent Document 1).

  That is, as shown in FIG. 7, a plurality of positive electrode plates 1 and negative electrode plates 2 are laminated via a separator 3 (not shown), and then are formed into a flat plate shape, respectively. The ear part 9 is sandwiched between the comb teeth 12.

  Next, in the state where various lead parts called lead part rods 14 and pole pole parts 18 having a substantially rectangular parallelepiped shape are arranged on the comb teeth 12, the plasma welding apparatus 13, a burner (not shown), etc. Heat from above using. Then, these parts are melted and solidified, and welded and integrated to manufacture an electrode plate group having the pole column 8 and the strap 6. Here, it is known that when the plasma welding apparatus 13 is used for welding, the heating temperature and the heating position at the time of melting are easily controlled, and high-precision welding is possible.

  Then, after inserting the electrode plate group having the strap 6 and the pole column 8 into the resin battery case 4, a resin lid 5 is attached to the upper portion thereof by a heat welding method or the like and sealed to control the lead acid battery. (FIG. 8).

  The various lead parts called the lead part rod 14 and the pole part 18 described above use a pair of split molds 31 by a normal method, and a plurality of products, for example, FIG. Then, three products were manufactured (for example, refer to Patent Document 2). That is, as shown in FIG. 6, the copper core 11 is put on the protruding copper core holder 22 of the bottom plate 21. The copper core 11 is embedded in the terminal 7 at the tip of the pole 8 after the battery is completed, and is used for bolt connection with an external load (not shown) and a crimp terminal. (FIG. 8).

  A pair of split molds 31 are placed on the bottom plate 21 (in FIG. 6, in order to facilitate the explanation of the product part 32, only the back half mold is shown, and the front half mold is omitted. The pair of split molds 31 are closed, and a hot water lid 41 is placed thereon. Then, cork powder is sprayed on the base plate 21, the split mold 31, and the water cup 41 in advance for the purpose of heat insulation and release, etc., and the cartridge heater 36 is inserted into the heater hole 37 of the split mold 31, and 240 ° C. Heat to the extent (FIG. 5).

  Then, the molten metal 15 of lead alloy heated to about 500 ° C. is poured by using the scissors 16 until the hot water 19 is formed from the gate 42 of the hot water lid 41 to supply hot water. Then, after about 90 seconds have passed and the lead alloy melt 15 has solidified, for example, as shown in FIG. The part with the hot water 19 was mechanically cut and separated, the split mold 31 was opened and released, and the three pole column parts 18 as products were taken out and manufactured. Note that the raw material (lead alloy) of the hot metal 19 is heated and melted again and reused as the molten metal 15.

JP-A-2005-347183 JP2007-167907

  However, when the conventional method for producing a lead component as described above is used, there is a problem that the temperature variation of the split mold 31 is large when casting. In particular, it was recognized that the temperature at both end portions in the longitudinal direction of the split mold tends to be low. In the case of the split mold 31 capable of manufacturing a large number of pole column parts 18, the temperature variation further increases depending on the position of casting (for example, six pole column parts 18 are manufactured in FIG. 5). An example of the split mold 31 is shown.) When the split mold 31 having a large temperature variation is used, it has an effect on the cooling and solidification time of the molten metal. As a result, there is a problem that defects during casting are likely to occur.

  In addition, if the temperature variation increases, it is not suitable for mass production because it is necessary to determine the manufacturing tact based on the part of the split mold that has the highest temperature as the cooling and solidification time of the molten metal. There are also problems such as being easy to cut due to excessive load, and cork powder for heat insulation and the like being easily dropped off.

  An object of the present invention is to solve the above-described problems, and to provide a method for manufacturing a lead component for a lead storage battery that can suppress temperature variations of the split mold 31.

  In order to solve the above-described problem, in the present invention, the structure of the cartridge heater for heating the split mold is improved to suppress the variation in the split mold temperature.

That is, in the invention of claim 1, a pair of split molds and a top having a pouring gate are placed on the bottom plate in order, and a molten lead alloy is poured from the pouring gate into the lower die, and then solidified and separated. In the manufacturing method of lead parts for lead storage batteries manufactured by molding,
In the split heater hole, one cartridge heater is inserted in the longitudinal direction. The cartridge heater has a low heat generating portion at the center portion and a high heat generating portion at the tip portion and the root portion. And
The split mold is cast while strongly heating both end portions in the longitudinal direction.

According to the invention of claim 2, a pair of split molds and a cup having a gate are placed on the bottom plate in order, and a molten lead alloy is poured from the gate into the split mold below to solidify and release. In the manufacturing method of lead parts for lead storage batteries manufactured by
In the split heater hole, two cartridge heaters are inserted in the longitudinal direction,
The tip of the cartridge heater has a low heat generation part and a high heat generation part at the root part,
The two cartridge heaters are inserted in the heater holes so that the low heat generating portion approaches,
The split mold is cast while strongly heating both end portions in the longitudinal direction.

  By using the manufacturing method according to the present invention, when casting a lead part, it is possible to reduce the variation in the split mold temperature. Can be provided. In addition, since the manufacturing tact can be shortened, there is mass productivity, the life of the heater for heating can be extended, and the cork powder can be prevented from falling off.

  As will be described later, the method for manufacturing a lead component for a lead storage battery according to the present invention is an improvement in the structure of the cartridge heater 36 for heating the split mold 31, in particular, the heat generating portion.

1. Cartridge heater and split mold structure This time, both stainless steel tubes were used and the appearance was cylindrical, but the experiment was conducted using three types of cartridge heaters 36 with different internal structures (Fig. 1-3: Examples 1 and 2 and comparative examples). Of the three types of cartridge heaters 36, conventionally, as shown in FIG. 3, a structure having a heat generating portion 35 constituted by one type of nichrome wire coil has been used.

  Here, FIG. 4 shows a schematic view of a cartridge heater 36 according to the present invention used in Example 2 described later. That is, a heat generating portion 35 composed of a nichrome wire coil is embedded inside the stainless steel tube. The heat generating portion 35 has a low heat generating portion 38 at the tip portion and a high heat generating portion 39 at the base portion, and has a length of about 200 mm, which is slightly short. The cartridge heater 36 used in Example 1 and the comparative example has a length dimension of about 400 mm, which is about twice as long as the cartridge heater 36 of FIG.

  Here, in the cartridge heater 36 shown in FIG. 4, as an example, the output of the low heat generating portion 38 is set to 100 W, and the output of the high heat generating portion 39 is set to 450 W. That is, when the cartridge heater 36 is energized for a certain period of time, the high heat generating portion 39 at the root portion can be heated with an output 4.5 times that of the low heat generating portion 38 at the tip portion.

  Next, FIG. 5 shows a schematic diagram of the split mold structure used in the experiment. That is, it comprises a pair of left and right split molds 31 and has a longitudinal dimension of about 400 mm. A heater hole 37 for inserting the cartridge heater 36 is formed in a slightly lower part of each split mold 31 so as to penetrate in the longitudinal direction.

2. Method for Producing Lead Part for Lead Acid Battery Among various lead parts for lead acid battery, a method for producing the pole part 18 will be described in detail with reference to FIGS. 6, 7, and 8. In addition, various lead parts for lead-acid batteries are usually manufactured by a so-called gravity casting method in which molten metal is naturally dropped and cast.

  As shown in FIG. 6, a copper core 11 having a nut shape is put on a copper core stand 22 having a protruding shape of a bottom plate 21 in advance. As shown in FIG. 8, the copper core 11 is embedded in the terminal 7 after the battery is completed, and is used for bolt connection with an external load (not shown) and a crimp terminal. .

  A pair of split molds 31 are placed on the bottom plate 21 (in FIG. 6, only the back half mold is shown, and the front half mold is omitted for easy explanation of the shape of the product portion 32. ) Next, the split mold 31 is closed, and a hot water lid 41 having a pouring gate 42 is placed thereon. Note that cork powder is sprayed on the steel base plate 21, split mold 31, and hot water lid 41 for the purpose of improving heat insulation and facilitating mold release work. The split mold 31 is heated to about 240 ° C. by the cartridge heater 36 in advance. Then, the molten lead 15 heated to about 500 ° C. using the scissors 16 is supplied from the spout 42 of the lid 41 to the product part 32 of the split mold 31 by pouring in excess until the hot water 19 is formed. To do.

  Then, after about 90 seconds, the lead alloy melt 15 was cooled and solidified, and for example, as shown in FIG. The pole column part 18 formed by the part 32 and the feeder 19 formed by the hot water lid plate 44 are mechanically cut and separated. In addition, although the part of the hot water lid 41 is shifted rightward, it can be cut and separated by a method such as twisting this part.

  After cutting between the parts of the pole column part 18 and the feeder 19, the split mold 31 is mechanically opened to release the pole part 18 as a product and take it out to produce a lead part. Note that the lead alloy material in the portion of the hot metal 19 formed at the gate 42 of the hot water lid 41 is heated and melted again and reused as the molten metal 15.

3. Example 1, Example 2 and Comparative Example Hereinafter, the structure of the cartridge heater 36 inserted into the split mold 31 which is a characteristic part of the present invention will be described in detail.
(1) Example 1
A schematic diagram of Example 1 is shown in FIG. Here, the cartridge heater 36 according to the present invention used in the first embodiment has a low heat generation portion 38 at the center portion and a high heat generation portion 39 at the tip portion and the root portion. Is about 400 mm. A total of two cartridge heaters 36 are inserted into the heater holes 37 of the pair of split molds 31, one in the longitudinal direction (FIG. 2).

  Here, as an example, the output of the low heat generating portion 38 at the center is 100 W, and the output of the high heat generating portion 39 at the tip and root is 450 W. That is, the lead parts for the lead storage battery can be cast while strongly heating the both end portions in the longitudinal direction for each split mold 31 by one cartridge heater 36. Therefore, both end portions in the longitudinal direction of the split mold in which the mold temperature tends to be low can be strongly heated.

  As shown in FIG. 2, the temperature of a pair of split molds 31 is measured by two temperature sensors 40 using thermocouples, and each cartridge heater 36 is set to be turned on and off at 240 ° C. After standing for about 1 hour, the temperatures of the parts (1) to (14) were measured as shown in FIG. As a result, as shown in FIG. 2, the temperature variation could be 21 ° C. This result was able to be greatly reduced as compared with the conventional temperature variation of 32 ° C. (see comparative example described later: FIG. 3).

Therefore, the manufacturing method of the lead component for lead acid batteries which cannot produce the defect at the time of casting easily can be provided. In addition, since the manufacturing tact can be shortened, there is mass productivity, the life of the heater for heating can be extended, and the cork powder can be prevented from falling off.
(2) Example 2
FIG. 4 shows a schematic view of the cartridge heater 36 according to the present invention used in the second embodiment. That is, the tip portion has a low heat generation portion 38 and the root portion has a high heat generation portion 39, and the length dimension is about 200 mm. Then, a total of four pieces are inserted into the heater holes 37 of the pair of split molds 31 in such a manner that two low heat generation portions 38 approach each other in the longitudinal direction (FIG. 1).

  As shown in FIG. 1, two cartridge heaters 36 are inserted into the heater holes 37 of the pair of split molds 31 in the length direction from opposite directions. In other words, the two cartridge heaters 36 are inserted so that the low heat generation portion 38 approaches the center portion of the split mold 31 and the high heat generation portion 39 is disposed at both end portions of the split mold 31. did.

  Here, as an example, the output of the low heat generating portion 38 of the cartridge heater 36 is 100 W, and the output of the high heat generating portion 39 is 450 W. That is, the arrangement of the cartridge heater 36 according to the present invention used in the second embodiment can cast lead parts for a lead storage battery while strongly heating both longitudinal ends of the split mold 31. Therefore, both end portions in the longitudinal direction of the split mold in which the mold temperature tends to be low can be strongly heated.

  As shown in FIG. 1, the temperature of the split mold 31 is measured by four temperature sensors 40 using thermocouples, and each cartridge heater 36 is set to be turned on and off at 240 ° C. After standing for a period of time, the temperatures of the parts (1) to (14) were measured as shown in the figure. As a result, as shown in FIG. 1, the temperature variation could be 13 ° C., and the temperature variation could be further reduced as compared with Example 1. That is, since temperature control is performed using the temperature sensor 40 for each of the four cartridge heaters 36 in total, fine temperature control can be performed.

In addition to the effects similar to those of the first embodiment, the cartridge heater 36 used in the second embodiment is approximately half the length of the cartridge heater 36 used in the first embodiment. There is almost no seizure with 31. Therefore, the cartridge heater 36 can be easily replaced even when the heat generating portion 35 is disconnected due to deterioration with time or the like, which is excellent in terms of equipment maintenance.
(3) Comparative Example As a comparative example, one having one type of heat generating portion 35 at the tip has been conventionally used. That is, the cartridge heater 36 used in the comparative example is composed of only one type of heat generating portion 35 with an output of 300 W, and has a lengthwise dimension of about 400 mm. A total of two inserts are inserted, one for each pair of split molds 31 (FIG. 3).

  As shown in FIG. 3, the temperature of the split mold 31 is measured by two temperature sensors 40 using thermocouples, and each cartridge heater 36 is set to be turned on and off at 240 ° C. After being allowed to stand for a period of time, the temperatures of the parts (1) to (14) were measured as shown in FIG. As a result, as shown in FIG. 3, a temperature variation of 32 ° C. was measured.

  As described above, when the manufacturing method according to the present invention is used, variation in split mold temperature can be reduced, and therefore a method for manufacturing a lead component for a lead-acid battery that is less prone to defects during casting is provided. Can do. In addition, since the manufacturing tact can be shortened, there is mass productivity, the life of the heater for heating can be extended, and the cork powder can be prevented from falling off.

  In the best mode for carrying out the invention described above, the manufacturing method of the pole column component 18 has been described in detail. However, as in the case of the lead component rod 14 (FIG. 7) having a simpler shape. Also, it can be used in the same manner for the manufacturing method of lead parts for other lead storage batteries.

  The present invention can be used for manufacturing lead parts for lead storage batteries such as the pole pole part 18 and the lead part bar 14 that are used when welding the electrode plates at the time of manufacturing the lead storage battery.

It is the schematic of the split type temperature distribution at the time of using the heating system concerning Example 2. FIG. It is the schematic of the split type temperature distribution at the time of using the heating system concerning Example 1. FIG. It is the schematic of the split type temperature distribution at the time of using the heating system conventionally used. 6 is a schematic diagram of a cartridge heater according to Embodiment 2. FIG. It is the schematic of a split type structure and a cartridge heater. It is the schematic of the manufacturing method of polar pole components. It is the schematic of the welding method of an electrode group. It is a notch section perspective view of a control valve type lead acid battery.

Explanation of symbols

1: positive electrode plate, 2: negative electrode plate, 3: separator, 4: battery case, 5: lid, 6: strap,
7: Terminal, 8: Polar pole, 9: Ear part, 10: Safety valve part, 11: Copper core, 12: Comb teeth,
13: Plasma welding apparatus, 14: Lead component bar, 15: Molten metal, 16: Fence, 18: Polar pole component,
19: Pressing hot water, 21: Bottom plate, 22: Copper core stand, 31: Split mold, 32: Product part,
33: Silicon rubber, 34: Glass lead wire, 35: Heat generating part, 36: Cartridge heater, 37: Heater hole part, 38: Low heat generating part, 39: High heat generating part, 40: Temperature sensor,
41: Cup, 42: Gate

Claims (2)

On the bottom plate, a pair of split molds and a cup with a gate are placed in order, and a molten lead alloy is poured from the gate into the split mold below to supply hot water, and then solidified and released for production. In the lead component manufacturing method,
In the split heater hole, one cartridge heater is inserted in the longitudinal direction,
The central portion of the cartridge heater has a low heat generation portion, and the tip portion and the root portion have a high heat generation portion.
A method for producing a lead component for a lead-acid battery, wherein both ends of the split mold in the longitudinal direction are cast while being strongly heated. On the bottom plate, a pair of split molds and a cup with a gate are placed in order, and a molten lead alloy is poured from the gate into the split mold below to supply hot water, and then solidified and released for production. In the lead component manufacturing method,
In the split heater hole, two cartridge heaters are inserted in the longitudinal direction,
The tip of the cartridge heater has a low heat generation part and a high heat generation part at the root part,
The two cartridge heaters are inserted in the heater holes so that the low heat generating portion approaches,
A method for producing a lead component for a lead-acid battery, wherein both ends of the split mold in the longitudinal direction are cast while being strongly heated.

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