JP2014100784A - Roll forming method of porous metal foil and coiled porous metal foil formed by the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a roll forming method which facilitates machining, can reduce a machining cost, forms fine holes in a metal foil at prescribed layout and an aperture ratio, and removes dust, machining wastes, and fines resulting from environment or a machining process itself during machining, and also to provide the metal foil formed by the same.SOLUTION: A roll forming system performs continuous machining such as hole forming on a metal foil with thickness of 50 μm or smaller by using a metallic forming roll with fine projections formed on its surface and elastic body receiving rolls each facing the forming roll while interposing the metal foil therebetween. In addition, the roll forming system brushes off machining waste and fines embedded in an elastic body of a first receiving roll immediately after machining by actions of a plurality of elastic fiber brush rolls rotating at high speed. Forward in a rotation direction of the forming roll, a plurality of receiving rolls are disposed and the plurality of elastic fiber brush rolls are further disposed to cope with half-cutting and to remove the machining waste, the fines and dust adhering to a foil surface.

Description

  The present invention relates to a roll molding method of a porous metal foil used as a collector electrode foil used in a battery, a capacitor or the like as an electric energy source for electric vehicles and home appliances instead of conventional fossil energy.

  Furthermore, the present invention is a porous metal foil used as a collector electrode foil used in batteries, capacitors, etc., and rewinds a long metal foil wound in a coil shape to form a long metal foil as a forming roll Coiled porous metal foil formed by a forming method in which a large number of fine holes are formed in a metal foil by sandwiching it between a metal roll and a receiving roll, and a long metal foil after the microhole forming is wound up again to remove foreign matters. About.

  In recent years, with the rapid development of multimedia technology, the use of secondary batteries as an alternative energy on a global scale, including electric vehicles that are used in portable electronic devices and are changing at an accelerated pace here. There is a need for a smaller, lighter and higher performance without waiting.

  In lithium batteries, the development of electrode active materials has been energetically performed mainly for the purpose of improving energy density and reducing costs. Each of these positive and negative active materials is a positive electrode aluminum foil and a negative electrode that are current collectors. Has a problem in that the adhesion to the copper foil surface is poor and a local peeling phenomenon is likely to occur, and the hole communicating with the metal current collector in Patent Document 1 (Japanese Patent Publication No. 7-70327) is caused by this peeling phenomenon. The electrode performance is significantly improved.

  Moreover, as a manufacturing method of perforated foil, conventionally, a part of the material of the foil is melted by a method of forming a hole by pressing using an uneven die (punching die) or a chemical treatment such as etching. A method of forming holes is used.

  For example, in Patent Document 2 (Japanese Patent No. 3666558), a metal foil is sandwiched between a die having a punched hole and an elastic body and passed between rolls, whereby the elastic body is pressed to apply the metal foil. A method of forming a hole in a metal foil by deforming into a punching hole of a mold, wherein the mold and the elastic body are each formed of an annular body having a length sufficiently larger than the outer peripheral length of the roll. A method for producing a perforated foil for rotational movement is disclosed.

  Further, in Patent Document 3 (Japanese Patent Laid-Open No. 2001-79795), processing is easy, the processing cost can be reduced, burrs can be prevented from being generated or broken during processing, and a strong porous metal. This is a method of manufacturing a foil sheet, in which a metal foil sheet with a thickness of 50 μm or less is laminated with an ultraviolet curable adhesive, heat-peelable adhesive or water-soluble adhesive tape, and then punched into the ultraviolet curable adhesive tape and the metal foil sheet by punching. A method for forming a porous metal foil sheet comprising uniformly punching a large number of small holes having a rate of 25% or more, and then causing the adhesive tape to lose its adhesive force and peeling the adhesive tape from the metal foil sheet. It is disclosed.

  Furthermore, in patent document 4 (Unexamined-Japanese-Patent No. 2002-216775), the electrode of the secondary battery which can enlarge the aperture ratio of a collector foil and can form many small holes in a thin collector foil A current collector foil molding method and molding apparatus, wherein a non-porous current collector foil is passed over an elastic belt between an embossing roll having a large number of convex portions and a flat roll having no irregularities. And forming a through hole at the location of the current collector foil pressed by the convex portion and embedding a punched residue generated at the time of forming the through hole in the elastic belt. A method and apparatus for forming a foil that is removed from an elastic belt are disclosed.

  Further, in Patent Document 5 (Japanese Patent Application Laid-Open No. 2001-1007), a hole capable of efficiently producing a perforated foil having a high degree of freedom such as the size and pitch of the hole without incurring high costs. It is a manufacturing method of bright foil. When a metal foil is placed on an elastic body on a base plate and a grooved roll is pushed into the elastic body, the elastic body is deformed and the metal foil is pushed into the groove of the roll. The metal foil is sheared by the edge of the groove and the elastic body, and the portion of the metal foil pressed against the elastic body by the protrusion of the roll becomes a punched residue, and a perforated foil in which holes are formed is obtained. A method is disclosed. Similarly, Patent Document 6 (Japanese Patent Application Laid-Open No. 2002-113535) is a method for manufacturing a perforated foil that does not cause cracks in the peripheral ribs of a formed quadrangular hole. In the rhombus convex portion formed on the surface of the processing roll constituting the roll of the other, the opposing vertex of one set of the two opposing vertices is arranged along the roll rotation direction, and the other set is opposed. A system is disclosed in which vertices are arranged along the roll axis direction and the interval between one set of vertices is set longer than the interval between the other set of vertices.

Japanese Patent Publication No. 7-70327 Japanese Patent No. 3666558 JP 2001-79795 A JP 2002-216775 A Japanese Patent Laid-Open No. 2001-1007 JP 2002-113535 A

Non-Patent Document 1 discloses a technique for manufacturing a perforated metal foil by gravure printing and an etching method.
http: // www. nihonseiiaku. co. jp / kenkyu / alumi. htm

  In this invention, it aims at manufacture of the mechanical porous metal foil which does not use a process liquid, and aims at manufacture of the metal foil by especially novel roll forming. However, even in mechanical forming, in the conventional roll forming method described above, since the receiving roll is an elastic body as compared with the forming roll that is a mold as described above, the hole shape of the processed metal foil is In addition, burr-like burrs are generated in the direction in which the processing blade comes off, and it is certain that the foil thickness after processing becomes thick, and in addition to that, there is a possibility of defective dimensions including processing waste.

  In addition, the hole processing in the conventional roll molding is performed by a pair of molding parts of a mold roll and a receiving roll whose surface is made of rubber. Here, the dimensional variation between the mold of the receiving roll and the molding roll main body, However, due to variations in the rubber material, hardness, and rubber density of the receiving roll, there was a problem that incomplete machining that could not be completely removed due to half cut occurred.

  Furthermore, in punching by the conventional roll forming method, the scraps adhere to the elastic roll surface, which is the receiving roll, due to the construction method, and even if it is eliminated by resin brush and air pressure or suction. This is sufficient and cannot be removed during one rotation of the roll. When the next processing is started in such a state, the processing waste adhering to the surface of the receiving roll cannot be excluded, and depending on the attachment position, is sandwiched between fine burrs of “burrs”. More and more, making it difficult to eliminate. In the prior art, it is impossible to completely eliminate the state of these difficult-to-exclude machining scraps.

  In addition, because the receiving roll is an elastic body with a roll-shaped mold having a convex shape, burr-like burrs always occur, and the metal foil thickness after processing becomes thicker than the original foil, so that customer specifications cannot be satisfied Also occurs. In addition, when drilling in roll forming, fine metal fine powder moves around and adheres to the foil surface in addition to relatively large scraps.

  In the above-described conventional mechanical forming technology, although there is a proposal for improving the burr after forming, it causes a short circuit phenomenon that becomes a fatal defect of the porous electrode foil as a product such as a secondary battery. At present, there is almost no mention of removal of processing waste, fine powder, and dust. However, due to the failure and recovery accidents of several major battery manufacturers in recent years, the quality of the porous electrode foil is not only the removal of burrs, but also the elimination of processed waste, fine powder and dust released on the porous electrode foil in the future. It has become an important issue.

  A roll forming system that forms a fine convex shape on the surface of a current metal roll and consists of a receiving roll made of an elastic body facing the metal foil, and performs continuous processing such as drilling on a long metal foil. For example, in the case of foil punching in, the processing part is only a pair of rolls such as a metal roll and rubber, the processing opportunity is only once, and the processing part is formed at a very short distance It is. Therefore, due to various conditions such as the accuracy of each roll or roll assembly, density variation of rubber rollers, etc., vibration during processing of the machine, etc., the positional relationship between the metal foil and the mold varies and the half-cut punching process is not completed. There is a problem that a state in which a part of the chips is connected to a metal foil as a base material without being removed in the state (see FIG. 9B, which will be described later).

  In addition, it is unavoidable in the past that the scraps randomly attached to the rubber receiving roll that acts as a concave mold, and the chipping occurs when drilling occurs during drilling. It will be rolled up while leaving it.

  The above-mentioned two kinds of scraps cannot be eliminated by the conventional processing / gradual scrap method. In addition to these scraps, in actual processing, fine chips are scattered and adhere to the base material, and a temporary response is possible by rotating a normal commercially available adhesive roller etc. against the base material surface. However, roll cleaning cannot be performed in a continuous molding process, and a stable dust removal function cannot be maintained.

  The present inventors have already filed Japanese Patent Application No. 2008-164891 as a basic invention, but by further development, although fine holes could be processed with a molding roll, the scrap was made of rubber as a concave mold. It has also been found that it is buried in the receiving roll and cannot be eliminated, and the next processing is adversely affected.

  The porous electrode foil of the present invention is packaged by being assembled in a stacked or wound manner. At that time, the inclusion of metal debris grows due to an electrical / chemical reaction and the obstacle penetrates the spacer and causes a short circuit or the like. There is a risk of causing a fatal defect. Therefore, in order to be a material for electronic parts, it is an important quality factor that no foreign matter or dust other than the necessary material is attached or caught. Therefore, the present invention plays an important role in maintaining the quality of the electrodes of these electronic components by suppressing the generation of processing waste and thoroughly eliminating the mechanism in forming the porous electrode foil.

  In order to solve the problems as described above, the inventors have improved the overall apparatus and method, and provided a roll metal foil roll forming apparatus and a porous metal foil roll forming method that further enhance the metal foil moldability. It is intended to provide. Furthermore, another object of the present invention is to provide a porous metal foil formed by the method. That is, an object of the present invention is to obtain a coiled porous metal foil as a final product that realizes removal of burrs from the porous metal foil and elimination of processing waste, fine powder, and dust.

In the roll metal foil roll forming method of the present invention, a long metal foil wound in a coil shape is rewound, and the long metal foil is sandwiched between a forming roll and a receiving roll, and a large number of fine metal foils are placed on the metal foil. A roll metal foil roll forming method in which a punched hole is formed, and the long metal foil after the fine punched hole is wound into a coil shape again,
The forming roll is formed with a large number of fine convex shapes over the entire circumference of the circumferential roll surface, and the receiving roll is elastically deformed by being pressed against the convex shape on the surface of the forming roll. A first receiving roll having substantially the same function and performance provided by a plurality of the receiving rolls and facing the forming roll along the flow of the metal foil. And a second receiving roll,
The long metal foil is configured to be bitten and introduced at a biting position A and to be separated at a separation position C with respect to the convex mold on the surface of the forming roll, and from the biting position A to the separation position C. The molding region X is configured to occupy 180 degrees or more of the entire circumferential surface of the molding roll,
As a result, the long metal foil maintains a state of being bitten with respect to the convex mold on the surface of the forming roll in the forming region X, rotates together with the forming roll, and the forming roll and the first and The plurality of fine punch holes are formed between the second receiving roll and the metal foil by the subsequent second receiving roll even if half cut of the metal foil punching hole occurs in the first receiving roll. So that all the holes are molded,
The strips of the long metal foil punched and formed by the convex mold formed on the surface of the forming roll are left on the first and second receiving rolls,
The scraps left on the first and second receiving rolls are removed from the elastic body surface of each receiving roll by rotating brushes respectively provided for the first and second receiving rolls. .

  As a result, the long metal foil to be processed is processed while rotating together in a state where the long metal foil has been engaged with the convex shape on the surface of the circumferential forming roll for a long time, thereby completely processing the holes in the metal foil. Is something that can be achieved.

  According to the roll metal foil roll forming method of the present invention, the long metal is formed by a rolling roll provided in the middle of the porous metal foil transfer line before the long metal foil after the fine punching is wound into a coil shape. It is characterized in that the burr-like processing return generated by fine punching of the foil is rolled and finished to near the foil thickness.

  Thereby, even if it is processing with a single forming roll, it becomes possible to perform multi-stage forming processing, and the problem of scraps due to half cut is solved, and furthermore, by rolling in the porous metal foil transfer line, Even if this metal foil is used as an electrical element for a secondary battery, it is possible to eliminate the electrical or mechanical adverse effects caused by burrs.

  In the roll metal foil roll forming method of the present invention, the long metal foil after fine punching is rolled by a roll provided in the middle of the porous metal foil transfer line before being wound into a coil again. In addition, by passing or sucking compressed gas to or from the transported porous metal foil, the processing waste, fine powder, and dust accompanying the porous metal foil are removed, and the rolling roll further The burr-like processing return generated by the processing of the long metal foil is rolled to near the foil thickness and then wound up again.

  Since the roll metal foil roll forming method of the present invention is to rewind after removing foreign matters such as processing waste, fine powder, and dust accompanying the porous metal foil in this way, it is as flat as possible. It is possible to provide a coiled porous metal foil from which foreign matter has been removed.

The coiled porous molded metal foil of the present invention is obtained by rewinding a long metal foil wound in a coil shape, and sandwiching the long metal foil between a forming roll and a receiving roll, thereby making a large number of fine metal foils. A coiled porous metal foil in which a punched hole is formed and the long metal foil after the fine punched hole is wound up again,
The forming roll has a large number of fine convex molds formed on the entire surface of the circumferential roll, and the receiving roll is pressed against the convex mold on the molding roll surface. A plurality of receiving rolls, and a first receiving roll having substantially the same function and performance provided facing the forming roll along the flow of the long metal foil, and a first roll It is composed of two receiving rolls,
The long metal foil is configured to be bitten and introduced at a biting position A and to be separated at a separation position C with respect to a convex mold on the surface of the forming roll, from the biting position A to the separation position C. Is formed so as to occupy 180 degrees or more of the entire circumferential surface of the forming roll,
As a result, the long metal foil maintains a state of being bitten with respect to the convex mold on the surface of the forming roll in the forming region X, rotates together with the forming roll, and the forming roll and the first and The plurality of fine punch holes are formed between the second receiving roll and the metal foil by the subsequent second receiving roll even if half cut of the metal foil punching hole occurs in the first receiving roll. So that all the holes are molded,
The strips of the long metal foil punched and formed by the convex mold formed on the surface of the forming roll are left on the first and second receiving rolls,
The scraps left on the first and second receiving rolls are removed from the elastic body surfaces of the receiving rolls by rotary brushes provided for the first and second receiving rolls, respectively.
The long metal foil after forming the fine punched hole is rolled by a rolling roll provided in the middle of the porous metal foil transfer line before being wound again in a coil shape, and then passed through a substantially sealed space portion. In this section, foreign substances such as processing waste, fine powder, and dust accompanying the porous metal foil are removed by spraying or sucking compressed gas to the transporting porous metal foil.

  By producing the coil-shaped porous molded metal foil of the present invention by the above-described production method, generation of scraps during the molding process is suppressed as much as possible, and further, machining scrap, fine powder, Since the foreign matter such as dust is removed and then wound up again, it is possible to provide a coiled porous molded metal foil that is as flat as possible and from which foreign matter has been removed.

  The current demand for metal foils for current collectors for electronic parts such as secondary batteries and capacitors is to be continuously produced in large quantities at low cost. For this reason, mechanical processing methods include “lass processing” and “punching processing”. And other technologies have also been established. According to the present invention, as is clear from the above detailed description, a long current collector provided as a roll-shaped metal foil is automatically and continuously drilled at high speed, and a porous electrode foil is used. The most important factor that affects the quality of maintaining the characteristics of the secondary battery, which can prevent the remaining of the processing scrap and metal fine powder, which is a fatal obstacle to the electronic devices, and is the lowest cost collection of processing scrap and metal fine powder as much as possible. The present invention proposes a roll metal foil roll forming apparatus and a porous metal foil roll forming method capable of reliably providing an electric foil. Further, by such a method, a coiled porous metal foil is proposed as a low-cost current collector foil with as little processing scraps and fine metal powder as possible.

  In particular, metal scraps and fine powder in porous electrode foils in lithium secondary batteries, etc. are a cause of major obstacles such as growing inside itself and becoming a social problem due to secular change. The industrial value of the mobile device market is remarkable.

The layout which shows the forming roll unit of the 1st Example of the apparatus applied to the metal foil roll forming method of this invention, and a waste removal unit. The whole block diagram of the apparatus applied to the metal foil roll forming method of this invention. The whole block diagram of another Example of the apparatus applied to the metal foil roll forming method of this invention. (A), (B), (C), (D) Sectional drawing which shows the modification of the receiving roll applied to the method of this invention. (A), (B), (C), (D) Explanatory drawing which shows the modification of the microprotrusion of the forming roll applied to the method of this invention. The arrangement | positioning figure which shows the forming roll unit in the 2nd Example of the apparatus applied to the metal foil roll forming method of this invention, and a waste removal unit. The arrangement | positioning figure which shows the forming roll unit in the 3rd Example of the apparatus applied to the metal foil roll forming method of this invention, and a waste removal unit. The perspective view which shows the drive mechanism of the waste removal unit of the apparatus applied to the metal foil roll shaping | molding method of this invention. (A), (B) Explanatory drawing of shaping | molding process operation | movement of the metal foil roll shaping | molding method of this invention. The detailed drawing of the rolling mechanism of the perforated metal foil of the apparatus applied to the metal foil roll forming method of the present invention. (A), (B), (C) The detail drawing of the dust removal apparatus of the apparatus applied to the metal foil roll shaping | molding method of this invention. Explanatory drawing regarding the improvement of the roll forming process of the metal foil side edge part of this invention. The schematic block diagram of the ultrasonic wave and electric field etching unit suitable for the metal foil roll forming process of this invention. The schematic block diagram of the trimming apparatus of the metal foil both-ends part of the metal foil roll forming process of this invention.

  The present invention has been made in view of the problems of the prior art as described above, and its object is to continuously collect a large amount of stable chips and dust, and a current collector for an electrode without adhesion As a result, it is possible to manufacture a perforated metal foil that can be significantly reduced in cost compared with other conventional methods. In other words, the present invention more effectively eliminates the problem of half-cutting that cannot be avoided as long as the method using a metal roll mold and a rubber receiving roll is used, and pinching of scraps between punching burrs. Of a porous metal foil roll forming apparatus and a porous metal foil roll forming method capable of simultaneously achieving two problems, and a reliable removal of scrap rubber receiving rolls. It is a proposal. Furthermore, this invention aims at provision of the coil-shaped porous metal foil shape | molded by the method.

  First, the cause of half-cut (incompletely unplugged state) is that punching is conventionally performed in a molding process in which a metal foil is sandwiched only once between a roll mold and a receiving roll. Because. In the present invention, the metal foil molding process pass line (molding region X) is kept long in the contact state around the roll mold, and is first bitten between the roll mold and the receiving roll. In the molding process from the position A to the separation position C, the convex mold of the roll mold is rotated together with the metal foil in a state of being bitten in the through-molding hole of the metal foil, and this contact state is maintained. In the meantime, when the receiving roll placed next to the receiving roll at the biting position is again punched by press contact with the roll mold, the processing state with multiple roll blades will elapse. Incomplete punching state / half-cutting is a complete punching state. In this method, by further increasing the number of receiving rolls, it is possible to further increase the number of molding steps (the number of steps) and obtain a more complete drawing state. In the present specification, an embodiment provided with three or more receiving rolls is not particularly described, but this can be easily implemented by those skilled in the art by applying the idea of the present invention. .

  Next, a description will be given of countermeasures against “missing burrs” that occur extremely rarely due to “residual scraps” on the receiving roll. This is “scraps” in a state where “residual scraps” are sandwiched as “slips” in the mold roll mold. With regard to the “cutting burrs”, a rotating brush having resin elastic fibers planted on the surface is rotated in a state of being opposed to the molding roll mold, and the fine mold of the molding roll becomes a through hole in the metal foil. In a state where the metal foil is still biting, it is opposed to the formed metal foil and rotated at a high speed of about 1000 rpm, thereby eliminating the processing waste accompanied by the formed metal foil.

  The roll metal foil roll forming method of the present invention is to form a large number of holes in a metal foil inserted between a forming roll having a large number of convex molds on the surface and a receiving roll having a surface of an elastic body. In this roll forming, the receiving roll is an important part. Therefore, the present invention is an improvement of the surface structure of the receiving roll in order to improve the half cut. At this time, the matter that needs to be further improved is countermeasures against burying “residual debris” on the receiving roll. That is, it is a problem that the “embedded chips” on the receiving roll adversely affect the newly supplied metal foil 20. The present invention is a significant improvement on this point.

  In order to achieve the above effect, it is effective to rotate the above-described rotating brush at high speed using a solid cam (groove cam) or a biaxial motor drive. As a result, by simultaneously moving and swinging in the biaxial direction at high speed, the force to try to eliminate the omnidirectional waste on the receiving roll acts in all directions, and it can be expected that the function to remove the processing waste will increase. It is. Such an exclusion function increases the number of times of contact of the rotating brush with the metal foil surface (specifically, the number of rotations or the number of oscillating resin brushes), thereby improving the accuracy of removing the target scraps. Is obvious.

  Moreover, the roll forming method of the porous metal foil of the present invention includes a step of removing dust by pressurization and suction in a container close to a seal in consideration of dust collection efficiency in the middle of a transfer line after processing the metal foil. At that time, a rectangular brush is installed in a plane on the part of the container where the porous metal foil passes, and is continuously brought into contact with the movement of the porous metal foil, and dust is lifted off from the surface. It makes it easy to suck. Processing dust, dust, etc. removed by circulating a suction air fluid having a predetermined pressure in the container are collected by a dust collector.

  In the roll metal foil roll forming method of the present invention, fine dust other than relatively large waste generated by processing such as scraps is commercially available at a position immediately before winding the porous metal foil after processing. It is useful to arrange a dust removal roller having a dry cleaning function. By increasing the number of times of dust removal by the dust removal roller (the number of dust removal rollers arranged), the accuracy of removing the target fine dust is improved.

  An object of the roll metal foil roll forming method of the present invention is to develop and provide a novel ultrasonic / electric field etching unit as a unit used in a dust removal / deburring process after roll metal foil roll forming. This ultrasonic / electric field etching unit is not only used as a unit incorporated in the roll metal foil roll forming apparatus used in the method of the present invention, but also as a single apparatus for various metal foils or plates. It can be diverted as an effective deburring technique. That is, in the roll metal foil roll forming method of the present invention, a long metal foil wound in a coil shape is rewound, and the long metal foil is sandwiched between a forming roll and a receiving roll, and a large number of metal foils are placed on the metal foil. A roll metal foil roll forming method in which fine holes are formed, and the long metal foil formed after the fine hole forming is wound into a coil shape again. The forming roll has fine protrusions over the entire circumference of the roll surface. A large number of molds are formed, and the receiving roll is a roll made of an elastic surface pressed against the convex mold on the surface of the forming roll, and the long metal foil after micro-hole forming is wound into a coil again. In the middle of the porous metal foil transfer line before being formed, it is configured to remove the portion with the possibility of generating fine dust at the tip of the burr formed around the fine hole of the long metal foil by ultrasonic / electric field etching means, As a result, processing burr of metal foil after molding Those capable of fruit removed.

  In the roll metal foil roll forming method of the present invention, it is possible to finish the burr-like burrs generated by the processing to a thickness close to the foil thickness by a rolling function that is sandwiched between a pair of flat metal rolls.

  However, finishing to near foil thickness by the rolling function in this way causes a new problem. That is, both sides in the width direction of the porous metal foil are unprocessed, so there is no burr-like processing return, and the raw foil is thin. When such foil materials with different thicknesses are uniformly pressed and rolled with a rolling roll, elongation occurs in the direction of foil transfer. Because of the difference, in the case of a long coil material, the difference in the amount of elongation is accumulated and wrinkles are generated and appear as stripes rolled on the foil surface. The roll metal foil roll forming apparatus and the porous metal foil roll forming method of the present invention are intended to prevent such a phenomenon.

  Furthermore, in the roll metal foil roll forming method of the present invention, it is also possible to continuously trim both side portions which are unstable in terms of processing conditions after the metal foil roll is formed to improve the quality of the porous metal foil.

  A roll metal foil roll forming apparatus used in the method of the present invention unwinds a long metal foil wound in a coil shape, and sandwiches the long metal foil between a forming roll and a receiving roll to form a metal foil. A roll metal foil roll forming apparatus for forming a large number of fine holes and winding the porous long metal foil after forming the fine holes into a coil again. The forming roll has many fine convex shapes on the roll surface. The receiving roll is a roll made of an elastic body pressed against the forming roll, and a plurality of receiving rolls are provided along the flow of the metal foil.

  Furthermore, the porous metal foil roll forming apparatus used in the method of the present invention has elastic fibers on the surface in order to scrape off the processing waste on the downstream side in the rotational direction from the opposing pressure contact portion of the receiving roll with the forming roll. A scraping brush is provided.

  Furthermore, the porous metal foil roll forming apparatus used in the method of the present invention has a rotating brush having elastic fibers on the downstream side along the flow of the metal foil further than the plurality of receiving rolls, facing the forming roll. Provided.

  Further, in the porous metal foil roll forming apparatus used in the method of the present invention, the opposing pressure contact position between the first receiving roll and the forming roll provided on the upstream side along the flow of the metal foil is unrolled long. The opposing pressure contact position B between the second receiving roll and the forming roll provided in the vicinity of the position A where the metal foil starts to contact the forming roll and downstream of the first receiving roll along the flow of the metal foil is long. Near the middle position of the area where the metal foil is in contact with the forming roll, and the installation position of the rotating brush facing the forming roll is near the position C where the porous long metal foil after micropore forming begins to separate from the forming roll. is there.

  Furthermore, the porous metal foil roll forming apparatus used in the method of the present invention was generated by processing the metal foil in the middle of the metal foil transfer line before the long metal foil after microhole forming was wound again in a coil shape. In order to roll and finish the burr-like work return to a thickness close to the foil thickness, a rolling roll that rotates oppositely is provided.

  Furthermore, the porous metal foil roll forming apparatus used in the method of the present invention has a substantially sealed space part in the middle of the porous metal foil transfer line before the long metal foil after microhole forming is wound again in a coil shape. A unit for removing foreign matters such as processing waste, fine powder, and dust accompanying the porous metal foil by blowing or sucking compressed gas to the transfer porous metal foil is provided.

  As an example, the roll metal foil roll forming method of the present invention using the apparatus as described above rewinds a long metal foil wound in a coil shape, and uses the long metal foil to form a forming roll and a receiving roll. It is a roll metal foil roll forming method in which a large number of fine holes are formed in a metal foil by sandwiching them, and the long porous metal foil after the fine hole forming is wound into a coil shape again. A large number of fine convex molds are formed, and the receiving roll is a roll made of an elastic body pressed against the forming roll, and the receiving roll is substantially the same provided along the flow of the metal foil. It is composed of a first receiving roll and a second receiving roll having functions and performances, and even if half cut of the metal foil hole occurs in the first receiving roll, the second receiving roll that follows the metal foil Like to mold Characterized in that was.

  Furthermore, the roll metal foil roll forming method of the present invention is a metal foil processed by a rolling roll provided in the middle of the porous metal foil transfer line before the long metal foil after micropore forming is wound into a coil shape again. The burr-like processing return generated by the step is rolled to a thickness close to the foil thickness and finished.

  Furthermore, the present invention is also provided in a coiled porous metal foil. The coiled porous metal foil is rewound from a long metal foil wound in a coil shape, and the long metal foil is placed between a forming roll and a receiving roll. Is a coiled porous metal foil formed by forming a large number of fine holes in a metal foil and winding up the long porous metal foil after forming the fine holes again. A large number of molds are formed, and the receiving roll is a roll made of an elastic body pressed against the forming roll, and the receiving roll has substantially the same function and performance provided along the flow of the metal foil. The first receiving roll and the second receiving roll are provided, and even if a half cut of the metal foil hole occurs in the first receiving roll, the metal foil is molded by the subsequent second receiving roll. And fine hole forming After being rolled by a rolling roll provided in the middle of the porous metal foil transfer line before the long metal foil is coiled again, a substantially sealed space is provided, and the compressed gas is transferred to the transferred porous metal foil therein. By blowing or sucking, the foreign matter such as processing waste, fine powder, and dust accompanying the porous metal foil is removed, and the burr-like processing return generated by the processing of the metal foil by the rolling roll is close to the foil thickness. The coiled porous metal foil is flat and has foreign matters removed after being rolled and finished.

Here, a roll metal foil roll forming apparatus for realizing the porous metal foil roll forming method of the present invention will also be described. This roll forming apparatus for porous metal foil rewinds a long metal foil wound in a coil shape, and sandwiches the long metal foil between a forming roll and a receiving roll to form a large number of fine holes in the metal foil. It is a roll metal roll forming device for forming and winding the formed long metal foil after the microhole forming into a coil shape again,
The forming roll is formed with a number of fine convex shapes over the entire circumference of the circumferential roll surface, and the receiving roll is formed from an elastic body surface pressed against the convex shape of the forming roll surface. A roll of
The long metal foil is configured to be bitten and introduced at a biting position A and to be separated at a separation position C with respect to the convex mold on the surface of the forming roll, and from the biting position A to the separation position C. The molding region X is configured to occupy 180 degrees or more of the entire circumferential surface of the molding roll,
Thus, the long metal foil is configured to rotate with the forming roll while maintaining the state of being bitten with respect to the convex mold on the surface of the forming roll in the forming region X.

  Thereby, the long metal foil to be processed rotates together with the convex shape on the surface of the circumferential forming roll for a long time, thereby completely achieving the processing of the hole in the metal foil. Is possible.

  Furthermore, in the roll metal foil roll forming apparatus for realizing the porous metal foil roll forming method of the present invention, the convex mold formed on the surface of the molding roll forms a crater-shaped concave on the top.

  Thereby, it is possible to avoid that the punched chips are deformed by the crater-like recesses and buried in the elastic body surface of the receiving roll and adversely affect the next forming process.

  Furthermore, in the roll metal foil roll forming apparatus that realizes the roll metal foil roll forming method of the present invention, the receiving roll is disposed in the forming region X so as to face the convex mold on the surface of the forming roll, In addition, a plurality of stages are provided along the flow direction of the metal foil.

  Thereby, even if it is a process by one shaping | molding roll, a multi-stage shaping | molding process is attained and the problem of the extraction scraps by a half cut is eliminated.

  Further, in the roll metal foil roll forming apparatus for realizing the roll metal foil roll forming method of the present invention, the elastic body surface formed on the receiving roll is configured to have a strong and weak elastic distribution in the axial direction thereof, Elasticity distribution at a position corresponding to the axial position where the convex mold formed on the surface of the forming roll is arranged is weak, and elasticity at a position corresponding to the axial position where the convex mold is not arranged is strengthened It consists of

  In this way, the elastic body surface of the receiving roll forms a strong and weak elastic distribution in the axial direction, so that when punching holes, the corresponding part of the forming roll convex is soft and the periphery is hardened, It is possible to achieve an effect similar to that of pressing the material at the time of punching with the punching die.

  Furthermore, the roll metal foil roll forming apparatus for realizing the porous metal foil roll forming method of the present invention, in the forming region X on the downstream side in the rotational direction from the opposing pressure contact portion of the forming roll with the receiving roll, In order to scrape off the processing waste, a scraping brush having elastic fibers arranged on the surface is provided.

  As a result, it is possible to scrape as much as possible the processing waste that arrives at the molded metal foil that is transferred to the subsequent processing.

Furthermore, a roll metal foil roll forming apparatus that realizes the roll metal foil roll forming method of the present invention rewinds a long metal foil wound in a coil shape, and forms the long metal foil into a forming roll and a receiving roll. A metal foil roll forming apparatus for forming a large number of fine holes in a metal foil and winding the formed long metal foil into a coil again after forming the fine holes,
The forming roll is formed of a number of fine convex shapes over the entire circumference of the roll surface, and the receiving roll is a roll made of an elastic surface pressed against the convex shape of the forming roll surface. ,
In the middle of the porous metal foil transfer line before the long metal foil after the micro-hole forming is wound into a coil shape, the burr-like processing return generated by the processing of the metal foil is rolled to near the foil thickness. In order to finish, rolling rolls rotating opposite to each other are provided.

  Thereby, even if this metal foil is used as an electrical element for a secondary battery, it is possible to eliminate the adverse electrical or mechanical effects caused by burrs.

  Furthermore, the roll metal foil roll forming apparatus that realizes the roll metal foil roll forming method according to the present invention is in the middle of the porous metal foil transfer line before the long metal foil after the micro-hole forming is wound into a coil shape again. And before the rolling process by the said rolling roll, it comprises so that embossing may be given to the unprocessed both-sides edge part of the said metal foil.

  Thereby, during the rolling process in the porous metal foil transfer line, it is possible to eliminate the difference in elongation rate due to rolling in the width direction of the metal foil, and to suppress the generation of wrinkles on the side edges of the metal foil. It is.

Furthermore, a roll metal foil roll forming apparatus that realizes the roll metal foil roll forming method of the present invention rewinds a long metal foil wound in a coil shape, and forms the long metal foil into a forming roll and a receiving roll. A metal foil roll forming apparatus for forming a large number of fine holes in a metal foil and winding the formed long metal foil into a coil again after forming the fine holes,
The forming roll is formed of a number of fine convex shapes over the entire circumference of the roll surface, and the receiving roll is a roll made of an elastic surface pressed against the convex shape of the forming roll surface. ,
Possibility of generation of fine dust at the tip of burrs formed around the microholes of the long metal foil in the middle of the porous metal foil transfer line before the long metal foil after forming the microholes is wound up again in a coil shape Some portions are provided with ultrasonic / electric field etching means.

  Thereby, the fine dust from the processing burr | flash of the metal foil after shaping | molding can be removed effectively.

  Hereinafter, embodiments of the present invention will be described more specifically with reference to the drawings. First, roll forming of the porous metal foil of the present invention will be described in detail with reference to the entire drawing. A porous metal foil roll forming apparatus for realizing the method of the present invention is a device for geometrically squeezing and arranging a large number of micropores in a metal foil as a current collector for an electrode of an electronic component such as a secondary battery. For example, as shown in FIG. 1, a metal molding in which a number of fine projections (embosses) 11 (300 to 600 μmφ) formed by machining techniques or the like are geometrically arranged at regular intervals. A fine hole is formed in the metal foil 20 such as aluminum or copper by the roll 10 and a receiving roll 30 made of an elastic body (for example, synthetic rubber) on the outer peripheral surface that rotates in synchronization with the roll 10. At this time, the receiving roll 30 made of a surface elastic body (for example, synthetic rubber) is pressed and rolled against the metal forming roll 10 with a predetermined pressing force.

  As a result, fine holes are formed in the metal foil 20, and at this time, scraps 21 having a thickness of 300 to 600 μmφ and a thickness of 10 to 100 μm are generated. Most of the scraps 21 are separated from the metal foil 20 and are transferred (attached or buried) with the rubber roll as the receiving roll 30, but a part is accompanied by the metal foil 20. The scraps 21 accompanying the metal foil 20 are scraped off by the brush roll 50 arranged on the downstream side of the receiving roll 30. The rotation direction of the brush roll 50 is preferably a direction opposite to the transfer direction of the metal foil 20, but may be rotated in the same direction.

  In this way, the scrap 21 and the fine metal powder are separated from the metal foil 20 by the receiving roll 30 whose surface is a rubber roll, and the scrap 21 and the like accompanying the metal foil 20 without being completely separated (FIG. 9 ( B) can improve the scraping effect by additionally arranging a biaxial motor driving mechanism 501 and the like on the circumference of the forming roll 10 (see FIG. 8). As shown in FIG. 8, in the biaxial motor drive mechanism 501, the rotation operation of the brush roll 50 is achieved by the high-speed rotation motor 502. In addition, the entire biaxial motor drive mechanism 501 is swung at high speed in the axial direction of the forming roll 10 by the rotation motor 503 and the cam 504. By this rotation operation and high-speed movement / oscillation operation, the force for omnidirectional removal is also applied to the scraps 21 sandwiched in the hole after processing, and the removal function of the processing scraps 21 is enhanced. It can be expected.

  Further, although peeled off and separated from the metal foil 20, it adheres to the fine protrusions (emboss) 11 as the convex shape of the forming roll 10, and is accompanied by the convex shape 11 of the forming roll 10 and the like even if the separation position C is exceeded. In order to remove dust and the like, dust is directly scraped off from the surface of the forming roll 10 by providing a brush roll 56 that is disposed on the upstream side in the rotational direction from the introduction portion of the metal foil 20 of the forming roll 10. be able to. The dust or the like accompanying the convex mold 11 of the forming roll 10 beyond the separation position C has a very great adverse effect upon the subsequent forming of the metal foil 20 that is newly supplied and bitten into the forming roll 10. Must be removed.

  Further, as will be described later, in the entire configuration of the porous metal foil roll forming apparatus that realizes the method of the present invention, the pressure and suction with the brush are performed during the movement of the foil to the winding portion of the porous metal foil after forming. The container and the dust removal roll with a dry cleaning function are used to obtain a coiled porous metal foil by winding it as a current collector having fine pores of a regular array in a wide range without any metal piece or metal powder. .

  With respect to more detailed examples, a porous metal foil roll forming apparatus that realizes the method of the present invention will be sequentially described with reference to the accompanying drawings. The porous metal foil roll forming apparatus as the first embodiment is shown in detail in FIG. 1 at a forming portion by the forming roll 10 and the receiving roll 30, and FIG. 2 shows the overall apparatus configuration.

  In the first embodiment shown in FIG. 1, the first and second receiving rolls 30 and 40 are rolled by rotating the metal foil 20 with respect to the forming roll 10 having an outer diameter of 100 to 500 mmφ. is there. At this time, the long metal foil 20 is configured to be introduced into the convex mold 11 on the surface of the forming roll 10 at the engagement position A and to be separated at the separation position C. And the shaping | molding process area | region X from the biting position A to the separation | spacing position C is comprised so that 180 degree | times or more may be occupied in the forming roll surface perimeter area. Thereby, the long metal foil 20 is configured to rotate together with the forming roll 10 while maintaining the state of being bitten with respect to the convex mold 11 on the surface of the forming roll 10 in the forming region X. The long metal foil 20 to be processed rotates together with the convex mold 11 on the surface of the circumferential forming roll 10 for a long time, thereby completely forming the hole in the metal foil 20. It is possible to do. That is, conventionally, the metal foil is perforated in the forming process by the sandwiching operation in one short time between the roll mold and the receiving roll, thereby solving the problem of half cut. This is one of the basic technical ideas of the present invention.

  Further, as described above, another basic technical idea of the present invention is that a plurality of receiving rolls 30 and 40 are provided to face the forming roll 10. This also solves the problem of half-cut due to the forming process by the conventional metal foil being sandwiched once between the roll mold and the receiving roll. The first and second receiving rolls 30 and 40 roll while being pressed against the forming roll 10 with a predetermined pressure. Around the forming roll 10, a brush roll 50 having a wire length of 16 mm and a resin wire having an outer diameter of 80 mmφ and 0.25 φmm is disposed on the downstream side of the flow of the metal foil 20. At this time, the brush roll 50 is rotated (opposite to the rotation direction of the forming roll 10) by the high-speed rotation motor 502 (FIG. 8) in opposition to the movement direction of the metal foil 20 to be processed, and the rotation motor 503 and By the cam 504, the whole is swung at high speed in the axial direction of the forming roll 10, and the scraps 21 accompanying the metal foil 20 are removed from the metal foil 20.

  Furthermore, the outline of all the processes from the delivery of the metal foil 20 to the winding of the porous metal foil roll forming apparatus for realizing the method of the present invention will be described with reference to FIG. In this entire process, in the roll forming process of the metal foil 20 or the like of the reel-shaped material including the contents described in the above embodiments, the processing waste and dust remain on the reel-shaped porous metal foil 26 wound as a product. A porous metal foil roll forming apparatus and a roll metal foil roll forming method are proposed.

  Since the forming roll units 10, 30, 40 and the scrap removal unit 50 in all the steps of the porous metal foil roll forming apparatus shown in FIG. 2 have the same configuration as that of each embodiment, detailed description thereof will not be given here. . In the perforated metal foil roll forming apparatus of FIG. 2, the long metal foil 20 is fed out from the reel-shaped metal foil 25 in the direction of the arrow, and is sandwiched between the forming roll 10 and the first receiving roll 30 by the introduction roll 31. Micropores are formed by the convex cutting edge mold 11 (not shown in FIG. 2) on the surface of the forming roll 10. The scraps 21 are once captured in the rubber on the surface of the first receiving roll 30, and then peeled and separated from the metal foil 20 after forming the micro holes by the rotation of the first receiving roll 30. The scraps 21 adhering to the rubber on the surface of the first receiving roll 30 are wiped off by the brush-off brush rolls 39, 39 provided downstream.

  The forming process of the metal foil 20 to be processed is performed such that the metal foil 20 to be processed having a width of 260 mm is rewound from the feed roller 25 and transferred in the direction of the arrow, and is sandwiched between the forming roll 10 and the receiving roll 30. By being sandwiched in the vicinity and pressed with a predetermined pressure 8 (15 Mpa), the fine convex cutting edge mold (emboss) 11 on the forming roll 10 comes into contact with the surface of the metal foil 20, and the receiving roll 30. When the resistance within the elastic limit of the elasticity of the rubber surpasses the breaking force of the metal foil 20 to be processed, micro-hole processing is performed. Immediately after, the resistance disappears instantaneously, and the convex 11 of the forming roll 10 is pressed. The elastic rubber on the surface of the receiving roll 30 that has been elastically deformed returns to its original shape, and the scraps 21 are left on the receiving roll 30. The scraps 21 left on the receiving roll 30 are removed from the receiving roll 30 by the rotating brushes 39 and 39. Moreover, the processing waste etc. accompanying the metal foil 20 after shaping | molding are removed from the metal foil 20 with the brush roll 50. FIG. Thereafter, the formed metal foil 20 is rolled by a rolling unit 80 so that “burr” as a processing burr generated in the metal foil 20 by the punching process is brought to a level close to the original foil thickness before the roll forming process. ing. Furthermore, at the subsequent stage, immediately before winding of the processed finished foil, an air dust removing unit 90 and a dust removing roller unit 100 with a cleaning function are provided for the purpose of eliminating the fine dust that comes with the metal foil 20 by any chance. .

  Further, in the roll metal foil roll forming apparatus (FIG. 3) improved as a more practical apparatus, the metal foil 20 to be processed unwound from the feed roller 25 passes through several tension rolls (not indicated). While being rewound and transported in the direction of the arrow, it is sandwiched in the vicinity of the sandwiching position A (not indicated in FIG. 3) between the molding roll 10 and the receiving roll 30 and pressed with a predetermined pressure, thereby forming the molding. The fine convex shape on the roll 10 is brought into contact with the surface of the metal foil 20 and fine hole processing is performed. The scraps 21 left on the receiving roll 30 are removed from the receiving roll 30 by the rotating brushes 39 and 39. Moreover, the processing waste etc. which accompany the metal foil 20 after shaping | molding are removed from the metal foil 20 with the 4-unit brush roll 51,52,53,54. Thereafter, the formed metal foil 20 is rolled by the primary rolling unit 80 with the processing burr generated in the metal foil 20 by the punching process. Further, an air dust removing unit 90 is provided at the subsequent stage for the purpose of eliminating punching fine powder accompanying the metal foil 20.

  Further, a slitter unit 110 (described later) is provided at a subsequent stage by circular upper and lower slitter blades that slit unprocessed portions of both edge portions of the metal foil 20. Next, a No1 cleaning roll unit 100 with a cleaning function having an adhesive sheet on the surface is provided through a step roll (no symbol), and the processing fine powder still accompanying the metal foil 20 is removed. Further, a secondary rolling unit 88 is provided at the subsequent stage of the No1 cleaning roll unit 100. The metal foil 20 transferred by the secondary rolling unit 88 rolls “burr” as a processing burr generated by the punching process so that the foil thickness is close to the original foil thickness before the roll forming process. . In the secondary rolling unit 88, a cleaning roll (not indicated) having adhesiveness is disposed opposite to a pair of rolling rolls.

  No1 and No2 with a cleaning function having adhesiveness in the subsequent stage in order to eliminate punching fine powder that accompanies the metal foil 20 just before winding of the processed finished foil even after each of the above means. The cleaning roll units 100 and 100 are provided, and then the metal foil 20 in which the edge position of the metal foil 20 is controlled by the edge position control device (EPC) 120 to completely remove dust is taken up by the winding roll 26. The product is rolled up to complete the product.

  The outer peripheral surface of the elastic receiving roll 30 used in the present invention is configured as shown in FIG. That is, the receiving roll 30 includes an inner metal receiving roll core 32 and an outer peripheral roll 33 of an elastic body (for example, synthetic rubber) on the outer peripheral surface.

The appropriate value of the pressure between the convex (embossed) 11 of the forming roll 10 and the receiving roll 30 slightly changes depending on the thickness and width of the material 20 to be processed, the arrangement of the geometric holes, etc. Table 1 shows one optimal example.

  When the metal foil 20 to be processed is sandwiched between the forming rolls 10 at the sandwiching position A and the forming process is started, the metal mold 20 is pressed and punched by the fine mold 11 with respect to the forming roll 10 thereafter. In other words, basically, all the fine holes are inclined at the height h1 (0.1 to 0.4 mm) of the convex part top diameter d1 (0.3 to 1.0 mmφ) of the forming roll 10. It is transferred to the vicinity of the separation position C in a state where the convex shape (emboss) 11 of a convex fine cutting edge having an angle α1 (10 ° to 45 °) is inserted. Thereafter, the direction-changing rollers 60 and 66 having a diameter of about 30 mmφ are arranged to direct the direction toward the most downstream winding roller 26. Thereby, in the forming region X from the sandwiching position A to immediately before the separation position C, the metal foil 20 continues to be pressed / perforated with respect to the forming roll 10 for a long time. Become.

  In the forming region X in the state of pressurization and hole processing from the sandwiching position A of the metal foil 20 to the position just before the separation position C, the metal foil 20 to be processed has a pressure of 15 MPa after finishing the forming process by the receiving roll 30. It passes between the forming roll 10 and the second receiving roll 40 with the applied pressure. At that time, the pressing force is applied again to the metal foil 20 to be processed, and the same micro-hole processing as in the first processing is performed, so that the half-cut (incomplete punching) portion is made a through-hole state. be able to.

  The installation range of the first receiving roll 30 and the second receiving roll 40 provided facing the forming roll 10 is within a forming region X (180 ° to 270 °) from the vicinity of the sandwiching position A to the vicinity of the separation position C. Thus, it can be set as appropriate within a range of about 90 ° to 180 ° from the vicinity of the sandwiching position A to the vicinity of the second forming position B. In the present invention, as explained so far, a long-time molding process state is maintained, and a plurality of processing operations are achieved by a plurality of receiving rolls facing a plurality of molding rolls 10 and half-cut (incomplete Therefore, it is possible to install third and subsequent receiving rolls (not shown) on the downstream side along the circumference of the forming roll 10. For this purpose, it is necessary to take a wide molding region from the vicinity of the sandwiching position A to the vicinity of the separation position C. By doing this, or by increasing the outer diameter of the forming roll 10 as much as possible, the arrangement position and quantity of the receiving rolls increase, and the purpose of eliminating the half-cut (incomplete punching) as much as possible is achieved. Correspondence becomes possible.

  Here, in order to consider the problem of half-cut (incomplete punching), the “sharpness” will be considered in comparison with the roll forming and die-cutting techniques of the present invention. In the case of punching with a general mold, machining is realized by reciprocating a punch (convex type corresponding to the fine protrusion (emboss) of the present invention) against a die (concave type corresponding to the receiving roll of the present invention). At this time, the material around the die and the punch is pressed by the material presser, and the material punched by the punch enters the die. Then, the material that has entered the die is discharged out of the die by a knockout pin or the like in the punch raising process to complete the processing. The concept of processing accuracy in this case is based on the premise that both the die and the punch are made of a rigid and non-deformable material.

  Here, when the roll forming of the present invention is compared with punching using a general mold, in the case of the roll forming of the present invention, the elastic body on the surface of the receiving roll 30 that is a concave mold (in FIG. It is clear that it is advantageous for “sharpness” to make the hardness of the portion where the fine projection (emboss) 11 that is convex with respect to the roll 33) enters is softer than the hardness of the peripheral portion. However, in the configuration of the receiving roll 30 shown in FIG. 4A, since the elastic body has a uniform thickness with respect to the entire width of the receiving roll, it is theoretically considered to have a uniform hardness. If this is taken as an example of a thorough process using a mold, this corresponds to the fact that the die is deformed, and complete punching cannot be guaranteed.

  Therefore, in the present invention, as shown in FIG. 4B, a predetermined uneven shape 34 is formed on the outer peripheral surface side of the receiving roll mandrel 32 at a position opposite to the convex fine protrusion (emboss) 11. Thus, a soft portion a (corresponding to the hollow portion at the center of the die in general punching) and a hard portion b (corresponding to the material pressing portion in general punching) are formed of the outer peripheral roll 33 of the elastic body. (See FIG. 3D). In the configuration of the receiving roll 30 in FIG. 4B, the thickness and hardness of the elastic body are generally inversely proportional to each other and correspond to the position of the fine protrusion (emboss) 11 that is the convex shape of the present invention. Thus, by arranging the thick part a, molding close to punching with a mold is possible (see FIG. 4C). In this case, the rising angle α of the concavo-convex shape 34 is possible, but the one without the rising angle (the rising angle is 90 degrees) is effective. The reason is that the concave edge portion of the receiving roll mandrel 32 and the edge portion of the fine protrusion (emboss) 11 fulfill the blade function. The uneven shape 34 is configured by forming a circumferentially protruding peak row on the outer peripheral surface of the roll core 32.

  Next, countermeasures for “residual debris” buried on the receiving roll 30 after the metal foil 20 is formed will be described. As shown in FIGS. 1 and 2, the scraps 21 attached to the elastic body 33 on the surface of the receiving roll 30 are wiped off by the brush-off brush rolls 39, 39 provided downstream. However, if this scrap 21 is buried in the elastic body 33 on the surface of the receiving roll 30 and becomes “residual scrap”, it has an adverse effect on the next forming step, and the characteristics as a metal foil cannot be maintained. Is.

  Thus, by forcibly scraping off dust adhering to and adhering to the surface of the forming roll 30, it cannot be said that it is complete only by taking measures against “residual debris”. Therefore, in the present invention, a method for easily removing “residual waste” is considered. The idea devised for this purpose is to form a concave portion of a predetermined pattern on the top of the convex fine protrusion (emboss) 11 of the forming roll 10.

  This will be described with reference to FIG. Forming a concave portion having a predetermined pattern on the top of the convex fine protrusion (emboss) 11 of the forming roll 10 has the purposes of (1) improving sharpness and (2) improving chip removability.

  First, in order to improve the sharpness, when the convex fine protrusions (embosses) 11 act on the metal foil 20 as a rotary blade, the metal foil 20 is cut into the blade as shown in the left and right views of FIG. If it is improved so that no slip phenomenon occurs in the meantime, the sharpness is improved. For this purpose, a recess 35 is formed on the top of the fine protrusion (emboss) 11 (the right view in FIG. 5A). Accordingly, as shown in the lower right part of FIG. 5C, the edge portion of the fine protrusion (emboss) 11 sharply cuts into the metal foil 20. And the improvement of sharpness can be achieved in combination with the convex shape 34 on the outer peripheral surface side of the receiving roll mandrel 32 shown in FIG.

  Next, with regard to the improvement in chip removability, as shown in the right diagram of FIG. 5D, in the case where the top of the emboss is flat shown in the left diagram of FIG. There is no guarantee that there will be no danger of completely entering the elastic body 33 of the receiving roll 30 and becoming buried chips 21 'that cannot be removed. As in the present invention, as a metal foil used as a collector electrode foil used in batteries, capacitors, etc. as electric energy sources for electric vehicles and home appliances, even the possibility of extremely small residual chips is large. May be a problem. Therefore, it has been considered that the shape of the buried chips 21 ′ can be surely removed by the rotating brushes 39 and 39.

  That is, as shown in the right figure of FIG. 5A, the concave portion 35 is formed on the top of the convex fine protrusion (emboss) 11 (see the upper right figure in FIG. 5B), thereby being molded. As shown in the lower right part of FIG. 5B, the chip 21 is formed with a convex part (not shown) corresponding to the concave part 35 at the top of the fine protrusion (emboss) 11 (FIG. 5B right figure). under). As a result, when the emboss top is flat, the chips 21 become buried chips 21 ′, which may be difficult to be removed by the rotating brushes 39, 39. Even if the convex portion is formed on the chip 21 and becomes the embedded chip 21 ′ on the receiving roll 30, reliable removal is possible. In the embodiment of the present invention, the rotating brushes 39 are used, but the object can also be achieved by providing a scraper (not shown in detail) consisting of one or more blades. Of course, a scraper and a rotating brush can be used in combination. Thus, the basis of reliable and stable drilling is that no residual chips exist on the surface of the receiving roll 30. Here, the rough dimension of the convex fine protrusion (emboss) 11 having the concave portion 35 formed on the top is such that the height h2 of the convex die 11 is 0.1 to 0.4 mm, and the depth h3 of the concave portion 35 is 0.1. It is preferable that the diameter d2 of the top surface of the convex mold 11 is 0.3 to 1.0 mm and the diameter d3 of the concave portion 35 is 0.2 to 0.8 mm.

  Next, in the second embodiment shown in FIG. 6, the first brush roll 50, the second brush roll 55, and the third pay-off are further downstream of the first receiving roll 30 and the second receiving roll 40. A brush roll 56 is provided.

  The brush rolls 50 and 55 and the brush-off brush roll 56 applied to the metal foil roll forming apparatus that realizes the method of the present invention have substantially the same structure. The brush rolls 50 and 55 and the brush-off brush roll 56 are resin-made conductive and elastic brushes, and are excluded by being pinched and fixed between burrs having a very small height when drilling. It has a hardness and a compactness effective for eliminating difficult residual scraps 21. The dimensions of these brush rolls 50 and 55 may be set arbitrarily depending on the relationship with the installation space. However, effective hardness and compactness are required to remove the scrap 21 remaining in the processing hole. The material of the brush rolls 50 and 55 of this embodiment is mainly carbon fiber, and nylon fiber can be used in combination as required. The rotation direction of the brush rolls 50 and 55 of the present embodiment is the direction opposite to the direction of rotational movement of the metal foil 20 to be processed, the rotation speed is around 800 rpm, and the roll mold rotation speed is 8 to 10 rpm. It is. Further, in order to eliminate dust and the like adhering to the fine protrusions (embosses) 11 of the forming roll 10, a brush brush 56 is provided on the upstream side in the rotational direction from the introduction portion of the metal foil 20 of the forming roll 10. The dust can be directly scraped off from the convex fine protrusions (embosses) 11 of the forming roll 10. In this case, as a matter of course, it is necessary to remove dust by a suction device (not shown) or the like so that the removed chips 21 do not fall on the newly supplied metal foil 20.

  Further, in the third embodiment of the metal foil roll forming apparatus for realizing the method of the present invention, as shown in FIG. 7, a plurality of brush rolls 51, 52, 53, 54 (quadruple brush rolls) should be selected as much as possible within the range permitted by various conditions such as the outer diameter of the forming roll 10 and the installation space, roll forming mold production, etc. It is possible to increase the number of brush rolls that rotate and swing. As a result, it is possible to eliminate the difficult-to-remove residual scrap 21 that is sandwiched and fixed between “burrs” having a small burr shape after molding. Further, in order to eliminate dust and the like adhering to the convex fine protrusions (embosses) 11 of the forming roll 10, as in the second embodiment, the rotational direction is higher than the introduction portion of the metal foil 20 of the forming roll 10. By providing the brush-off brush roll 56 on the upstream side, dust can be directly scraped off from the fine protrusions (embosses) 11 of the forming roll 10.

  Next, the invention of the metal foil roll forming method of the present invention will be described mainly with reference to FIG. In the metal foil roll forming method of the present invention, the convex cutting edge mold (emboss) 11 on the surface of the forming roll 10 moves and moves in the direction of movement of the metal foil 20 in order to perform processing in the trajectory of the forming roll 10 rotating. In synchronization with the speed, the metal foil 20 approaches while moving in the rotational direction of the forming roll 10. The metal foil 20 to be processed is sandwiched in the vicinity of the sandwiching position A by the convex cutting edge mold (emboss) 11 on the surface of the forming roll 10 and the receiving roll 30. The rubber on the surface of the receiving roll 30 starts to be deformed by the pressing force from the convex cutting die (emboss) 11 on the surface of the forming roll 10 and starts to cut the sandwiched metal foil 20. As the forming roll 10 advances, the convex cutting edge mold (emboss) 11 on the surface of the forming roll 10 enters the rubber on the surface of the receiving roll 30, and the convex cutting edge mold 11 approaches the end of the deformation. Accordingly, the scrap 21 is cut from the metal foil 20 to be processed, and the scrap 21 is left in the rubber on the surface of the receiving roll 30 and separated from the metal foil 20 (FIG. 8A).

  However, since the surface rubber pressure of the receiving roll 30 which is a cutting reaction force with respect to the convex cutting edge mold (emboss) 11 is unstable, the formation of the punched hole 22 tends to be incompletely processed. Therefore, in the metal foil roll forming method of the present invention, a wide forming region X from the vicinity of the sandwiching position A to the vicinity of the separation position C is taken on the circumference of the forming roll 10, and the metal is placed on the forming roll 10 in the region X. The foil 20 is wound for a long time, and the plurality of receiving rolls 30 and 40 meanwhile the metal foil 20 is reliably in contact at the maximum rubber deformation position (maximum reaction force position) on the receiving roll surface. It becomes possible.

  Furthermore, in the present invention, incomplete machining that is expected to occur due to the above-described instability of the reaction force only by the rotation of the plurality of receiving rolls 30 and 40 facing each other, that is, half-cut or burr-like minute height “ Since it may be difficult to eliminate the scraps 21 (FIG. 9B) sandwiched and fixed between “burrs”, measures are also taken. That is, as shown in FIG. 8 described above, a two-axis drive mechanism is employed in which the rotating brush roll 50 is swung in the axial direction at a stroke length of 2 mm at 100 spm.

  In this way, in the metal foil roll forming method of the present invention, the removal operation of the residual debris 21 and the like which are sandwiched and fixed between the burrs having a minute height after forming is difficult to achieve is achieved. Is done. This removal operation is performed in an atmosphere in which air with a static pressure of 2.5 Kpa is sucked in the enclosed space. Although not shown in detail in these configurations, each brush roll 50 is covered by covering the molding processing region X from the vicinity of the sandwiching position A to the vicinity of the separation position C with a surrounded space and sucking air in the space. The extracted dust and fine powder soared in the space surrounded by etc. are securely stored by a dust collector (not shown).

  In this way, in the present invention, after the first molding processing operation between the forming roll 10 and the first receiving roll 30, the metal foil 20 is rotated while being wound around the forming roll 10 for a long time. Then, the second receiving roll 40 receives the second forming process operation. Here, incompletely processed parts that are not completely removed by the first molding process operation, that is, half cuts, scraps 21 and the like that are sandwiched and fixed between “burrs” having a minute height of burrs, etc. The second molding process is completely processed. Also in the second molding operation region, the scrap 21 extracted from the metal foil 20 adheres to the rubber on the surface of the second receiving roll 40 and is wiped off by the brushing brush roll 49 provided downstream.

  Also by the above, the scraps 21 and dust accompanying the metal foil 20 after the forming process are removed by the scrap removing unit 50. The metal foil 20 from which the scraps 21, dusts, and the like have been removed is changed in direction by the lead-out rolls 60 and 66 after exiting the forming process region, and is generated in the metal foil 20 by the punching process at the horizontal movement position after the direction change. The “burr” as the processing burr is rolled by the rolling unit 80 to bring the foil thickness to a level close to the original foil thickness before the roll forming process.

  10, this rolling unit 80 is provided with a pair of 80 mmφ metal rolls 81 and 82 at the top and bottom, 120 mmφ reinforcing rollers 83 and 84 as backups, and guide rolls 85 and 86 on both sides thereof. It is arranged. The guide rolls 85 and 86 arranged on both sides are commonly called “zebra rolls” and have a function of spreading the metal foil 20 in the width direction. In addition, about pressurization, the thickness after pressurization is managed by giving a roll structure sufficient intensity | strength and controlling the clearance gap between rolls. Further, the lower roll 82 of 80 mmφ is rotated in synchronization with the winding speed of the metal foil 20 by a motor (not shown) to feed the foil. When deformation of the upper and lower rolls 81 and 82 cannot be ignored due to conditions such as the thickness of the metal foil 20 to be processed, it is effective to install the reinforcing rolls 83 and 84.

  Thus, it is possible to roll the “burr” as a processing burr generated in the metal foil 20 by the punching process with the rolling unit 80 so that the thickness of the foil is close to the original foil thickness before the roll forming process. There is one new problem that may occur here. This will be described with reference to FIG.

  For example, when a hole is formed in the metal foil 20 using an apparatus that implements the method of the present invention, a processing burr as shown in the left and right views of FIG. However, in each figure of FIG. 12, the burr is drawn with emphasis for ease of understanding. In the subsequent process, the metal foil 20 in which the processing burr is generated is rolled by the rolling unit 80 on the “burr” as the processing burr c remaining on the back surface of the formed punching hole 22, so The thickness is approximately equal to the thickness of. At this time, the amount of elongation at the time of rolling differs between the processed portion a (porous forming processed portion) of the metal foil 20 and the unprocessed portion b (both edges of the foil). For this reason, as shown in the left figure of FIG. 12 (B), many wrinkles d may generate | occur | produce in the metal foil 20 after rolling. This is because when foil materials having different thicknesses (thickness of processed part a = t2, thickness of unprocessed part b = t1, t2> t1) are uniformly pressed and rolled by a rolling roll 80, the foil material extends in the direction of movement of the foil. Since the unprocessed portion b (thickness t1) and the processed portion a (thickness t2) have different elongations, wrinkles d occur frequently in the long continuous processing, and the streaks rolled on the foil surface It appears. Such a phenomenon is theoretically clear and is an unavoidable problem in processing a metal foil with a small rolling amount in the rolling process.

  Therefore, in the present invention, as shown in the left drawing of FIG. 12C, the embossed portion that does not penetrate the unprocessed portion b at the same time as the through-hole processing of the punched hole 22 is performed on the processed portion a of the metal foil 20. e is processed in the same pattern. The height (t3) of the embossed portion e is substantially equal to or slightly lower than the height (t2) of the burrs c in the hole processing, as shown in the right figure of FIG. 12C (t3 ≦ t2). Is desirable. Thereby, it is possible to prevent the occurrence of wrinkles after rolling by making the elongation ratios of both in roll processing as equal as possible. An example of a specific shape of the embossed portion e is shown in the left and right views of FIG. The left figure of FIG. 12 (D) is a bowl-shaped embossing, and the right figure of FIG. 12 (D) shows an example in which a “ki” -shaped embossing is formed.

  Such an embossing processing method can be realized by rounding the edge of the blade portion of the convex fine protrusion (emboss) 11 of the same forming roll 10 or by providing a protrusion of another shape, and the end of the receiving roll 30. This can also be realized by step processing in the vicinity of the part, that is, by making the diameter of the receiving roll 30 in the vicinity of the end part smaller than the diameter of the hole processing part in the central part. Here, it is important to adjust so that t3≈t2 or t3 ≦ t2 by any means.

  In the embodiment of the present invention, it is also possible to actively provide a new dust removal cleaning / deburring unit. The new dust removal cleaning / deburring unit is an ultrasonic wave / electric field etching means 150, and its details are shown in FIG. This ultrasonic / electric field etching means 150 is not only used for deburring the porous metal foil 20 of the present invention, but is also generally used for deburring a plate-like / web-like material that is continuously supplied. Diversion to slitter deburring means is also possible.

  The ultrasonic / electric field etching means 150 is provided with an ultrasonic cleaning tank 151 provided with an ultrasonic oscillator 160 inside, and by utilizing the characteristic that electric charges and ultrasonic waves concentrate on the convex portion, the present porous metal It has a function of facing and conveying the processing return surface of the foil to the ultrasonic oscillator 160. In this ultrasonic cleaning tank 151, cleaning water 152 is put up to the liquid level 153, and this cleaning water 152 is circulated. The circulating wash water 152 is reduced in pressure while passing through a filter (not shown) made of a hollow fiber membrane, and the air in the wash water is removed (degassed) to eliminate the air braking effect. The metal foil 20 to be treated is fed by the electrode roller 155 toward the periphery of the rotating drum 154 and separated by the nipple roll 156. Meanwhile, the metal foil 20 contacts the periphery of the rotating drum 154 and is simultaneously rotated. Electrode pieces 159 are arranged in the vicinity of the periphery of the rotating drum 154 at a slight distance, and electrode members 157 and 158 are provided at both ends thereof. The electrode members 157 and 158 and the rotary drum 154 are configured such that their installation heights can be adjusted (detailed configurations are not shown).

  With such a configuration, the ultrasonic / electric field etching means 150 generates an electric field between the electrode piece 159 around the rotating drum 154 (energization of the metal foil 20 by the electrode roller 155), and an ultrasonic oscillator is generated there. The ultrasonic wave oscillated by 160 is applied to perform deburring by metal fatigue, but the vibration effect on the burrs is enhanced by enhancing the force of generating and collapsing vacuum cavities in the cavitation of cleaning water 152 by ultrasonic waves. It is what raises.

  The metal foil 20 drawn from the rotary drum 154 by the nipple roll 156 is dried by the hot air drying chamber 165. It is appropriate that the ultrasonic / electric field etching means 150 is provided in front of the second rolling means in a state where there is a convex shape after processing as a system of an actual roll forming apparatus for porous metal foil. This is arranged at the position of the arrow A in the system configuration diagram of FIG. Furthermore, as another aspect, it is also possible to arrange at the position of the arrow B in the system configuration diagram of FIG. 3, that is, before the ear end position control device (EPC) 120, which is just before winding the processed metal foil. is there.

  In the system of the metal foil roll forming apparatus showing the overall configuration for realizing the method of the present invention in FIG. 2, it is possible to eliminate the punching fine powder that accompanies the metal foil 20 just before winding the finished processed foil. For the purpose, an air dust removing unit 90 and a dust removing roller unit 100 with a cleaning function are provided. In the system of the metal foil roll forming apparatus shown in FIG. 3, the air dust removal unit 90 is provided immediately after the rolling process by the first rolling roll 80.

As shown in FIGS. 11 (A) and (B), the air dust removing unit 90 is ideally adapted to the air pitch adjusted to the hole pitch (FIG. 11 (C)) after the metal foil 20 is formed as much as possible. The metal foil 20 after fine hole processing is formed between the plate 124 having the ejection holes 121, 121, 121... And the plate 125 having the air suction holes 122, 122, 122. Is a unit that moves. In addition, a soft brush 123 surrounded by a rectangle is disposed at a position where the metal foil 20 moves on the plate so as to come into contact with the foil surface, and has a function of peeling the fine powder from the surface of the metal foil 20. The fine powder is exfoliated and fluttered up so that air can be collected. The jet air pressure is ² to 3 kg / cm ² , and the suction is 2.5 Kpa at the dust collector static pressure. The necessary number of air passage holes for dust removal are provided in the upper and lower plates having an area of 100 mm wide by 100 mm long diagonal holes having a width of 1 mm.

  As described above, according to the method for forming a perforated metal foil of the present invention that excludes processing waste, fine powder, and dust, the hole of the metal foil is formed by pressing a simple mold against the elastic body. In addition, it is easy to control costs and is a continuous forming method because it is a roll molding method. Furthermore, it is fine for fine hole processing to thin foil, which is a trend of current collector electrode application using the metal foil in the future. The convex metal mold makes it possible to provide the market with an ideal metal foil that is stable and highly productive, does not contain processing dust, fine powder, and dust, and has a reduced thickness of processing dust.

  Accordingly, the present invention allows a metal foil having a thickness of 50 μm or less to be elongated with a metal forming roll having a fine convex shape formed on the surface thereof and a receiving roll made of an elastic body facing the metal foil. It is a roll forming system that performs continuous processing such as drilling on metal foil. At the same time, one or more processing scraps and fine powders embedded in the elastic body of the first receiving roll immediately after processing are operated by a plurality of elastic fiber brush rolls rotating at high speed and in the direction of rotation of the forming roll. The second and third receiving rolls (having the same function and performance as the first receiving roll) are disposed, and the metal foil is fitted on the convex portion of the forming roll and is mechanically stable. While being transferred, the processing waste and the like are removed by the high-speed rotation operation of the plurality of elastic fiber brush rolls. In addition, an adhesive rubber roller that has its own cleaning function or an ultrasonic / electric field etching unit is placed immediately before winding of the metal foil to cope with half-cutting and to eliminate processing dust, foil surface adhering fine powder and dust. A roll forming system is provided. As a result, processing waste, foil surface adhering fine powder, and dust that are unavoidable due to vibrations in processing equipment in the apparatus, accumulation of assembly tolerances, and the like are to be eliminated.

  As mentioned above, in the case of punching with a general mold, as a general theory, it is possible to perform precision processing and to improve the sharpness by suppressing the escape during processing of the material as much as possible. Become. On the other hand, in the case of processing by the forming roll of the present invention, as shown in FIG. 14 (A), the vicinity of the central portion a of the forming roll 10 is the contact between the elastic body outer peripheral roll 33 of the receiving roll 30 and the metal foil 20. Although all the surfaces have a material pressing function, there is no member to be pressed in the vicinity of the end face b of the forming roll 10, and the hole machining becomes an unstable portion L. Therefore, it is possible to improve the quality of the metal foil 20 by continuously trimming the unstable portion L (FIG. 14B) and sucking or removing the processing waste in the post-molding process. In the system of the metal foil roll forming apparatus that realizes the method of the present invention, the overall configuration of which is shown in FIG.

  The present invention is particularly used for a portable electronic device, a lithium ion battery of an electric vehicle, and a lithium ion capacitor, and mainly describes a copper foil as an example. Is not limited to copper foil, but can also be applied to aluminum foil, and its use is not limited to secondary batteries.

10 forming rolls, 11 convex cutting edge molds (fine projections, embossing),
20 Metal foil (working foil), 21 Excavation, 21 'Implanted swarf 25 Delivery roller, 26 Take-up roll 30 First receiving roll, 39 Draw-off brush roll,
40 Second receiving roll, 49 Brush-off brush roll,
50, 55 Brush roll, 56 Brush-off brush roll 80 Rolling unit, 90 Air dust removal unit 100 Dust removal roller unit, 110 Slitter unit 120 Ear end position control device (EPC)
150 Ultrasonic and electric field etching means

  The present invention relates to a roll molding method of a porous metal foil used as a collector electrode foil used in a battery, a capacitor or the like as an electric energy source for electric vehicles and home appliances instead of conventional fossil energy.

  Furthermore, the present invention is a porous metal foil used as a collector electrode foil used in batteries, capacitors, etc., and rewinds a long metal foil wound in a coil shape to form a long metal foil as a forming roll Coiled porous metal foil formed by a forming method in which a large number of fine holes are formed in a metal foil by sandwiching it between a metal roll and a receiving roll, and a long metal foil after the microhole forming is wound up again to remove foreign matters. About.

  In recent years, with the rapid development of multimedia technology, the use of secondary batteries as an alternative energy on a global scale, including electric vehicles that are used in portable electronic devices and are changing at an accelerated pace here. There is a need for a smaller, lighter and higher performance without waiting.

  In lithium batteries, the development of electrode active materials has been energetically performed mainly for the purpose of improving energy density and reducing costs. Each of these positive and negative active materials is a positive electrode aluminum foil and a negative electrode that are current collectors. Has a problem in that the adhesion to the copper foil surface is poor and a local peeling phenomenon is likely to occur, and the hole communicating with the metal current collector in Patent Document 1 (Japanese Patent Publication No. 7-70327) is caused by this peeling phenomenon. The electrode performance is significantly improved.

  Moreover, as a manufacturing method of perforated foil, conventionally, a part of the material of the foil is melted by a method of forming a hole by pressing using an uneven die (punching die) or a chemical treatment such as etching. A method of forming holes is used.

  For example, in Patent Document 2 (Japanese Patent No. 3666558), a metal foil is sandwiched between a die having a punched hole and an elastic body and passed between rolls, whereby the elastic body is pressed to apply the metal foil. A method of forming a hole in a metal foil by deforming into a punching hole of a mold, wherein the mold and the elastic body are each formed of an annular body having a length sufficiently larger than the outer peripheral length of the roll. A method for producing a perforated foil for rotational movement is disclosed.

  Further, in Patent Document 3 (Japanese Patent Laid-Open No. 2001-79795), processing is easy, the processing cost can be reduced, burrs can be prevented from being generated or broken during processing, and a strong porous metal. This is a method of manufacturing a foil sheet, in which a metal foil sheet with a thickness of 50 μm or less is laminated with an ultraviolet curable adhesive, heat-peelable adhesive or water-soluble adhesive tape, and then punched into the ultraviolet curable adhesive tape and the metal foil sheet by punching. A method for forming a porous metal foil sheet comprising uniformly punching a large number of small holes having a rate of 25% or more, and then causing the adhesive tape to lose its adhesive force and peeling the adhesive tape from the metal foil sheet. It is disclosed.

  Furthermore, in patent document 4 (Unexamined-Japanese-Patent No. 2002-216775), the electrode of the secondary battery which can enlarge the aperture ratio of a collector foil and can form many small holes in a thin collector foil A current collector foil molding method and molding apparatus, wherein a non-porous current collector foil is passed over an elastic belt between an embossing roll having a large number of convex portions and a flat roll having no irregularities. And forming a through hole at the location of the current collector foil pressed by the convex portion and embedding a punched residue generated at the time of forming the through hole in the elastic belt. A method and apparatus for forming a foil that is removed from an elastic belt are disclosed.

  Further, in Patent Document 5 (Japanese Patent Application Laid-Open No. 2001-1007), a hole capable of efficiently producing a perforated foil having a high degree of freedom such as the size and pitch of the hole without incurring high costs. It is a manufacturing method of bright foil. When a metal foil is placed on an elastic body on a base plate and a grooved roll is pushed into the elastic body, the elastic body is deformed and the metal foil is pushed into the groove of the roll. The metal foil is sheared by the edge of the groove and the elastic body, and the portion of the metal foil pressed against the elastic body by the protrusion of the roll becomes a punched residue, and a perforated foil in which holes are formed is obtained. A method is disclosed. Similarly, Patent Document 6 (Japanese Patent Application Laid-Open No. 2002-113535) is a method for manufacturing a perforated foil that does not cause cracks in the peripheral ribs of a formed quadrangular hole. In the rhombus convex portion formed on the surface of the processing roll constituting the roll of the other, the opposing vertex of one set of the two opposing vertices is arranged along the roll rotation direction, and the other set is opposed. A system is disclosed in which vertices are arranged along the roll axis direction and the interval between one set of vertices is set longer than the interval between the other set of vertices.

Japanese Patent Publication No. 7-70327 Japanese Patent No. 3666558 JP 2001-79795 A JP 2002-216775 A Japanese Patent Laid-Open No. 2001-1007 JP 2002-113535 A

Non-Patent Document 1 discloses a technique for manufacturing a perforated metal foil by gravure printing and an etching method.
http: // www. nihonseiiaku. co. jp / kenkyu / alumi. htm

  In this invention, it aims at manufacture of the mechanical porous metal foil which does not use a process liquid, and aims at manufacture of the metal foil by especially novel roll forming. However, even in mechanical forming, in the conventional roll forming method described above, since the receiving roll is an elastic body as compared with the forming roll that is a mold as described above, the hole shape of the processed metal foil is In addition, burr-like burrs are generated in the direction in which the processing blade comes off, and it is certain that the foil thickness after processing becomes thick, and in addition to that, there is a possibility of defective dimensions including processing waste.

  In addition, the hole processing in the conventional roll molding is performed by a pair of molding parts of a mold roll and a receiving roll whose surface is made of rubber. Here, the dimensional variation between the mold of the receiving roll and the molding roll main body, However, due to variations in the rubber material, hardness, and rubber density of the receiving roll, there was a problem that incomplete machining that could not be completely removed due to half cut occurred.

  Furthermore, in punching by the conventional roll forming method, the scraps adhere to the elastic roll surface, which is the receiving roll, due to the construction method, and even if it is eliminated by resin brush and air pressure or suction. This is sufficient and cannot be removed during one rotation of the roll. When the next processing is started in such a state, the processing waste adhering to the surface of the receiving roll cannot be excluded, and depending on the attachment position, is sandwiched between fine burrs of “burrs”. More and more, making it difficult to eliminate. In the prior art, it is impossible to completely eliminate the state of these difficult-to-exclude machining scraps.

  In addition, because the receiving roll is an elastic body with a roll-shaped mold having a convex shape, burr-like burrs always occur, and the metal foil thickness after processing becomes thicker than the original foil, so that customer specifications cannot be satisfied Also occurs. In addition, when drilling in roll forming, fine metal fine powder moves around and adheres to the foil surface in addition to relatively large scraps.

  In the above-described conventional mechanical forming technology, although there is a proposal for improving the burr after forming, it causes a short circuit phenomenon that becomes a fatal defect of the porous electrode foil as a product such as a secondary battery. At present, there is almost no mention of removal of processing waste, fine powder, and dust. However, due to the failure and recovery accidents of several major battery manufacturers in recent years, the quality of the porous electrode foil is not only the removal of burrs, but also the elimination of processed waste, fine powder and dust released on the porous electrode foil in the future. It has become an important issue.

  A roll forming system that forms a fine convex shape on the surface of a current metal roll and consists of a receiving roll made of an elastic body facing the metal foil, and performs continuous processing such as drilling on a long metal foil. For example, in the case of foil punching in, the processing part is only a pair of rolls such as a metal roll and rubber, the processing opportunity is only once, and the processing part is formed at a very short distance It is. Therefore, due to various conditions such as the accuracy of each roll or roll assembly, density variation of rubber rollers, etc., vibration during processing of the machine, etc., the positional relationship between the metal foil and the mold varies and the half-cut punching process is not completed. There is a problem that a state in which a part of the chips is connected to a metal foil as a base material without being removed in the state (see FIG. 9B, which will be described later).

  In addition, it is unavoidable in the past that the scraps randomly attached to the rubber receiving roll that acts as a concave mold, and the chipping occurs when drilling occurs during drilling. It will be rolled up while leaving it.

  The above-mentioned two kinds of scraps cannot be eliminated by the conventional processing / gradual scrap method. In addition to these scraps, in actual processing, fine chips are scattered and adhere to the base material, and a temporary response is possible by rotating a normal commercially available adhesive roller etc. against the base material surface. However, roll cleaning cannot be performed in a continuous molding process, and a stable dust removal function cannot be maintained.

  The present inventors have already filed Japanese Patent Application No. 2008-164891 as a basic invention, but by further development, although fine holes could be processed with a molding roll, the scrap was made of rubber as a concave mold. It has also been found that it is buried in the receiving roll and cannot be eliminated, and the next processing is adversely affected.

  The porous electrode foil of the present invention is packaged by being assembled in a stacked or wound manner. At that time, the inclusion of metal debris grows due to an electrical / chemical reaction and the obstacle penetrates the spacer and causes a short circuit or the like. There is a risk of causing a fatal defect. Therefore, in order to be a material for electronic parts, it is an important quality factor that no foreign matter or dust other than the necessary material is attached or caught. Therefore, the present invention plays an important role in maintaining the quality of the electrodes of these electronic components by suppressing the generation of processing waste and thoroughly eliminating the mechanism in forming the porous electrode foil.

  In order to solve the problems as described above, the inventors have improved the overall apparatus and method, and provided a roll metal foil roll forming apparatus and a porous metal foil roll forming method that further enhance the metal foil moldability. It is intended to provide. Furthermore, another object of the present invention is to provide a porous metal foil formed by the method. That is, an object of the present invention is to obtain a coiled porous metal foil as a final product that realizes removal of burrs from the porous metal foil and elimination of processing waste, fine powder, and dust.

In the roll metal foil roll forming method of the present invention, a long metal foil wound in a coil shape is rewound, and the long metal foil is sandwiched between a forming roll and a receiving roll, and a large number of fine metal foils are placed on the metal foil. It is a roll metal foil roll forming method in which a punched through hole is formed, and the long metal foil after the fine punched through hole is formed is coiled again.
The forming roll is formed with a large number of fine punching dies over the entire circumference of the circumferential roll surface, and the receiving roll is elastically pressed against the punching dies on the surface of the forming roll. A roll made of a deformable elastic surface ,
Before SL long metal foil for punching convex of the forming roll surface is configured to be separated meshing at spaced positions C introduced narrowing seen in biting position A,
The long metal foil This ensures is rotated together with the molding roll while maintaining a state of being caught against punching convex front Symbol forming roll surface, between the forming roll and before Ki受 only roll In the meantime, the numerous fine through-holes are molded, and a burr-like processing return is generated by the fine through-hole processing,
Punching waste of the long metal foil is stamped by punching convex formed on the forming roll surface is left before Ki受 only on the roll,
Those receiving only vent scraps left on the roll, so as to remove from the resilient surface of the receiving roll by with respect to those receiving only the roll set kicked the rotary brush,
Embossing that does not penetrate the part where the through hole of the long metal foil is not formed is given,
When the height of the embossed portion subjected to the embossing is t3 and the height of the burr-like processed return formed by fine punching through holes is t2,
t3≈t2 or t3 ≦ t2 .

In the roll metal foil roll forming method according to the present invention, the non-penetrating embossing applied to the portion of the long metal foil where the through-hole is not formed is performed by performing the fine punching through-hole forming on the long metal foil. It is characterized by being applied simultaneously.

  As a result, the long metal foil to be processed is processed while rotating together in a state where the long metal foil has been engaged with the convex shape on the surface of the circumferential forming roll for a long time, thereby completely processing the holes in the metal foil. Is something that can be achieved.

The roll metal foil roll forming method of the present invention is characterized in that the long metal foil after forming the fine punched through- hole is rolled by the rolling roll provided in the middle of the porous metal foil transfer line before being coiled again. The burr-like processing return generated by the fine punching through- hole processing of the metal foil is rolled and finished to near the foil thickness .

  Thereby, even if it is processing with a single forming roll, it becomes possible to perform multi-stage forming processing, and the problem of scraps due to half cut is solved, and furthermore, by rolling in the porous metal foil transfer line, Even if this metal foil is used as an electrical element for a secondary battery, it is possible to eliminate the electrical or mechanical adverse effects caused by burrs.

In the roll metal foil roll forming method of the present invention, the long metal foil after forming the fine punched through hole was rolled by a roll provided in the middle of the porous metal foil transfer line before being wound into a coil shape again. later, by blowing or suction of compressed gas to the transfer feed porous metal foil, and wherein the re-wound is that after the processing refuse, fine-dust coming entrained in the porous metal foil is removed.

  Since the roll metal foil roll forming method of the present invention is to rewind after removing foreign matters such as processing waste, fine powder, and dust accompanying the porous metal foil in this way, it is as flat as possible. It is possible to provide a coiled porous metal foil from which foreign matter has been removed.

The coiled porous molded metal foil of the present invention is obtained by rewinding a long metal foil wound in a coil shape, and sandwiching the long metal foil between a forming roll and a receiving roll, thereby making a large number of fine metal foils. A coiled porous metal foil in which a punched through hole is formed, and the long metal foil after the fine punched through hole is formed is wound up again,
The forming roll has a large number of fine punching projections formed on the entire surface of the circumferential roll, and the receiving roll is elastically pressed against the punching projections on the forming roll surface. A roll consisting of the body surface ,
Before SL long metal foil, the molded to vent convex roll surface, it is configured so as to be separated in the introduction biting at the position A biting separating position C,
The long metal foil This ensures is rotated together with the molding roll while maintaining a state of being caught against punching convex front Symbol forming roll surface, between the forming roll and before Ki受 only roll In the meantime, the numerous fine through-holes are molded, and a burr-like processing return is generated by the fine through-hole processing,
Punching waste of the long metal foil is stamped by punching convex formed on the forming roll surface is left before Ki受 only on the roll,
Receiving only vent scraps left on the roll is removed from the elastic surface of the receiving the by pre Ki受 only rotating brushes kicked set with respect to roll rolls,
The long metal foil after the fine punched through hole is formed by embossing not penetrating the part where the through hole is not formed,
At this time, when the height of the embossed portion subjected to the embossing is t3 and the height of the burr-like processed return formed by fine punching through hole is t2, t3≈t2 or t3 ≦ t2. It has been processed
With the rolling roll provided in the middle of the porous metal foil transfer line before being coiled again, the burr-like processing return generated by fine punching through hole processing is rolled to near foil thickness,
After being rolled by the rolling rolls, by blowing or suction of compressed gas to those said transfer porous metal foil, the removal of foreign matter such as swarf, fines, dust coming entrained in the porous metal foil is applied It is characterized by that.

  By producing the coil-shaped porous molded metal foil of the present invention by the above-described production method, generation of scraps during the molding process is suppressed as much as possible, and further, machining scrap, fine powder, Since the foreign matter such as dust is removed and then wound up again, it is possible to provide a coiled porous molded metal foil that is as flat as possible and from which foreign matter has been removed.

  The current demand for metal foils for current collectors for electronic parts such as secondary batteries and capacitors is to be continuously produced in large quantities at low cost. For this reason, mechanical processing methods include “lass processing” and “punching processing”. And other technologies have also been established. According to the present invention, as is clear from the above detailed description, a long current collector provided as a roll-shaped metal foil is automatically and continuously drilled at high speed, and a porous electrode foil is used. The most important factor that affects the quality of maintaining the characteristics of the secondary battery, which can prevent the remaining of the processing scrap and metal fine powder, which is a fatal obstacle to the electronic devices, and is the lowest cost collection of processing scrap and metal fine powder as much as possible. The present invention proposes a roll metal foil roll forming apparatus and a porous metal foil roll forming method capable of reliably providing an electric foil. Further, by such a method, a coiled porous metal foil is proposed as a low-cost current collector foil with as little processing scraps and fine metal powder as possible.

  In particular, metal scraps and fine powder in porous electrode foils in lithium secondary batteries, etc. are a cause of major obstacles such as growing inside itself and becoming a social problem due to secular change. The industrial value of the mobile device market is remarkable.

The layout which shows the forming roll unit of the 1st Example of the apparatus applied to the metal foil roll forming method of this invention, and a waste removal unit. The whole block diagram of the apparatus applied to the metal foil roll forming method of this invention. The whole block diagram of another Example of the apparatus applied to the metal foil roll forming method of this invention. (A), (B), (C), (D) Sectional drawing which shows the modification of the receiving roll applied to the method of this invention. (A), (B), (C), (D) Explanatory drawing which shows the modification of the microprotrusion of the forming roll applied to the method of this invention. The arrangement | positioning figure which shows the forming roll unit in the 2nd Example of the apparatus applied to the metal foil roll forming method of this invention, and a waste removal unit. The arrangement | positioning figure which shows the forming roll unit in the 3rd Example of the apparatus applied to the metal foil roll forming method of this invention, and a waste removal unit. The perspective view which shows the drive mechanism of the waste removal unit of the apparatus applied to the metal foil roll shaping | molding method of this invention. (A), (B) Explanatory drawing of shaping | molding process operation | movement of the metal foil roll shaping | molding method of this invention. The detailed drawing of the rolling mechanism of the perforated metal foil of the apparatus applied to the metal foil roll forming method of the present invention. (A), (B), (C) The detail drawing of the dust removal apparatus of the apparatus applied to the metal foil roll shaping | molding method of this invention. Explanatory drawing regarding the improvement of the roll forming process of the metal foil side edge part of this invention. The schematic block diagram of the ultrasonic wave and electric field etching unit suitable for the metal foil roll forming process of this invention. The schematic block diagram of the trimming apparatus of the metal foil both-ends part of the metal foil roll forming process of this invention.

  The present invention has been made in view of the problems of the prior art as described above, and its object is to continuously collect a large amount of stable chips and dust, and a current collector for an electrode without adhesion As a result, it is possible to manufacture a perforated metal foil that can be significantly reduced in cost compared with other conventional methods. In other words, the present invention more effectively eliminates the problem of half-cutting that cannot be avoided as long as the method using a metal roll mold and a rubber receiving roll is used, and pinching of scraps between punching burrs. Of a porous metal foil roll forming apparatus and a porous metal foil roll forming method capable of simultaneously achieving two problems, and a reliable removal of scrap rubber receiving rolls. It is a proposal. Furthermore, this invention aims at provision of the coil-shaped porous metal foil shape | molded by the method.

  First, the cause of half-cut (incompletely unplugged state) is that punching is conventionally performed in a molding process in which a metal foil is sandwiched only once between a roll mold and a receiving roll. Because. In the present invention, the metal foil molding process pass line (molding region X) is kept long in the contact state around the roll mold, and is first bitten between the roll mold and the receiving roll. In the molding process from the position A to the separation position C, the convex mold of the roll mold is rotated together with the metal foil in a state of being bitten in the through-molding hole of the metal foil, and this contact state is maintained. In the meantime, when the receiving roll placed next to the receiving roll at the biting position is again punched by press contact with the roll mold, the processing state with multiple roll blades will elapse. Incomplete punching state / half-cutting is a complete punching state. In this method, by further increasing the number of receiving rolls, it is possible to further increase the number of molding steps (the number of steps) and obtain a more complete drawing state. In the present specification, an embodiment provided with three or more receiving rolls is not particularly described, but this can be easily implemented by those skilled in the art by applying the idea of the present invention. .

  Next, a description will be given of countermeasures against “missing burrs” that occur extremely rarely due to “residual scraps” on the receiving roll. This is “scraps” in a state where “residual scraps” are sandwiched as “slips” in the mold roll mold. With regard to the “cutting burrs”, a rotating brush having resin elastic fibers planted on the surface is rotated in a state of being opposed to the molding roll mold, and the fine mold of the molding roll becomes a through hole in the metal foil. In a state where the metal foil is still biting, it is opposed to the formed metal foil and rotated at a high speed of about 1000 rpm, thereby eliminating the processing waste accompanied by the formed metal foil.

  The roll metal foil roll forming method of the present invention is to form a large number of holes in a metal foil inserted between a forming roll having a large number of convex molds on the surface and a receiving roll having a surface of an elastic body. In this roll forming, the receiving roll is an important part. Therefore, the present invention is an improvement of the surface structure of the receiving roll in order to improve the half cut. At this time, the matter that needs to be further improved is countermeasures against burying “residual debris” on the receiving roll. That is, it is a problem that the “embedded chips” on the receiving roll adversely affect the newly supplied metal foil 20. The present invention is a significant improvement on this point.

  In order to achieve the above effect, it is effective to rotate the above-described rotating brush at high speed using a solid cam (groove cam) or a biaxial motor drive. As a result, by simultaneously moving and swinging in the biaxial direction at high speed, the force to try to eliminate the omnidirectional waste on the receiving roll acts in all directions, and it can be expected that the function to remove the processing waste will increase. It is. Such an exclusion function increases the number of times of contact of the rotating brush with the metal foil surface (specifically, the number of rotations or the number of oscillating resin brushes), thereby improving the accuracy of removing the target scraps. Is obvious.

  Moreover, the roll forming method of the porous metal foil of the present invention includes a step of removing dust by pressurization and suction in a container close to a seal in consideration of dust collection efficiency in the middle of a transfer line after processing the metal foil. At that time, a rectangular brush is installed in a plane on the part of the container where the porous metal foil passes, and is continuously brought into contact with the movement of the porous metal foil, and dust is lifted off from the surface. It makes it easy to suck. Processing dust, dust, etc. removed by circulating a suction air fluid having a predetermined pressure in the container are collected by a dust collector.

  In the roll metal foil roll forming method of the present invention, fine dust other than relatively large waste generated by processing such as scraps is commercially available at a position immediately before winding the porous metal foil after processing. It is useful to arrange a dust removal roller having a dry cleaning function. By increasing the number of times of dust removal by the dust removal roller (the number of dust removal rollers arranged), the accuracy of removing the target fine dust is improved.

  An object of the roll metal foil roll forming method of the present invention is to develop and provide a novel ultrasonic / electric field etching unit as a unit used in a dust removal / deburring process after roll metal foil roll forming. This ultrasonic / electric field etching unit is not only used as a unit incorporated in the roll metal foil roll forming apparatus used in the method of the present invention, but also as a single apparatus for various metal foils or plates. It can be diverted as an effective deburring technique. That is, in the roll metal foil roll forming method of the present invention, a long metal foil wound in a coil shape is rewound, and the long metal foil is sandwiched between a forming roll and a receiving roll, and a large number of metal foils are placed on the metal foil. A roll metal foil roll forming method in which fine holes are formed, and the long metal foil formed after the fine hole forming is wound into a coil shape again. The forming roll has fine protrusions over the entire circumference of the roll surface. A large number of molds are formed, and the receiving roll is a roll made of an elastic surface pressed against the convex mold on the surface of the forming roll, and the long metal foil after micro-hole forming is wound into a coil again. In the middle of the porous metal foil transfer line before being formed, it is configured to remove the portion with the possibility of generating fine dust at the tip of the burr formed around the fine hole of the long metal foil by ultrasonic / electric field etching means, As a result, processing burr of metal foil after molding Those capable of fruit removed.

  In the roll metal foil roll forming method of the present invention, it is possible to finish the burr-like burrs generated by the processing to a thickness close to the foil thickness by a rolling function that is sandwiched between a pair of flat metal rolls.

  However, finishing to near foil thickness by the rolling function in this way causes a new problem. That is, both sides in the width direction of the porous metal foil are unprocessed, so there is no burr-like processing return, and the raw foil is thin. When such foil materials with different thicknesses are uniformly pressed and rolled with a rolling roll, elongation occurs in the direction of foil transfer. Because of the difference, in the case of a long coil material, the difference in the amount of elongation is accumulated and wrinkles are generated and appear as stripes rolled on the foil surface. The roll metal foil roll forming apparatus and the porous metal foil roll forming method of the present invention are intended to prevent such a phenomenon.

  Furthermore, in the roll metal foil roll forming method of the present invention, it is also possible to continuously trim both side portions which are unstable in terms of processing conditions after the metal foil roll is formed to improve the quality of the porous metal foil.

  A roll metal foil roll forming apparatus used in the method of the present invention unwinds a long metal foil wound in a coil shape, and sandwiches the long metal foil between a forming roll and a receiving roll to form a metal foil. A roll metal foil roll forming apparatus for forming a large number of fine holes and winding the porous long metal foil after forming the fine holes into a coil again. The forming roll has many fine convex shapes on the roll surface. The receiving roll is a roll made of an elastic body pressed against the forming roll, and a plurality of receiving rolls are provided along the flow of the metal foil.

  Furthermore, the porous metal foil roll forming apparatus used in the method of the present invention has elastic fibers on the surface in order to scrape off the processing waste on the downstream side in the rotational direction from the opposing pressure contact portion of the receiving roll with the forming roll. A scraping brush is provided.

  Furthermore, the porous metal foil roll forming apparatus used in the method of the present invention has a rotating brush having elastic fibers on the downstream side along the flow of the metal foil further than the plurality of receiving rolls, facing the forming roll. Provided.

  Further, in the porous metal foil roll forming apparatus used in the method of the present invention, the opposing pressure contact position between the first receiving roll and the forming roll provided on the upstream side along the flow of the metal foil is unrolled long. The opposing pressure contact position B between the second receiving roll and the forming roll provided in the vicinity of the position A where the metal foil starts to contact the forming roll and downstream of the first receiving roll along the flow of the metal foil is long. Near the middle position of the area where the metal foil is in contact with the forming roll, and the installation position of the rotating brush facing the forming roll is near the position C where the porous long metal foil after micropore forming begins to separate from the forming roll. is there.

  Furthermore, the porous metal foil roll forming apparatus used in the method of the present invention was generated by processing the metal foil in the middle of the metal foil transfer line before the long metal foil after microhole forming was wound again in a coil shape. In order to roll and finish the burr-like work return to a thickness close to the foil thickness, a rolling roll that rotates oppositely is provided.

  Furthermore, the porous metal foil roll forming apparatus used in the method of the present invention has a substantially sealed space part in the middle of the porous metal foil transfer line before the long metal foil after microhole forming is wound again in a coil shape. A unit for removing foreign matters such as processing waste, fine powder, and dust accompanying the porous metal foil by blowing or sucking compressed gas to the transfer porous metal foil is provided.

  As an example, the roll metal foil roll forming method of the present invention using the apparatus as described above rewinds a long metal foil wound in a coil shape, and uses the long metal foil to form a forming roll and a receiving roll. It is a roll metal foil roll forming method in which a large number of fine holes are formed in a metal foil by sandwiching them, and the long porous metal foil after the fine hole forming is wound into a coil shape again. A large number of fine convex molds are formed, and the receiving roll is a roll made of an elastic body pressed against the forming roll, and the receiving roll is substantially the same provided along the flow of the metal foil. It is composed of a first receiving roll and a second receiving roll having functions and performances, and even if half cut of the metal foil hole occurs in the first receiving roll, the second receiving roll that follows the metal foil Like to mold Characterized in that was.

  Furthermore, the roll metal foil roll forming method of the present invention is a metal foil processed by a rolling roll provided in the middle of the porous metal foil transfer line before the long metal foil after micropore forming is wound into a coil shape again. The burr-like processing return generated by the step is rolled to a thickness close to the foil thickness and finished.

  Furthermore, the present invention is also provided in a coiled porous metal foil. The coiled porous metal foil is rewound from a long metal foil wound in a coil shape, and the long metal foil is placed between a forming roll and a receiving roll. Is a coiled porous metal foil formed by forming a large number of fine holes in a metal foil and winding up the long porous metal foil after forming the fine holes again. A large number of molds are formed, and the receiving roll is a roll made of an elastic body pressed against the forming roll, and the receiving roll has substantially the same function and performance provided along the flow of the metal foil. The first receiving roll and the second receiving roll are provided, and even if a half cut of the metal foil hole occurs in the first receiving roll, the metal foil is molded by the subsequent second receiving roll. And fine hole forming After being rolled by a rolling roll provided in the middle of the porous metal foil transfer line before the long metal foil is coiled again, a substantially sealed space is provided, and the compressed gas is transferred to the transferred porous metal foil therein. By blowing or sucking, the foreign matter such as processing waste, fine powder, and dust accompanying the porous metal foil is removed, and the burr-like processing return generated by the processing of the metal foil by the rolling roll is close to the foil thickness. The coiled porous metal foil is flat and has foreign matters removed after being rolled and finished.

Here, a roll metal foil roll forming apparatus for realizing the porous metal foil roll forming method of the present invention will also be described. This roll forming apparatus for porous metal foil rewinds a long metal foil wound in a coil shape, and sandwiches the long metal foil between a forming roll and a receiving roll to form a large number of fine holes in the metal foil. It is a roll metal roll forming device for forming and winding the formed long metal foil after the microhole forming into a coil shape again,
The forming roll is formed with a number of fine convex shapes over the entire circumference of the circumferential roll surface, and the receiving roll is formed from an elastic body surface pressed against the convex shape of the forming roll surface. A roll of
The long metal foil is configured to be bitten and introduced at a biting position A and to be separated at a separation position C with respect to the convex mold on the surface of the forming roll, and from the biting position A to the separation position C. The molding region X is configured to occupy 180 degrees or more of the entire circumferential surface of the molding roll,
Thus, the long metal foil is configured to rotate with the forming roll while maintaining the state of being bitten with respect to the convex mold on the surface of the forming roll in the forming region X.

  Thereby, the long metal foil to be processed rotates together with the convex shape on the surface of the circumferential forming roll for a long time, thereby completely achieving the processing of the hole in the metal foil. Is possible.

  Furthermore, in the roll metal foil roll forming apparatus for realizing the porous metal foil roll forming method of the present invention, the convex mold formed on the surface of the molding roll forms a crater-shaped concave on the top.

  Thereby, it is possible to avoid that the punched chips are deformed by the crater-like recesses and buried in the elastic body surface of the receiving roll and adversely affect the next forming process.

  Furthermore, in the roll metal foil roll forming apparatus that realizes the roll metal foil roll forming method of the present invention, the receiving roll is disposed in the forming region X so as to face the convex mold on the surface of the forming roll, In addition, a plurality of stages are provided along the flow direction of the metal foil.

  Thereby, even if it is a process by one shaping | molding roll, a multi-stage shaping | molding process is attained and the problem of the extraction scraps by a half cut is eliminated.

  Further, in the roll metal foil roll forming apparatus for realizing the roll metal foil roll forming method of the present invention, the elastic body surface formed on the receiving roll is configured to have a strong and weak elastic distribution in the axial direction thereof, Elasticity distribution at a position corresponding to the axial position where the convex mold formed on the surface of the forming roll is arranged is weak, and elasticity at a position corresponding to the axial position where the convex mold is not arranged is strengthened It consists of

  In this way, the elastic body surface of the receiving roll forms a strong and weak elastic distribution in the axial direction, so that when punching holes, the corresponding part of the forming roll convex is soft and the periphery is hardened, It is possible to achieve an effect similar to that of pressing the material at the time of punching with the punching die.

  Furthermore, the roll metal foil roll forming apparatus for realizing the porous metal foil roll forming method of the present invention, in the forming region X on the downstream side in the rotational direction from the opposing pressure contact portion of the forming roll with the receiving roll, In order to scrape off the processing waste, a scraping brush having elastic fibers arranged on the surface is provided.

  As a result, it is possible to scrape as much as possible the processing waste that arrives at the molded metal foil that is transferred to the subsequent processing.

Furthermore, a roll metal foil roll forming apparatus that realizes the roll metal foil roll forming method of the present invention rewinds a long metal foil wound in a coil shape, and forms the long metal foil into a forming roll and a receiving roll. A metal foil roll forming apparatus for forming a large number of fine holes in a metal foil and winding the formed long metal foil into a coil again after forming the fine holes,
The forming roll is formed of a number of fine convex shapes over the entire circumference of the roll surface, and the receiving roll is a roll made of an elastic surface pressed against the convex shape of the forming roll surface. ,
In the middle of the porous metal foil transfer line before the long metal foil after the micro-hole forming is wound into a coil shape, the burr-like processing return generated by the processing of the metal foil is rolled to near the foil thickness. In order to finish, rolling rolls rotating opposite to each other are provided.

  Thereby, even if this metal foil is used as an electrical element for a secondary battery, it is possible to eliminate the adverse electrical or mechanical effects caused by burrs.

  Furthermore, the roll metal foil roll forming apparatus that realizes the roll metal foil roll forming method according to the present invention is in the middle of the porous metal foil transfer line before the long metal foil after the micro-hole forming is wound into a coil shape again. And before the rolling process by the said rolling roll, it comprises so that embossing may be given to the unprocessed both-sides edge part of the said metal foil.

  Thereby, during the rolling process in the porous metal foil transfer line, it is possible to eliminate the difference in elongation rate due to rolling in the width direction of the metal foil, and to suppress the generation of wrinkles on the side edges of the metal foil. It is.

Furthermore, a roll metal foil roll forming apparatus that realizes the roll metal foil roll forming method of the present invention rewinds a long metal foil wound in a coil shape, and forms the long metal foil into a forming roll and a receiving roll. A metal foil roll forming apparatus for forming a large number of fine holes in a metal foil and winding the formed long metal foil into a coil again after forming the fine holes,
The forming roll is formed of a number of fine convex shapes over the entire circumference of the roll surface, and the receiving roll is a roll made of an elastic surface pressed against the convex shape of the forming roll surface. ,
Possibility of generation of fine dust at the tip of burrs formed around the microholes of the long metal foil in the middle of the porous metal foil transfer line before the long metal foil after forming the microholes is wound up again in a coil shape Some portions are provided with ultrasonic / electric field etching means.

  Thereby, the fine dust from the processing burr | flash of the metal foil after shaping | molding can be removed effectively.

  Hereinafter, embodiments of the present invention will be described more specifically with reference to the drawings. First, roll forming of the porous metal foil of the present invention will be described in detail with reference to the entire drawing. A porous metal foil roll forming apparatus for realizing the method of the present invention is a device for geometrically squeezing and arranging a large number of micropores in a metal foil as a current collector for an electrode of an electronic component such as a secondary battery. For example, as shown in FIG. 1, a metal molding in which a number of fine projections (embosses) 11 (300 to 600 μmφ) formed by machining techniques or the like are geometrically arranged at regular intervals. A fine hole is formed in the metal foil 20 such as aluminum or copper by the roll 10 and a receiving roll 30 made of an elastic body (for example, synthetic rubber) on the outer peripheral surface that rotates in synchronization with the roll 10. At this time, the receiving roll 30 made of a surface elastic body (for example, synthetic rubber) is pressed and rolled against the metal forming roll 10 with a predetermined pressing force.

  As a result, fine holes are formed in the metal foil 20, and at this time, scraps 21 having a thickness of 300 to 600 μmφ and a thickness of 10 to 100 μm are generated. Most of the scraps 21 are separated from the metal foil 20 and are transferred (attached or buried) with the rubber roll as the receiving roll 30, but a part is accompanied by the metal foil 20. The scraps 21 accompanying the metal foil 20 are scraped off by the brush roll 50 arranged on the downstream side of the receiving roll 30. The rotation direction of the brush roll 50 is preferably a direction opposite to the transfer direction of the metal foil 20, but may be rotated in the same direction.

  In this way, the scrap 21 and the fine metal powder are separated from the metal foil 20 by the receiving roll 30 whose surface is a rubber roll, and the scrap 21 and the like accompanying the metal foil 20 without being completely separated (FIG. 9 ( B) can improve the scraping effect by additionally arranging a biaxial motor driving mechanism 501 and the like on the circumference of the forming roll 10 (see FIG. 8). As shown in FIG. 8, in the biaxial motor drive mechanism 501, the rotation operation of the brush roll 50 is achieved by the high-speed rotation motor 502. In addition, the entire biaxial motor drive mechanism 501 is swung at high speed in the axial direction of the forming roll 10 by the rotation motor 503 and the cam 504. By this rotation operation and high-speed movement / oscillation operation, the force for omnidirectional removal is also applied to the scraps 21 sandwiched in the hole after processing, and the removal function of the processing scraps 21 is enhanced. It can be expected.

  Further, although peeled off and separated from the metal foil 20, it adheres to the fine protrusions (emboss) 11 as the convex shape of the forming roll 10, and is accompanied by the convex shape 11 of the forming roll 10 and the like even if the separation position C is exceeded. In order to remove dust and the like, dust is directly scraped off from the surface of the forming roll 10 by providing a brush roll 56 that is disposed on the upstream side in the rotational direction from the introduction portion of the metal foil 20 of the forming roll 10. be able to. The dust or the like accompanying the convex mold 11 of the forming roll 10 beyond the separation position C has a very great adverse effect upon the subsequent forming of the metal foil 20 that is newly supplied and bitten into the forming roll 10. Must be removed.

  Further, as will be described later, in the entire configuration of the porous metal foil roll forming apparatus that realizes the method of the present invention, the pressure and suction with the brush are performed during the movement of the foil to the winding portion of the porous metal foil after forming. The container and the dust removal roll with a dry cleaning function are used to obtain a coiled porous metal foil by winding it as a current collector having fine pores of a regular array in a wide range without any metal piece or metal powder. .

  With respect to more detailed examples, a porous metal foil roll forming apparatus that realizes the method of the present invention will be sequentially described with reference to the accompanying drawings. The porous metal foil roll forming apparatus as the first embodiment is shown in detail in FIG. 1 at a forming portion by the forming roll 10 and the receiving roll 30, and FIG. 2 shows the overall apparatus configuration.

  In the first embodiment shown in FIG. 1, the first and second receiving rolls 30 and 40 are rolled by rotating the metal foil 20 with respect to the forming roll 10 having an outer diameter of 100 to 500 mmφ. is there. At this time, the long metal foil 20 is configured to be introduced into the convex mold 11 on the surface of the forming roll 10 at the engagement position A and to be separated at the separation position C. And the shaping | molding process area | region X from the biting position A to the separation | spacing position C is comprised so that 180 degree | times or more may be occupied in the forming roll surface perimeter area. Thereby, the long metal foil 20 is configured to rotate together with the forming roll 10 while maintaining the state of being bitten with respect to the convex mold 11 on the surface of the forming roll 10 in the forming region X. The long metal foil 20 to be processed rotates together with the convex mold 11 on the surface of the circumferential forming roll 10 for a long time, thereby completely forming the hole in the metal foil 20. It is possible to do. That is, conventionally, the metal foil is perforated in the forming process by the sandwiching operation in one short time between the roll mold and the receiving roll, thereby solving the problem of half cut. This is one of the basic technical ideas of the present invention.

  Further, as described above, another basic technical idea of the present invention is that a plurality of receiving rolls 30 and 40 are provided to face the forming roll 10. This also solves the problem of half-cut due to the forming process by the conventional metal foil being sandwiched once between the roll mold and the receiving roll. The first and second receiving rolls 30 and 40 roll while being pressed against the forming roll 10 with a predetermined pressure. Around the forming roll 10, a brush roll 50 having a wire length of 16 mm and a resin wire having an outer diameter of 80 mmφ and 0.25 φmm is disposed on the downstream side of the flow of the metal foil 20. At this time, the brush roll 50 is rotated (opposite to the rotation direction of the forming roll 10) by the high-speed rotation motor 502 (FIG. 8) in opposition to the movement direction of the metal foil 20 to be processed, and the rotation motor 503 and By the cam 504, the whole is swung at high speed in the axial direction of the forming roll 10, and the scraps 21 accompanying the metal foil 20 are removed from the metal foil 20.

  Furthermore, the outline of all the processes from the delivery of the metal foil 20 to the winding of the porous metal foil roll forming apparatus for realizing the method of the present invention will be described with reference to FIG. In this entire process, in the roll forming process of the metal foil 20 or the like of the reel-shaped material including the contents described in the above embodiments, the processing waste and dust remain on the reel-shaped porous metal foil 26 wound as a product. A porous metal foil roll forming apparatus and a roll metal foil roll forming method are proposed.

  Since the forming roll units 10, 30, 40 and the scrap removal unit 50 in all the steps of the porous metal foil roll forming apparatus shown in FIG. 2 have the same configuration as that of each embodiment, detailed description thereof will not be given here. . In the perforated metal foil roll forming apparatus of FIG. 2, the long metal foil 20 is fed out from the reel-shaped metal foil 25 in the direction of the arrow, and is sandwiched between the forming roll 10 and the first receiving roll 30 by the introduction roll 31. Micropores are formed by the convex cutting edge mold 11 (not shown in FIG. 2) on the surface of the forming roll 10. The scraps 21 are once captured in the rubber on the surface of the first receiving roll 30, and then peeled and separated from the metal foil 20 after forming the micro holes by the rotation of the first receiving roll 30. The scraps 21 adhering to the rubber on the surface of the first receiving roll 30 are wiped off by the brush-off brush rolls 39, 39 provided downstream.

  The forming process of the metal foil 20 to be processed is performed such that the metal foil 20 to be processed having a width of 260 mm is rewound from the feed roller 25 and transferred in the direction of the arrow, and is sandwiched between the forming roll 10 and the receiving roll 30. By being sandwiched in the vicinity and pressed with a predetermined pressure 8 (15 Mpa), the fine convex cutting edge mold (emboss) 11 on the forming roll 10 comes into contact with the surface of the metal foil 20, and the receiving roll 30. When the resistance within the elastic limit of the elasticity of the rubber surpasses the breaking force of the metal foil 20 to be processed, micro-hole processing is performed. Immediately after, the resistance disappears instantaneously, and the convex 11 of the forming roll 10 is pressed. The elastic rubber on the surface of the receiving roll 30 that has been elastically deformed returns to its original shape, and the scraps 21 are left on the receiving roll 30. The scraps 21 left on the receiving roll 30 are removed from the receiving roll 30 by the rotating brushes 39 and 39. Moreover, the processing waste etc. accompanying the metal foil 20 after shaping | molding are removed from the metal foil 20 with the brush roll 50. FIG. Thereafter, the formed metal foil 20 is rolled by a rolling unit 80 so that “burr” as a processing burr generated in the metal foil 20 by the punching process is brought to a level close to the original foil thickness before the roll forming process. ing. Furthermore, at the subsequent stage, immediately before winding of the processed finished foil, an air dust removing unit 90 and a dust removing roller unit 100 with a cleaning function are provided for the purpose of eliminating the fine dust that comes with the metal foil 20 by any chance. .

  Further, in the roll metal foil roll forming apparatus (FIG. 3) improved as a more practical apparatus, the metal foil 20 to be processed unwound from the feed roller 25 passes through several tension rolls (not indicated). While being rewound and transported in the direction of the arrow, it is sandwiched in the vicinity of the sandwiching position A (not indicated in FIG. 3) between the molding roll 10 and the receiving roll 30 and pressed with a predetermined pressure, thereby forming the molding. The fine convex shape on the roll 10 is brought into contact with the surface of the metal foil 20 and fine hole processing is performed. The scraps 21 left on the receiving roll 30 are removed from the receiving roll 30 by the rotating brushes 39 and 39. Moreover, the processing waste etc. which accompany the metal foil 20 after shaping | molding are removed from the metal foil 20 with the 4-unit brush roll 51,52,53,54. Thereafter, the formed metal foil 20 is rolled by the primary rolling unit 80 with the processing burr generated in the metal foil 20 by the punching process. Further, an air dust removing unit 90 is provided at the subsequent stage for the purpose of eliminating punching fine powder accompanying the metal foil 20.

  Further, a slitter unit 110 (described later) is provided at a subsequent stage by circular upper and lower slitter blades that slit unprocessed portions of both edge portions of the metal foil 20. Next, a No1 cleaning roll unit 100 with a cleaning function having an adhesive sheet on the surface is provided through a step roll (no symbol), and the processing fine powder still accompanying the metal foil 20 is removed. Further, a secondary rolling unit 88 is provided at the subsequent stage of the No1 cleaning roll unit 100. The metal foil 20 transferred by the secondary rolling unit 88 rolls “burr” as a processing burr generated by the punching process so that the foil thickness is close to the original foil thickness before the roll forming process. . In the secondary rolling unit 88, a cleaning roll (not indicated) having adhesiveness is disposed opposite to a pair of rolling rolls.

  No1 and No2 with a cleaning function having adhesiveness in the subsequent stage in order to eliminate punching fine powder that accompanies the metal foil 20 just before winding of the processed finished foil even after each of the above means. The cleaning roll units 100 and 100 are provided, and then the metal foil 20 in which the edge position of the metal foil 20 is controlled by the edge position control device (EPC) 120 to completely remove dust is taken up by the winding roll 26. The product is rolled up to complete the product.

  The outer peripheral surface of the elastic receiving roll 30 used in the present invention is configured as shown in FIG. That is, the receiving roll 30 includes an inner metal receiving roll core 32 and an outer peripheral roll 33 of an elastic body (for example, synthetic rubber) on the outer peripheral surface.

The appropriate value of the pressure between the convex (embossed) 11 of the forming roll 10 and the receiving roll 30 slightly changes depending on the thickness and width of the material 20 to be processed, the arrangement of the geometric holes, etc. Table 1 shows one optimal example.

  When the metal foil 20 to be processed is sandwiched between the forming rolls 10 at the sandwiching position A and the forming process is started, the metal mold 20 is pressed and punched by the fine mold 11 with respect to the forming roll 10 thereafter. In other words, basically, all the fine holes are inclined at the height h1 (0.1 to 0.4 mm) of the convex part top diameter d1 (0.3 to 1.0 mmφ) of the forming roll 10. It is transferred to the vicinity of the separation position C in a state where the convex shape (emboss) 11 of a convex fine cutting edge having an angle α1 (10 ° to 45 °) is inserted. Thereafter, the direction-changing rollers 60 and 66 having a diameter of about 30 mmφ are arranged to direct the direction toward the most downstream winding roller 26. Thereby, in the forming region X from the sandwiching position A to immediately before the separation position C, the metal foil 20 continues to be pressed / perforated with respect to the forming roll 10 for a long time. Become.

  In the forming region X in the state of pressurization and hole processing from the sandwiching position A of the metal foil 20 to the position just before the separation position C, the metal foil 20 to be processed has a pressure of 15 MPa after finishing the forming process by the receiving roll 30. It passes between the forming roll 10 and the second receiving roll 40 with the applied pressure. At that time, the pressing force is applied again to the metal foil 20 to be processed, and the same micro-hole processing as in the first processing is performed, so that the half-cut (incomplete punching) portion is made a through-hole state. be able to.

  The installation range of the first receiving roll 30 and the second receiving roll 40 provided facing the forming roll 10 is within a forming region X (180 ° to 270 °) from the vicinity of the sandwiching position A to the vicinity of the separation position C. Thus, it can be set as appropriate within a range of about 90 ° to 180 ° from the vicinity of the sandwiching position A to the vicinity of the second forming position B. In the present invention, as explained so far, a long-time molding process state is maintained, and a plurality of processing operations are achieved by a plurality of receiving rolls facing a plurality of molding rolls 10 and half-cut (incomplete Therefore, it is possible to install third and subsequent receiving rolls (not shown) on the downstream side along the circumference of the forming roll 10. For this purpose, it is necessary to take a wide molding region from the vicinity of the sandwiching position A to the vicinity of the separation position C. By doing this, or by increasing the outer diameter of the forming roll 10 as much as possible, the arrangement position and quantity of the receiving rolls increase, and the purpose of eliminating the half-cut (incomplete punching) as much as possible is achieved. Correspondence becomes possible.

  Here, in order to consider the problem of half-cut (incomplete punching), the “sharpness” will be considered in comparison with the roll forming and die-cutting techniques of the present invention. In the case of punching with a general mold, machining is realized by reciprocating a punch (convex type corresponding to the fine protrusion (emboss) of the present invention) against a die (concave type corresponding to the receiving roll of the present invention). At this time, the material around the die and the punch is pressed by the material presser, and the material punched by the punch enters the die. Then, the material that has entered the die is discharged out of the die by a knockout pin or the like in the punch raising process to complete the processing. The concept of processing accuracy in this case is based on the premise that both the die and the punch are made of a rigid and non-deformable material.

  Here, when the roll forming of the present invention is compared with punching using a general mold, in the case of the roll forming of the present invention, the elastic body on the surface of the receiving roll 30 that is a concave mold (in FIG. It is clear that it is advantageous for “sharpness” to make the hardness of the portion where the fine projection (emboss) 11 that is convex with respect to the roll 33) enters is softer than the hardness of the peripheral portion. However, in the configuration of the receiving roll 30 shown in FIG. 4A, since the elastic body has a uniform thickness with respect to the entire width of the receiving roll, it is theoretically considered to have a uniform hardness. If this is taken as an example of punching with a mold, this corresponds to the fact that the die is deformed, and complete punching cannot be guaranteed.

  Therefore, in the present invention, as shown in FIG. 4B, a predetermined uneven shape 34 is formed on the outer peripheral surface side of the receiving roll mandrel 32 at a position opposite to the convex fine protrusion (emboss) 11. Thus, a soft portion a (corresponding to the hollow portion at the center of the die in general punching) and a hard portion b (corresponding to the material pressing portion in general punching) are formed of the outer peripheral roll 33 of the elastic body. (See FIG. 3D). In the configuration of the receiving roll 30 in FIG. 4B, the thickness and hardness of the elastic body are generally inversely proportional to each other and correspond to the position of the fine protrusion (emboss) 11 that is the convex shape of the present invention. Thus, by arranging the thick part a, molding close to punching with a mold is possible (see FIG. 4C). In this case, the rising angle α of the concavo-convex shape 34 is possible, but the one without the rising angle (the rising angle is 90 degrees) is effective. The reason is that the concave edge portion of the receiving roll mandrel 32 and the edge portion of the fine protrusion (emboss) 11 fulfill the blade function. The uneven shape 34 is configured by forming a circumferentially protruding peak row on the outer peripheral surface of the roll core 32.

  Next, countermeasures for “residual debris” buried on the receiving roll 30 after the metal foil 20 is formed will be described. As shown in FIGS. 1 and 2, the scraps 21 attached to the elastic body 33 on the surface of the receiving roll 30 are wiped off by the brush-off brush rolls 39, 39 provided downstream. However, if this scrap 21 is buried in the elastic body 33 on the surface of the receiving roll 30 and becomes “residual scrap”, it has an adverse effect on the next forming step, and the characteristics as a metal foil cannot be maintained. Is.

  Thus, by forcibly scraping off dust adhering to and adhering to the surface of the forming roll 30, it cannot be said that it is complete only by taking measures against “residual debris”. Therefore, in the present invention, a method for easily removing “residual waste” is considered. The idea devised for this purpose is to form a concave portion of a predetermined pattern on the top of the convex fine protrusion (emboss) 11 of the forming roll 10.

  This will be described with reference to FIG. Forming a concave portion having a predetermined pattern on the top of the convex fine protrusion (emboss) 11 of the forming roll 10 has the purposes of (1) improving sharpness and (2) improving chip removability.

  First, in order to improve the sharpness, when the convex fine protrusions (embosses) 11 act on the metal foil 20 as a rotary blade, the metal foil 20 is cut into the blade as shown in the left and right views of FIG. If it is improved so that no slip phenomenon occurs in the meantime, the sharpness is improved. For this purpose, a recess 35 is formed on the top of the fine protrusion (emboss) 11 (the right view in FIG. 5A). Accordingly, as shown in the lower right part of FIG. 5C, the edge portion of the fine protrusion (emboss) 11 sharply cuts into the metal foil 20. And the improvement of sharpness can be achieved in combination with the convex shape 34 on the outer peripheral surface side of the receiving roll mandrel 32 shown in FIG.

  Next, with regard to the improvement in chip removability, as shown in the right diagram of FIG. 5D, in the case where the top of the emboss is flat shown in the left diagram of FIG. There is no guarantee that there will be no danger of completely entering the elastic body 33 of the receiving roll 30 and becoming buried chips 21 'that cannot be removed. As in the present invention, as a metal foil used as a collector electrode foil used in batteries, capacitors, etc. as electric energy sources for electric vehicles and home appliances, even the possibility of extremely small residual chips is large. May be a problem. Therefore, it has been considered that the shape of the buried chips 21 ′ can be surely removed by the rotating brushes 39 and 39.

  That is, as shown in the right figure of FIG. 5A, the concave portion 35 is formed on the top of the convex fine protrusion (emboss) 11 (see the upper right figure in FIG. 5B), thereby being molded. As shown in the lower right part of FIG. 5B, the chip 21 is formed with a convex part (not shown) corresponding to the concave part 35 at the top of the fine protrusion (emboss) 11 (FIG. 5B right figure). under). As a result, when the emboss top is flat, the chips 21 become buried chips 21 ′, which may be difficult to be removed by the rotating brushes 39, 39. Even if the convex portion is formed on the chip 21 and becomes the embedded chip 21 ′ on the receiving roll 30, reliable removal is possible. In the embodiment of the present invention, the rotating brushes 39 are used, but the object can also be achieved by providing a scraper (not shown in detail) consisting of one or more blades. Of course, a scraper and a rotating brush can be used in combination. Thus, the basis of reliable and stable drilling is that no residual chips exist on the surface of the receiving roll 30. Here, the rough dimension of the convex fine protrusion (emboss) 11 having the concave portion 35 formed on the top is such that the height h2 of the convex die 11 is 0.1 to 0.4 mm, and the depth h3 of the concave portion 35 is 0.1. It is preferable that the diameter d2 of the top surface of the convex mold 11 is 0.3 to 1.0 mm and the diameter d3 of the concave portion 35 is 0.2 to 0.8 mm.

  Next, in the second embodiment shown in FIG. 6, the first brush roll 50, the second brush roll 55, and the third pay-off are further downstream of the first receiving roll 30 and the second receiving roll 40. A brush roll 56 is provided.

  The brush rolls 50 and 55 and the brush-off brush roll 56 applied to the metal foil roll forming apparatus that realizes the method of the present invention have substantially the same structure. The brush rolls 50 and 55 and the brush-off brush roll 56 are resin-made conductive and elastic brushes, and are excluded by being pinched and fixed between burrs having a very small height when drilling. It has a hardness and a compactness effective for eliminating difficult residual scraps 21. The dimensions of these brush rolls 50 and 55 may be set arbitrarily depending on the relationship with the installation space. However, effective hardness and compactness are required to remove the scrap 21 remaining in the processing hole. The material of the brush rolls 50 and 55 of this embodiment is mainly carbon fiber, and nylon fiber can be used in combination as required. The rotation direction of the brush rolls 50 and 55 of the present embodiment is the direction opposite to the direction of rotational movement of the metal foil 20 to be processed, the rotation speed is around 800 rpm, and the roll mold rotation speed is 8 to 10 rpm. It is. Further, in order to eliminate dust and the like adhering to the fine protrusions (embosses) 11 of the forming roll 10, a brush brush 56 is provided on the upstream side in the rotational direction from the introduction portion of the metal foil 20 of the forming roll 10. The dust can be directly scraped off from the convex fine protrusions (embosses) 11 of the forming roll 10. In this case, as a matter of course, it is necessary to remove dust by a suction device (not shown) or the like so that the removed chips 21 do not fall on the newly supplied metal foil 20.

  Further, in the third embodiment of the metal foil roll forming apparatus for realizing the method of the present invention, as shown in FIG. 7, a plurality of brush rolls 51, 52, 53, 54 (quadruple brush rolls) should be selected as much as possible within the range permitted by various conditions such as the outer diameter of the forming roll 10 and the installation space, roll forming mold production, etc. It is possible to increase the number of brush rolls that rotate and swing. As a result, it is possible to eliminate the difficult-to-remove residual scrap 21 that is sandwiched and fixed between “burrs” having a small burr shape after molding. Further, in order to eliminate dust and the like adhering to the convex fine protrusions (embosses) 11 of the forming roll 10, as in the second embodiment, the rotational direction is higher than the introduction portion of the metal foil 20 of the forming roll 10. By providing the brush-off brush roll 56 on the upstream side, dust can be directly scraped off from the fine protrusions (embosses) 11 of the forming roll 10.

  Next, the invention of the metal foil roll forming method of the present invention will be described mainly with reference to FIG. In the metal foil roll forming method of the present invention, the convex cutting edge mold (emboss) 11 on the surface of the forming roll 10 moves and moves in the direction of movement of the metal foil 20 in order to perform processing in the trajectory of the forming roll 10 rotating. In synchronization with the speed, the metal foil 20 approaches while moving in the rotational direction of the forming roll 10. The metal foil 20 to be processed is sandwiched in the vicinity of the sandwiching position A by the convex cutting edge mold (emboss) 11 on the surface of the forming roll 10 and the receiving roll 30. The rubber on the surface of the receiving roll 30 starts to be deformed by the pressing force from the convex cutting die (emboss) 11 on the surface of the forming roll 10 and starts to cut the sandwiched metal foil 20. As the forming roll 10 advances, the convex cutting edge mold (emboss) 11 on the surface of the forming roll 10 enters the rubber on the surface of the receiving roll 30, and the convex cutting edge mold 11 approaches the end of the deformation. Accordingly, the scrap 21 is cut from the metal foil 20 to be processed, and the scrap 21 is left in the rubber on the surface of the receiving roll 30 and separated from the metal foil 20 (FIG. 8A).

  However, since the surface rubber pressure of the receiving roll 30 which is a cutting reaction force with respect to the convex cutting edge mold (emboss) 11 is unstable, the formation of the punched hole 22 tends to be incompletely processed. Therefore, in the metal foil roll forming method of the present invention, a wide forming region X from the vicinity of the sandwiching position A to the vicinity of the separation position C is taken on the circumference of the forming roll 10, and the metal is placed on the forming roll 10 in the region X. The foil 20 is wound for a long time, and the plurality of receiving rolls 30 and 40 meanwhile the metal foil 20 is reliably in contact at the maximum rubber deformation position (maximum reaction force position) on the receiving roll surface. It becomes possible.

  Furthermore, in the present invention, incomplete machining that is expected to occur due to the above-described instability of the reaction force only by the rotation of the plurality of receiving rolls 30 and 40 facing each other, that is, half-cut or burr-like minute height “ Since it may be difficult to eliminate the scraps 21 (FIG. 9B) sandwiched and fixed between “burrs”, measures are also taken. That is, as shown in FIG. 8 described above, a two-axis drive mechanism is employed in which the rotating brush roll 50 is swung in the axial direction at a stroke length of 2 mm at 100 spm.

  In this way, in the metal foil roll forming method of the present invention, the removal operation of the residual debris 21 and the like which are sandwiched and fixed between the burrs having a minute height after forming is difficult to achieve is achieved. Is done. This removal operation is performed in an atmosphere in which air with a static pressure of 2.5 Kpa is sucked in the enclosed space. Although not shown in detail in these configurations, each brush roll 50 is covered by covering the molding processing region X from the vicinity of the sandwiching position A to the vicinity of the separation position C with a surrounded space and sucking air in the space. The extracted dust and fine powder soared in the space surrounded by etc. are securely stored by a dust collector (not shown).

  In this way, in the present invention, after the first molding processing operation between the forming roll 10 and the first receiving roll 30, the metal foil 20 is rotated while being wound around the forming roll 10 for a long time. Then, the second receiving roll 40 receives the second forming process operation. Here, incompletely processed parts that are not completely removed by the first molding process operation, that is, half cuts, scraps 21 and the like that are sandwiched and fixed between “burrs” having a minute height of burrs, etc. The second molding process is completely processed. Also in the second molding operation region, the scrap 21 extracted from the metal foil 20 adheres to the rubber on the surface of the second receiving roll 40 and is wiped off by the brushing brush roll 49 provided downstream.

  Also by the above, the scraps 21 and dust accompanying the metal foil 20 after the forming process are removed by the scrap removing unit 50. The metal foil 20 from which the scraps 21, dusts, and the like have been removed is changed in direction by the lead-out rolls 60 and 66 after exiting the forming process region, and is generated in the metal foil 20 by the punching process at the horizontal movement position after the direction change. The “burr” as the processing burr is rolled by the rolling unit 80 to bring the foil thickness to a level close to the original foil thickness before the roll forming process.

  10, this rolling unit 80 is provided with a pair of 80 mmφ metal rolls 81 and 82 at the top and bottom, 120 mmφ reinforcing rollers 83 and 84 as backups, and guide rolls 85 and 86 on both sides thereof. It is arranged. The guide rolls 85 and 86 arranged on both sides are commonly called “zebra rolls” and have a function of spreading the metal foil 20 in the width direction. In addition, about pressurization, the thickness after pressurization is managed by giving a roll structure sufficient intensity | strength and controlling the clearance gap between rolls. Further, the lower roll 82 of 80 mmφ is rotated in synchronization with the winding speed of the metal foil 20 by a motor (not shown) to feed the foil. When deformation of the upper and lower rolls 81 and 82 cannot be ignored due to conditions such as the thickness of the metal foil 20 to be processed, it is effective to install the reinforcing rolls 83 and 84.

  Thus, it is possible to roll the “burr” as a processing burr generated in the metal foil 20 by the punching process with the rolling unit 80 so that the thickness of the foil is close to the original foil thickness before the roll forming process. There is one new problem that may occur here. This will be described with reference to FIG.

  For example, when a hole is formed in the metal foil 20 using an apparatus that implements the method of the present invention, a processing burr as shown in the left and right views of FIG. However, in each figure of FIG. 12, the burr is drawn with emphasis for ease of understanding. In the subsequent process, the metal foil 20 in which the processing burr is generated is rolled by the rolling unit 80 on the “burr” as the processing burr c remaining on the back surface of the formed punching hole 22, so The thickness is approximately equal to the thickness of. At this time, the amount of elongation at the time of rolling differs between the processed portion a (porous forming processed portion) of the metal foil 20 and the unprocessed portion b (both edges of the foil). For this reason, as shown in the left figure of FIG. 12 (B), many wrinkles d may generate | occur | produce in the metal foil 20 after rolling. This is because when foil materials having different thicknesses (thickness of processed part a = t2, thickness of unprocessed part b = t1, t2> t1) are uniformly pressed and rolled by a rolling roll 80, the foil material extends in the direction of movement of the foil. Since the unprocessed portion b (thickness t1) and the processed portion a (thickness t2) have different elongations, wrinkles d occur frequently in the long continuous processing, and the streaks rolled on the foil surface It appears. Such a phenomenon is theoretically clear and is an unavoidable problem in processing a metal foil with a small rolling amount in the rolling process.

  Therefore, in the present invention, as shown in the left drawing of FIG. 12C, the embossed portion that does not penetrate the unprocessed portion b at the same time as the through-hole processing of the punched hole 22 is performed on the processed portion a of the metal foil 20. e is processed in the same pattern. The height (t3) of the embossed portion e is substantially equal to or slightly lower than the height (t2) of the burrs c in the hole processing, as shown in the right figure of FIG. 12C (t3 ≦ t2). Is desirable. Thereby, it is possible to prevent the occurrence of wrinkles after rolling by making the elongation ratios of both in roll processing as equal as possible. An example of a specific shape of the embossed portion e is shown in the left and right views of FIG. The left figure of FIG. 12 (D) is a bowl-shaped embossing, and the right figure of FIG. 12 (D) shows an example in which a “ki” -shaped embossing is formed.

  Such an embossing processing method can be realized by rounding the edge of the blade portion of the convex fine protrusion (emboss) 11 of the same forming roll 10 or by providing a protrusion of another shape, and the end of the receiving roll 30. This can also be realized by step processing in the vicinity of the part, that is, by making the diameter of the receiving roll 30 in the vicinity of the end part smaller than the diameter of the hole processing part in the central part. Here, it is important to adjust so that t3≈t2 or t3 ≦ t2 by any means.

  In the embodiment of the present invention, it is also possible to actively provide a new dust removal cleaning / deburring unit. The new dust removal cleaning / deburring unit is an ultrasonic wave / electric field etching means 150, and its details are shown in FIG. This ultrasonic / electric field etching means 150 is not only used for deburring the porous metal foil 20 of the present invention, but is also generally used for deburring a plate-like / web-like material that is continuously supplied. Diversion to slitter deburring means is also possible.

  The ultrasonic / electric field etching means 150 is provided with an ultrasonic cleaning tank 151 provided with an ultrasonic oscillator 160 inside, and by utilizing the characteristic that electric charges and ultrasonic waves concentrate on the convex portion, the present porous metal It has a function of facing and conveying the processing return surface of the foil to the ultrasonic oscillator 160. In this ultrasonic cleaning tank 151, cleaning water 152 is put up to the liquid level 153, and this cleaning water 152 is circulated. The circulating wash water 152 is reduced in pressure while passing through a filter (not shown) made of a hollow fiber membrane, and the air in the wash water is removed (degassed) to eliminate the air braking effect. The metal foil 20 to be treated is fed by the electrode roller 155 toward the periphery of the rotating drum 154 and separated by the nipple roll 156. Meanwhile, the metal foil 20 contacts the periphery of the rotating drum 154 and is simultaneously rotated. Electrode pieces 159 are arranged in the vicinity of the periphery of the rotating drum 154 at a slight distance, and electrode members 157 and 158 are provided at both ends thereof. The electrode members 157 and 158 and the rotary drum 154 are configured such that their installation heights can be adjusted (detailed configurations are not shown).

  With such a configuration, the ultrasonic / electric field etching means 150 generates an electric field between the electrode piece 159 around the rotating drum 154 (energization of the metal foil 20 by the electrode roller 155), and an ultrasonic oscillator is generated there. The ultrasonic wave oscillated by 160 is applied to perform deburring by metal fatigue, but the vibration effect on the burrs is enhanced by enhancing the force of generating and collapsing vacuum cavities in the cavitation of cleaning water 152 by ultrasonic waves. It is what raises.

  The metal foil 20 drawn from the rotary drum 154 by the nipple roll 156 is dried by the hot air drying chamber 165. It is appropriate that the ultrasonic / electric field etching means 150 is provided in front of the second rolling means in a state where there is a convex shape after processing as a system of an actual roll forming apparatus for porous metal foil. This is arranged at the position of the arrow A in the system configuration diagram of FIG. Furthermore, as another aspect, it is also possible to arrange at the position of the arrow B in the system configuration diagram of FIG. 3, that is, before the ear end position control device (EPC) 120, which is just before winding the processed metal foil. is there.

  In the system of the metal foil roll forming apparatus showing the overall configuration for realizing the method of the present invention in FIG. 2, it is possible to eliminate the punching fine powder that accompanies the metal foil 20 just before winding the finished processed foil. For the purpose, an air dust removing unit 90 and a dust removing roller unit 100 with a cleaning function are provided. In the system of the metal foil roll forming apparatus shown in FIG. 3, the air dust removal unit 90 is provided immediately after the rolling process by the first rolling roll 80.

As shown in FIGS. 11 (A) and (B), the air dust removing unit 90 is ideally adapted to the air pitch adjusted to the hole pitch (FIG. 11 (C)) after the metal foil 20 is formed as much as possible. The metal foil 20 after fine hole processing is formed between the plate 124 having the ejection holes 121, 121, 121... And the plate 125 having the air suction holes 122, 122, 122. Is a unit that moves. In addition, a soft brush 123 surrounded by a rectangle is disposed at a position where the metal foil 20 moves on the plate so as to come into contact with the foil surface, and has a function of peeling the fine powder from the surface of the metal foil 20. The fine powder is exfoliated and fluttered up so that air can be collected. The jet air pressure is ² to 3 kg / cm ² , and the suction is 2.5 Kpa at the dust collector static pressure. The necessary number of air passage holes for dust removal are provided in the upper and lower plates having an area of 100 mm wide by 100 mm long diagonal holes having a width of 1 mm.

  As described above, according to the method for forming a perforated metal foil of the present invention that excludes processing waste, fine powder, and dust, the hole of the metal foil is formed by pressing a simple mold against the elastic body. In addition, it is easy to control costs and is a continuous forming method because it is a roll molding method. Furthermore, it is fine for fine hole processing to thin foil, which is a trend of current collector electrode application using the metal foil in the future. The convex metal mold makes it possible to provide the market with an ideal metal foil that is stable and highly productive, does not contain processing dust, fine powder, and dust, and has a reduced thickness of processing dust.

  Accordingly, the present invention allows a metal foil having a thickness of 50 μm or less to be elongated with a metal forming roll having a fine convex shape formed on the surface thereof and a receiving roll made of an elastic body facing the metal foil. It is a roll forming system that performs continuous processing such as drilling on metal foil. At the same time, one or more processing scraps and fine powders embedded in the elastic body of the first receiving roll immediately after processing are operated by a plurality of elastic fiber brush rolls rotating at high speed and in the direction of rotation of the forming roll. The second and third receiving rolls (having the same function and performance as the first receiving roll) are disposed, and the metal foil is fitted on the convex portion of the forming roll and is mechanically stable. While being transferred, the processing waste and the like are removed by the high-speed rotation operation of the plurality of elastic fiber brush rolls. In addition, an adhesive rubber roller that has its own cleaning function or an ultrasonic / electric field etching unit is placed immediately before winding of the metal foil to cope with half-cutting and to eliminate processing dust, foil surface adhering fine powder and dust. A roll forming system is provided. As a result, processing waste, foil surface adhering fine powder, and dust that are unavoidable due to vibrations in processing equipment in the apparatus, accumulation of assembly tolerances, and the like are to be eliminated.

  As mentioned above, in the case of punching with a general mold, as a general theory, it is possible to perform precision processing and to improve the sharpness by suppressing the escape during processing of the material as much as possible. Become. On the other hand, in the case of processing by the forming roll of the present invention, as shown in FIG. 14 (A), the vicinity of the central portion a of the forming roll 10 is the contact between the elastic body outer peripheral roll 33 of the receiving roll 30 and the metal foil 20. Although all the surfaces have a material pressing function, there is no member to be pressed in the vicinity of the end face b of the forming roll 10, and the hole machining becomes an unstable portion L. Therefore, it is possible to improve the quality of the metal foil 20 by continuously trimming the unstable portion L (FIG. 14B) and sucking or removing the processing waste in the post-molding process. In the system of the metal foil roll forming apparatus that realizes the method of the present invention, the overall configuration of which is shown in FIG.

  The present invention is particularly used for a portable electronic device, a lithium ion battery of an electric vehicle, and a lithium ion capacitor, and mainly describes a copper foil as an example. Is not limited to copper foil, but can also be applied to aluminum foil, and its use is not limited to secondary batteries.

10 forming rolls, 11 convex cutting edge molds (fine projections, embossing),
20 Metal foil (working foil), 21 Excavation, 21 'Implanted swarf 25 Delivery roller, 26 Take-up roll 30 First receiving roll, 39 Draw-off brush roll,
40 Second receiving roll, 49 Brush-off brush roll,
50, 55 Brush roll, 56 Brush-off brush roll 80 Rolling unit, 90 Air dust removal unit 100 Dust removal roller unit, 110 Slitter unit 120 Ear end position control device (EPC)
150 Ultrasonic and electric field etching means

Claims (4)

After rewinding a long metal foil wound in a coil shape, the fine metal foil is sandwiched between a forming roll and a receiving roll to form a large number of fine holes in the metal foil. It is a roll metal foil roll forming method for winding the long metal foil into a coil again,
The forming roll is formed with a large number of fine convex shapes over the entire circumference of the circumferential roll surface, and the receiving roll is elastically deformed by being pressed against the convex shape on the surface of the forming roll. A first receiving roll having substantially the same function and performance provided by a plurality of the receiving rolls and facing the forming roll along the flow of the metal foil. And a second receiving roll,
The long metal foil is configured to be bitten and introduced at a biting position A and to be separated at a separation position C with respect to the convex mold on the surface of the forming roll, and from the biting position A to the separation position C. The molding region X is configured to occupy 180 degrees or more of the entire circumferential surface of the molding roll,
As a result, the long metal foil maintains a state of being bitten with respect to the convex mold on the surface of the forming roll in the forming region X, rotates together with the forming roll, and the forming roll and the first and The plurality of fine punch holes are formed between the second receiving roll and the metal foil by the subsequent second receiving roll even if half cut of the metal foil punching hole occurs in the first receiving roll. So that all the holes are molded,
The strips of the long metal foil punched and formed by the convex mold formed on the surface of the forming roll are left on the first and second receiving rolls,
The scraps left on the first and second receiving rolls are removed from the elastic body surface of each receiving roll by rotating brushes respectively provided for the first and second receiving rolls. A roll forming method of a porous metal foil.   By the rolling roll provided in the middle of the porous metal foil transfer line before the long metal foil after the fine punching is formed again in a coil shape, the burr-like shape generated by the fine punching of the long metal foil The roll forming method for a porous metal foil according to claim 1, wherein the processing return is finished by rolling to near the foil thickness.   The long metal foil after forming the fine punched hole is rolled by a rolling roll provided in the middle of the porous metal foil transfer line before being coiled again, and then passes through a substantially sealed space, By blowing or sucking compressed gas to the transporting porous metal foil, processing waste, fine powder, and dust accompanying the porous metal foil are removed, and further, a burr-like shape generated by processing the long metal foil by a rolling roll is removed. The roll forming method for a porous metal foil according to claim 1, wherein the processing return is rolled up to near the foil thickness and then wound up again. After rewinding a long metal foil wound in a coil shape, the fine metal foil is sandwiched between a forming roll and a receiving roll to form a large number of fine holes in the metal foil. Coiled porous metal foil obtained by rewinding a long metal foil of
The forming roll has a large number of fine convex molds formed on the entire surface of the circumferential roll, and the receiving roll is pressed against the convex mold on the molding roll surface. A plurality of receiving rolls, and a first receiving roll having substantially the same function and performance provided facing the forming roll along the flow of the long metal foil, and a first roll It is composed of two receiving rolls,
The long metal foil is configured to be bitten and introduced at a biting position A and to be separated at a separation position C with respect to a convex mold on the surface of the forming roll, from the biting position A to the separation position C. Is formed so as to occupy 180 degrees or more of the entire circumferential surface of the forming roll,
As a result, the long metal foil maintains a state of being bitten with respect to the convex mold on the surface of the forming roll in the forming region X, rotates together with the forming roll, and the forming roll and the first and The plurality of fine punch holes are formed between the second receiving roll and the metal foil by the subsequent second receiving roll even if half cut of the metal foil punching hole occurs in the first receiving roll. So that all the holes are molded,
The strips of the long metal foil punched and formed by the convex mold formed on the surface of the forming roll are left on the first and second receiving rolls,
The scraps left on the first and second receiving rolls are removed from the elastic body surfaces of the receiving rolls by rotary brushes provided for the first and second receiving rolls, respectively.
The long metal foil after forming the fine punched hole is rolled by a rolling roll provided in the middle of the porous metal foil transfer line before being wound again in a coil shape, and then passed through a substantially sealed space portion. Coiled porous material characterized in that the processing waste, fine powder, and dust accompanying the porous metal foil are removed by blowing or sucking compressed gas to the transporting porous metal foil in the section. Molded metal foil.

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