JP3828805B2

JP3828805B2 - Bonded body of metal foil and metal member and method for manufacturing the same

Info

Publication number: JP3828805B2
Application number: JP2001398615A
Authority: JP
Inventors: 和正八代; 賢司河村; 賢信鬼頭
Original assignee: NGK Insulators Ltd
Current assignee: NGK Insulators Ltd
Priority date: 2001-05-02
Filing date: 2001-12-27
Publication date: 2006-10-04
Anticipated expiration: 2021-12-27
Also published as: JP2003019580A

Description

【０００１】
【発明の属する技術分野】
本発明は、金属箔体と金属部材との接合体（以下、単に「接合体」ともいう）、及びその製造方法に関する。さらに詳しくは、コスト性及び信頼性に優れた接合体、及び生産性に優れたその製造方法に関する。
【０００２】
【従来の技術】
従来、金属箔体と金属部材を接合するには、金属部材の接合部分にろう材を塗布し、又は金属箔体と金属部材との間にろう材を挟持させて、これらを電気炉に入れて全体を加熱する方法、又は電子ビーム等を用いて接合部分を加熱する方法等が一般的に用いられている。
【０００３】
しかし、これらの接合方法ではろう材を必要とするために、製造コストが高いという問題があった。また、エネルギー線を照射する際の金属箔体の損傷を抑制するため、溶接用のろう材には金属箔体に比べかなり低融点であるものしか用いることが出来ないために、ろう材の選択の幅が狭いという問題があり、さらに、金属箔体と金属部材の双方を溶解させるため、金属箔が損傷する場合もあり、得られる接合体の接合部分の機械的強度が低くなりやすいという問題があった。
【０００４】
【発明が解決しようとする課題】
本発明は、かかる従来の問題に鑑みてなされたものであり、その目的とするところは、ろう材を必要としないためにコスト性に優れ、また、金属箔体の損傷を与えずに金属部材のみを溶解させて金属箔体と金属部材とを溶着・接合させることにより、接合体の機械的強度が強いために信頼性に優れた金属箔体と金属部材との接合体、及び、生産性に優れた金属箔体と金属部材との接合体の製造方法を提供することにある。
【０００５】
【課題を解決するための手段】
すなわち、本発明によれば、少なくとも１枚の金属箔体の端縁と金属部材とを接合してなる金属箔体と金属部材との接合体であって、前記金属部材の形状が、平坦部と、その厚みが前記平坦部に比して厚く、その先端に接合面を持った凸状部とを有する形状であり、前記金属箔体の端縁のうちの前記金属部材と接合されるべく配列された端縁（接合端縁）の側面部と、前記金属部材の前記接合面とを、前記接合端縁近傍を屈曲することにより密着させた状態で前記凸状部にエネルギー線を照射し、前記凸状部を溶解して、前記凸状部と前記側面部とを溶着させることにより接合してなることを特徴とする金属箔体と金属部材との接合体が提供される。
【０００６】
本発明においては、金属箔体と金属部材とが銅又は銅合金から構成されていることが好ましく、金属箔体と金属部材との接合部分において、金属箔体から金属部材の方向へ柱状晶が形成されていることが好ましい。
【０００８】
本発明においては、凸状部の厚み（Ｌ_２）と、平坦部の厚み（Ｌ_１）との差が０．１ｍｍ以上であることが好ましく、平坦部の厚み（Ｌ_１）が０．２ｍｍ以上であることが好ましく、凸状部の厚み（Ｌ_２）が０．４ｍｍ以上であることが好ましい。
【０００９】
エネルギー線が、金属箔体の側面部を含む面の法線に対して、角度θ（０°≦θ≦３０°）で所定箇所に照射されてなることが好ましい。金属部材の凸状部が、側面部に垂直に交差するように配置されてなることが好ましい。エネルギー線が、側面部に垂直に交差する線に対して、角度が垂直で凸状部に照射されてなることが好ましい。エネルギー線が、金属箔体に直接照射しないでなることが好ましい。
【００１０】
本発明においては、エネルギー線の照射点におけるパワー密度が６ｋＷ／ｍｍ²以上であることが好ましく、凸状部の厚みをＬ₂（ｍｍ）、パワー密度をＥ（ｋＷ／ｍｍ²）としたとき、下記式（４）を満足することが好ましい。
【００１１】
【数４】
Ｌ₂≦Ｅ／７ …（４）
【００１２】
本発明においては、エネルギー線の照射点におけるスポット径が１ｍｍ以下であることが好ましく、金属部材におけるエネルギー線の照射点が平面状であることが好ましい。
【００１３】
本発明においては、隣り合う金属箔体どうしに間隙を保持して配列されてなることが好ましく、エネルギー線が、レーザー又は電子ビームによるものであることが好ましい。また、エネルギー線が連続波であることが好ましく、レーザーがＹＡＧレーザーであることが好ましい。
【００１４】
さらには、金属部材と金属箔体との接合を補助する接合材料が、金属箔体及び／若しくは凸状部に塗布され、又は金属箔体と凸状部との間に挟持されて、凸状部及び接合材料にエネルギー線を照射し、それらを溶解させて、溶解した凸状部及び接合材料を金属箔体の接合端縁に溶着させることにより形成されたものであってもよい。
【００１５】
これらの構成条件は、金属箔体及び金属部材が、それぞれ電気化学素子に用いられる金属箔体及び金属部材に好適に採用される。また、本発明によれば、金属箔体と金属部材との接合体を用いてなる電気化学素子が提供される。
【００１６】
また、本発明によれば、少なくとも１枚の金属箔体の端縁と金属部材の先端部とを接合して金属箔体と金属部材との接合体を製造する方法であって、前記金属部材の形状が、平坦部と、その厚みが前記平坦部に比して厚い凸状の前記先端部とを有する形状であり、前記金属箔体の端縁のうちの前記金属部材の先端部と接合されるべく配列された端縁（接合端縁）の側面部と、前記金属部材の前記先端部とを、前記接合端縁近傍を屈曲することにより密着させて前記金属箔体と前記金属部材を配置し、前記先端部にエネルギー線を照射し、それを溶解させて、溶解した前記先端部を側面部に溶着させて、金属箔体と金属部材との接合体を形成することを特徴とする金属箔体と金属部材との接合体の製造方法が提供される。
【００１７】
本発明においては、銅又は銅合金からなる金属箔体と金属部材を使用することが好ましい。
【００１８】
本発明においては、先端部の厚み（Ｌ_２）と、平坦部の厚み（Ｌ_１）との差が０．１ｍｍ以上である金属部材を使用することが好ましく、平坦部の厚み（Ｌ_１）が０．２ｍｍ以上である金属部材を使用することが好ましく、先端部の厚み（Ｌ_２）が０．４ｍｍ以上である金属部材を使用することが好ましい。
【００１９】
また、エネルギー線を、側面部を含む面の法線に対して、角度θ（０°≦θ≦３０°）で先端部に照射することが好ましい。金属部材の先端部を、側面部に垂直に交差するように配置することが好ましい。側面部に垂直に交差するエネルギー線を、エネルギー線発生装置により走査して照射することが好ましい。エネルギー線を、側面部に垂直に交差する線に対して、角度が垂直で先端部に照射することが好ましい。エネルギー線を金属箔体に直接照射しないことが好ましい。
【００２０】
本発明においては、照射点におけるパワー密度が６ｋＷ／ｍｍ^２以上となるようにエネルギー線を照射することが好ましく、先端部の厚みをＬ_２（ｍｍ）、前記パワー密度をＥ（ｋＷ／ｍｍ^２）としたとき、下記式（５）を満足するように前記エネルギー線を照射することが好ましい。
【００２１】
【数５】
Ｌ₂≦Ｅ／７ …（５）
【００２２】
本発明においては、エネルギー線の照射点が平面状である金属部材を用いることが好ましく、照射点におけるスポット径が１ｍｍ以下となるようにエネルギー線を照射することが好ましい。
【００２３】
本発明においては、隣り合う金属箔体どうしに間隙を保持して配列することが好ましく、エネルギー線としてレーザー又は電子ビームを用いることが好ましい。
【００２４】
また、本発明においては、レーザーとしてＹＡＧレーザーを用いることが好ましく、さらに、エネルギー線を、連続照射が可能なエネルギー線発生装置を用いて照射することが好ましい。エネルギー線を、側面部を含む面に平行な面上を移動して走査可能なエネルギー線発生装置を用いて照射することが好ましい。エネルギー線発生装置により、先端部にエネルギー線を走査して照射することが好ましい。配列された金属箔体の枚数に応じて金属部材を複数個用意し、複数個の金属部材を、それらの先端部が側面部に垂直に交差するようにして連続的に配置することが好ましい。
【００２５】
また、本発明によれば、少なくとも１枚の金属箔体の端縁と金属部材とを接合して金属箔体と金属部材との接合体を製造する方法であって、前記金属部材の形状が、平坦部と、その厚みが前記平坦部に比して厚く、その先端に接合面を持った凸状部とを有する形状であり、前記金属箔体の端縁のうち、前記金属部材と接合されるべく配列された端縁（接合端縁）の側面部と、前記金属部材の前記接合面とを、前記接合端縁近傍を屈曲することにより密着させて前記金属箔体と前記金属部材を配置し、前記凸状部にエネルギー線を照射し、それを溶解させて、溶解した前記凸状部を前記側面部に溶着させて、金属箔体と金属部材との接合体を形成することを特徴とする金属箔体と金属部材との接合体の製造方法が提供される。
【００２６】
本発明においては、銅又は銅合金からなる金属箔体と金属部材を使用することが好ましい。本発明においては、凸状部の厚み（Ｌ_２）と、平坦部の厚み（Ｌ_１）との差が０．１ｍｍ以上である金属部材を使用することが好ましく、平坦部の厚み（Ｌ_１）が０．２ｍｍ以上である金属部材を使用することが好ましく、凸状部の厚み（Ｌ_２）が０．４ｍｍ以上である金属部材を使用することが好ましい。
【００２７】
また、エネルギー線を、側面部を含む面の法線に対して、角度θ（０°≦θ≦３０°）で凸状部に照射することが好ましい。金属部材の凸状部を、側面部に垂直に交差するように配置することが好ましい。側面部に垂直に交差するエネルギー線を、エネルギー線発生装置により走査して照射することが好ましい。エネルギー線を、側面部に垂直に交差する線に対して、角度が垂直で凸状部に照射することが好ましい。エネルギー線を、金属箔体に直接照射しないことが好ましい。
【００２８】
本発明においては、照射点におけるパワー密度が６ｋＷ／ｍｍ²以上となるようにエネルギー線を照射することが好ましく、凸状部の厚みをＬ₂（ｍｍ）、パワー密度をＥ（ｋＷ／ｍｍ²）としたとき、下記式（６）を満足するようにエネルギー線を照射することが好ましい。
【００２９】
【数６】
Ｌ₂≦Ｅ／７ …（６）
【００３０】
本発明においては、照射点におけるスポット径が１ｍｍ以下となるようにエネルギー線を照射することが好ましく、エネルギー線の照射点が平面状である前記金属部材を用いることが好ましい。
【００３１】
本発明においては、隣り合う金属箔体どうしに間隙を保持して配列することが好ましく、エネルギー線として、レーザー又は電子ビームを用いることが好ましい。
【００３２】
また、本発明においては、レーザーとしてＹＡＧレーザーを用いることが好ましく、さらに、エネルギー線を、連続照射が可能なエネルギー線発生装置を用いて照射することが好ましい。エネルギー線を、側面部を含む面に平行な面上を移動して走査可能なエネルギー線発生装置を用いて照射することが好ましい。エネルギー線発生装置により、凸状部に前記エネルギー線を走査して照射することが好ましい。配列された金属箔体の枚数に応じて金属部材を複数個用意し、複数個の金属部材を、それらの凸状部が側面部に垂直に交差するようにして連続的に配置することが好ましい。
【００３３】
【発明の実施の形態】
以下、本発明の実施の形態を、図面を参照しつつ具体的に説明する。
【００３４】
図１に示すように、本発明の金属箔体１と金属部材４との接合体１１は、上述のように、少なくとも１枚の金属箔体１の端縁２と金属部材４とを接合してなる接合体である。なお、本発明に係る金属箔体と金属部材との接合体の構成材料である金属箔体１と金属部材４を構成する金属材料は、一般的な金属又はその合金等により構成されているものであればよいが、具体的にはチタン、銅、又はこれらの合金等から構成されていることが好ましく、特に銅又は銅合金から構成されていることが、接合状態の良好な接合体を提供できるために好ましい。
また、図２に示すように、本発明の接合体は、金属部材４の形状が、平坦部と、その厚みが平坦部に比して厚く、その先端に接合面を持った凸状部７とを有する形状であり、金属箔体１の接合端縁２の側面部１３と、金属部材４の接合面とを、接合端縁２近傍を屈曲することにより密着させた状態で凸状部７にエネルギー線を照射し、凸状部７を溶解して、凸状部７と側面部１３とを溶着させることにより接合してなるものである。
【００３５】
本発明の接合体に用いられる金属箔体の枚数は、１枚でもよいし、複数枚でも構わない。金属箔体の枚数が１枚である場合には、その端縁が金属部材の凸状部と複数箇所にて接合されるように金属箔体を構成する。その構成には特に制限はないが、例えば、１枚の金属箔体を同心円的に捲回したり、複数箇所を折り曲げることが挙げられる。金属箔体の枚数が複数枚である場合には、それらの接合端縁を大略揃えて配列して構成する。なお、金属箔体の枚数が複数枚である場合でも、そのうち１枚又は複数枚を同心円的に捲回したり、複数箇所を折り曲げて構成してもよい。
【００３６】
本発明の接合体に用いられる金属部材としては、特に制限はなく、例えば、汎用の成形方法により得られたものを使用することが出来る。
【００３７】
また、例えば図２に示す、金属部材４の形状については、平坦部と、その厚みが平坦部に比して厚く、その先端に接合面を持った凸状部７とを有する形状であれば特に制限はない。
前記凸状部の形状の具体的な例を図５、６に示す。本発明の接合体に用いられる金属部材４の凸状部７の形状は、図５に示すような台形状であってもよく、図６に示すような尖塔状であってもよい。
なお、図５、６においてＬ_１は平坦部１２の厚み、Ｌ_２は凸状部７の厚みを示す。
【００３８】
本発明の接合体においては、図５、６に示すように金属部材４は、平坦部１２と、その厚みが平坦部１２に比して厚く、その先端に接合面を持った凸状部７とを有する形状であり、凸状部７の厚み（Ｌ_２）と、平坦部１２の厚み（Ｌ_１）との差が０．１ｍｍ以上であることが好ましく、０．６ｍｍ以上であることがさらに好ましく、０．８ｍｍ以上であることが特に好ましい。凸状部７と平坦部１２との厚みの差が０．１ｍｍ未満である場合には、凸状部７の形状的な特徴が発揮されず、凸状部７と金属箔体１との接触状態が不安定となるために好ましくない。また、本発明の接合体においては凸状部７と平坦部１２との厚みの差の上限値については特に限定されないが、金属部材の加工精度及び強度等から適宜設定されればよく、例えば３ｍｍ以下であればよい。
【００３９】
接合に際して金属箔に金属部材を押さえ付けるときに、当該金属部材の変形や損傷等の発生を防止するといった観点からは、平坦部の厚み（Ｌ₁）が０．２ｍｍ以上であることが好ましく、０．３ｍｍ以上であることがさらに好ましく、０．４ｍｍ以上であることが特に好ましい。なお、平坦部の厚みの上限値については特に限定されないが、溶接部分とは直接的には関係のない部分であるため金属部材の強度及び重量等から適宜設定されればよく、例えば２ｍｍ以下であればよい。
【００４０】
また、凸状部の厚み（Ｌ₂）は０．４ｍｍ以上であることが好ましく、０．５ｍｍ以上であることがさらに好ましく、０．６ｍｍ以上であることが特に好ましい。このことにより、より強固に接合されてなる接合体とすることが出来る。なお、凸状部の厚みの上限値については特に限定されないが、照射されるエネルギー線のパワーの限界から適宜設定されればよい。
【００４１】
本発明の接合体に用いられる金属部材の形状に関して、以下に示す形状のものを好適な例として挙げることが出来る。
図２には、凸状部７を、その先端部６に有する金属部材４の例を示しているが、この場合には、金属部材４の上面側からエネルギー線８を照射することにより、金属部材４と金属箔体１の接合端縁２とを溶着させて接合させることが出来る。
【００４２】
図３には、図２の金属部材４に比べ、凸状部３３に厚みを有する金属部材３１の例を示している。この場合には、金属部材３１の上面側からエネルギー線３４を照射することによって、金属部材３１と金属箔体１の接合端縁２とを溶着させて接合させることが出来る。
【００４３】
図４には、金属部材の先端部ではない、所定箇所に凸状部５２を有する例を示しているが、この場合には、その凸状部５２を設けた金属部材５１の背面にエネルギー線５３を照射することにより、その金属部材５１と金属箔体１とを接合させることが出来る。
【００４４】
本発明においては、金属箔体と金属部材とが同種金属から構成されていることが好ましく、このことにより、金属箔体と金属部材とがよりよく溶着することとなるために、接合体の機械的強度が強く、信頼性の向上を図ることが出来る。
【００４５】
本発明の接合体の製造例として下記の方法を挙げることが出来る。すなわち、図２に示すように、平坦部と、その厚みが平坦部に比して厚く、その先端に接合面を持った凸状部７とを有する形状の金属部材４を用意し、金属箔体１の端縁のうちの金属部材４と接合されるべく配列された端縁（接合端縁）２近傍の側面部１３と、金属部材４の接合面とを、接合端縁２の近傍を屈曲することにより密着するように配置する。金属部材４の凸状部７にエネルギー線８を照射し、それを溶解させて、溶解した金属部材４の凸状部７を金属箔体１の接合端縁２に溶着させて、金属箔体１と金属部材４との接合体１１を形成する方法を挙げることが出来る。
【００４６】
このとき、接合端縁２近傍を屈曲することにより、側面部１３と、凸状部７の接合面とを密着させる。接合端縁２近傍を屈曲するには、予め適当な方法により接合端縁２近傍を屈曲しておくことの他、接合端縁２に接合されるべき金属部材４を適当な圧力で押さえ付けて屈曲する方法等を挙げることが出来る。
【００４７】
本発明の接合体においては、金属箔体と前記金属部材との接合部分に、金属箔体から金属部材の方向へ柱状晶が形成されていることが好ましい。一般に溶接金属は、溶融金属が母材（未溶融部）の結晶粒上に同一結晶方位をもって成長（エピタキシャル成長）する。このように形成された固相は熱源の移動に伴い、溶接ビード（溶融部分）内部へ成長する。この成長は、温度勾配の最も大きい方向に成長しやすく、その方向へほぼ一方向にのびた形態で成長し、このように成長した結晶は柱状晶と呼ばれる。
【００４８】
金属部材の溶融化した部分は、冷却されるにしたがって再結晶化するが、金属箔体を通じて溶融部分の熱が急速に拡散する。すなわち、金属箔体に密着した部分の溶融金属の温度が低下し、金属箔体と溶融金属の界面が核となって金属箔体から金属部材の方向へ柱状晶が形成しやすくなると考えられる。さらに、本発明では金属箔体の接合端縁近傍の側面部が金属部材と隙間なく密着して接触状態が良好であるために、金属箔体を通じた冷却効果により、柱状晶が形成しやすい状態となる。接合部分において金属箔体から金属部材の方向へ柱状晶が形成している本発明の接合体は、金属箔体と金属部材との接合状態が良好、すなわち、接合部分の機械的強度が強く信頼性に優れた接合体である。
【００４９】
また、本発明の接合体においては、図２に示すように、エネルギー線８が、金属箔体１の接合端縁２近傍の側面部１３を含む面の法線３に対して、角度θ（０°≦θ≦３０°）で凸状部７に照射されてなることが好ましく、角度θ（０°≦θ≦１０°）で照射されてなることがさらに好ましく、角度θ（０°≦θ≦５°）で照射されてなることが特に好ましい。また、エネルギー線８が、金属部材の凸状部７の表面に又はその前後近傍に合焦させてなることが好ましく、エネルギー線８が、金属箔体１に直接照射しないでなることが好ましい。
【００５０】
さらには、金属部材４の凸状部７が、側面部１３に垂直に交差するように配置されてなり、エネルギー線８が、側面部１３に垂直に交差する線をエネルギー線発生装置により走査、すなわち金属部材４の凸状部７を走査して照射することが好ましい。このとき、上述した、エネルギー線８が、金属箔体１の側面部１３を含む面の法線３に対して、角度θ（０°≦θ≦３０°）で凸状部７に照射されてなるということに加え、エネルギー線８が、側面部１３に垂直に交差する線に対して、角度が垂直で凸状部７に照射されてなることが好ましい。
これらにより、図１に示すように、ろう材を必要とせずに、金属箔体１と金属部材４の溶解体とを溶着させて、金属箔体１と金属部材４との接合体１１を形成することが出来るためにコストを低減することが出来る。また隣り合う金属箔体１が平行に並んでいなくてもその大略端縁を揃えて配列されていれば、複数枚の金属箔体１を一度の照射によって金属部材４と接合することも出来る。さらに、金属箔体１に損傷を与えずに、金属部材４の所定箇所（凸状部）のみを溶解させて金属箔体１と金属部材４とを溶着・接合することが出来、接合の機械的強度を向上させることが出来るために信頼性の向上を図ることが出来る。
【００５１】
なお、本発明でいう「接合端縁」とは、１枚の金属箔体における複数箇所の接合される端縁、或いは複数枚の金属箔体における、複数箇所に渡る、各金属箔体の接合される端縁を意味している。また、「側面部に略垂直に交差する」とは、複数の接合端縁近傍の側面部の全てを略垂直に交差することを意味している。
【００５２】
本発明の接合体においては、金属部材の凸状部にエネルギー線が照射されるに際して、当該エネルギー線の照射点におけるパワー密度が６ｋＷ／ｍｍ²以上であることが好ましく、７ｋＷ／ｍｍ²以上であることがさらに好ましく、８ｋＷ／ｍｍ²以上であることが特に好ましい。６ｋＷ／ｍｍ²未満であると、接合状態が良好ではなく、機械的強度が不充分となる場合が想定されるためである。なお、前記パワー密度の上限については特に限定されないが、金属部材やこれに接合される金属箔への損傷発生の回避等の観点から適宜決定されればよく、例えば６０ｋＷ／ｍｍ²以下であればよい。ここで、本発明にいうエネルギー線の「パワー密度」とは、エネルギー線のパワー（ｋＷ）を、金属部材の所定箇所において当該エネルギー線が照射される照射点のスポット面積（ｍｍ²）で除して得た値を意味する。
【００５３】
また、本発明の接合体においては、凸状部の厚みをＬ₂（ｍｍ）、前述のパワー密度をＥ（ｋＷ／ｍｍ²）としたとき、下記式（７）を満足することが好ましい。下記式（７）を満足するような条件でエネルギー線が照射されていることにより、本発明の接合体は金属箔体への損傷が抑制されており、接合部分の機械的強度も強いといった特性を有する接合体である。
【００５４】
【数７】
Ｌ₂≦Ｅ／７ …（７）
【００５５】
なお、より、接合の安定性を向上させ、接合部分の機械的強度も強いといった特性を有する接合体を得るといった観点からは、下記式（８）、（９）を満足することが好ましい。
【００５６】
【数８】
Ｌ₂≦Ｅ／９ …（８）
【００５７】
【数９】
Ｌ₂≦Ｅ／１０ …（９）
【００５８】
本発明の接合体においては、金属部材におけるエネルギー線の照射点が平面状であることが好ましい。このことにより、エネルギー線の乱反射が抑制され、特に金属箔体への損傷が抑制されているために、本発明の接合体は良好な接合状態であるという特性を有する。なお、エネルギー線の乱反射を抑制するといった観点からは、少なくとも照射点よりも広い範囲で平面状であればよい。
【００５９】
さらに本発明の接合体においては、照射点のスポット径が１ｍｍ以下であることが好ましい。このことにより、不要な箇所へのエネルギー線の照射が抑制され、特に金属箔体への損傷が抑制されているために、本発明の接合体は良好な接合状態であるという特性を有する。なお、本発明の接合体は、隣り合う金属箔体どうしが間隙を保持して配列されている場合に特に好適である。
【００６０】
また、例えば図２に示す、かかるエネルギー線８が、エネルギー密度が高く、発熱量も小さいレーザー又は電子ビームによるものであることが好ましく、また、エネルギー線が連続波であることが好ましい。このことにより、凸状部７の表面にエネルギーを集中させて照射することが出来るために凸状部７を効率的に溶解させることが出来、また金属箔体１の損傷を抑制することが出来る。なお、レーザーの中でも、ＹＡＧレーザーは焦点をよりよく絞ることが出来、焦点からはずれた部分に配置された金属箔体１の位置ではエネルギー密度はより小さくなり、金属箔体１の損傷をよりよく抑制することが出来ることから、特に好ましい。
【００６１】
また、本発明に係る接合体を製造するに際しては、例えば図２に示すエネルギー線８を、連続照射が可能なエネルギー線発生装置を用いて照射することが好ましく、エネルギー線８を、側面部１３を含む面に平行な面を走査可能なエネルギー線発生装置を用いて照射することが好ましい。なお、照射するエネルギー線の走査速度は、０．１〜１００ｍ／ｍｉｎであることが好ましく、１〜３０ｍ／ｍｉｎであることがさらに好ましく、２〜１０ｍ／ｍｉｎであることが特に好ましい。また、エネルギー線発生装置により、凸状部７にエネルギー線を走査して照射することが好ましい。さらに、本発明においては、配列された金属箔体１の枚数に応じ、金属部材４を複数個用意し、複数の金属部材４を、それらの凸状部７が側面部１３に垂直に交差するようにして、連続的に配置することが好ましい。これらのことにより、複数枚の金属箔体１を一度の照射によって接合することが出来ることとなる。
【００６２】
本発明の接合体を製造するに際して、ろう材等の接合補助材料は必要としないが、もちろん使用しても構わない。その場合には、金属部材と金属箔体との接合を補助する接合補助材料が、金属箔体及び／若しくは金属部材の凸状部に塗布され、又は金属箔体と金属部材の凸状部の間に挟持されて、凸状部及び接合材料にエネルギー線を照射し、それらを溶解させて、溶解した凸状部及び接合材料を金属箔体の接合端縁に溶着させることにより接合されたものであることが好ましい。
【００６３】
本発明の接合体は、その用途には特に制限はないが、電気化学素子に用いられることを好適例として挙げることが出来る。具体的には、金属箔体を電気化学素子の集電基板として、金属部材を集電基板から電流を導出するための集電部材として適用するものである。また、この電気化学素子としては、特に制限はないが、積層型電気化学素子や捲回型電気化学素子を好適例として挙げることが出来る。本発明の接合体は、金属箔体及び金属部材を構成する金属が銅又は銅合金である場合においては、例えば、捲回型電気化学素子を備えてなるリチウム二次電池の負極用材料として好適に用いることが出来る。この場合、銅又は銅合金から構成されている金属箔体の厚みは７μｍ〜１５μｍであることが好ましい。
【００６４】
次に、本発明に係る金属箔体と金属部材の接合体の製造方法の実施の形態を、図面を参照しつつ具体的に説明する。
【００６５】
図７に示すように、本発明の金属箔体と金属部材との接合体の製造方法は、少なくとも１枚の金属箔体１の端縁２と金属部材４の先端部５とを接合して接合体１０を製造する方法であって、金属部材４の形状が、平坦部と、その厚みが平坦部に比して厚い凸状の先端部６（凸状部７）とを有する形状であり、金属箔体１の端縁のうちの金属部材４の先端部６と接合されるべく配列された端縁（接合端縁）２の側面部１３と、金属部材４の先端部６とを、接合端縁２近傍を屈曲することにより密着させて金属箔体１と金属部材４を配置し、金属部材４の先端部５にエネルギー線７を照射し、それを溶解させて、溶解した金属部材４の先端部６を金属箔体１の側面部１３に溶着させて、金属箔体１と金属部材４との接合体１１を形成することを特徴とする。なお、本発明においては、金属箔体１と金属部材４を構成する金属材料として、一般的な金属又はその合金等を使用すればよく、具体的にはチタン、銅、又はこれらの合金等からなる金属箔体と金属部材を使用することが好ましく、特に銅又は銅合金からなる金属箔体と金属部材を使用することが、接合状態の良好な接合体が得られるために好ましい。
【００６６】
本発明の接合体の製造方法においては、接合端縁側に突出する凸状部６を先端部５に有する金属部材４を使用し、凸状部６と少なくとも１以上の接合端縁２近傍の側面部１３とが密着するように当該金属部材４を配置する。
【００６７】
このとき、接合端縁２近傍を屈曲することにより、側面部１３と、接合面を有する先端部６（凸状部７）とを密着させる。接合端縁２近傍を屈曲するには、予め適当な方法により接合端縁２近傍を屈曲しておくことの他、接合端縁２に接合されるべき金属部材４を適当な圧力で押さえ付けて屈曲する方法等を挙げることが出来る。
【００６８】
本発明の接合体の製造方法に用いられる金属箔体の枚数は、１枚でもよいし、複数枚でも構わない。金属箔体の枚数が１枚である場合には、その端縁が金属部材の先端部と複数箇所にて接合されるように金属箔体を構成する。その構成には特に制限はないが、例えば、１枚の金属箔体を同心円的に捲回したり、複数箇所を折り曲げることが挙げられる。金属箔体の枚数が複数枚である場合には、それらの接合端縁を大略揃えて配列して構成する。なお、金属箔体の枚数が複数枚である場合でも、そのうち１枚又は複数枚を同心円的に捲回したり、複数箇所を折り曲げて構成してもよい。
【００６９】
本発明の接合体の製造方法に用いられる金属部材としては、特に制限はなく、例えば、汎用の成形方法により得られたものを使用することが出来る。
【００７０】
また、例えば図７に示す、金属部材４の形状については、平坦部と、その厚みが平坦部に比して厚く、その先端に接合面を持った凸状の先端部６とを有する形状であれば特に制限はない。
【００７１】
本発明の接合体の製造方法においては、図５、６に示すように、平坦部１２と、その厚みが平坦部１２に比して厚く、その先端に接合面を持った凸状部７とを有する形状であり、凸状部の厚み（Ｌ_２）と、平坦部の厚み（Ｌ_１）との差が０．１ｍｍ以上である金属部材４を使用することが好ましく、０．６ｍｍ以上である金属部材４を使用することがさらに好ましく、０．８ｍｍ以上である金属部材４を使用することが特に好ましい。凸状部と平坦部との厚みの差が０．１ｍｍ未満である場合には、凸状部７の形状的な特徴が発揮されず、凸状部７と金属箔体１との接触状態が不安定となるために好ましくない。また、本発明の接合体の製造方法においては凸状部と平坦部との厚みの差の上限値については特に限定されないが、金属部材の加工精度及び強度等から適宜設定すればよく、例えば３ｍｍ以下であればよい。
【００７２】
接合に際して金属箔に金属部材を押さえ付けるときに、当該金属部材の変形や損傷等の発生を防止するといった観点からは、平坦部の厚み（Ｌ₁）が０．２ｍｍ以上である金属部材を使用することが好ましく、０．３ｍｍ以上である金属部材を使用することがさらに好ましく、０．４ｍｍ以上である金属部材を使用することが特に好ましい。なお、平坦部の厚みの上限値については特に限定されないが、溶接部分とは直接的には関係のない部分であるため金属部材の強度及び重量等から適宜設定すればよく、例えば２ｍｍ以下であればよい。
【００７３】
また、凸状の先端部の厚み（Ｌ_２）が０．４ｍｍ以上である金属部材を使用することが好ましく、０．５ｍｍ以上である金属部材を使用することがさらに好ましく、０．６ｍｍ以上である金属部材を使用することが特に好ましい。このことにより、より強固に接合された接合体を得ることが出来る。なお、先端部の厚みの上限値については特に限定されないが、照射するエネルギー線のパワーの限界から適宜設定されればよい。
【００７４】
本発明の接合体の製造方法においては、図７に示すように、エネルギー線８を、金属箔体１の接合端縁２近傍の側面部１３を含む面の法線３に対して、角度θ（０°≦θ≦３０°）で金属部材４の先端部６に照射することが好ましく、角度θ（０°≦θ≦１０°）で照射することがさらに好ましく、角度θ（０°≦θ≦５°）で照射することが特に好ましい。また、エネルギー線８を、金属部材４の先端部６（凸状部７）の表面に又はその前後近傍に合焦させることが好ましく、エネルギー線８を、金属箔体１に直接照射しないことが好ましい。
【００７５】
エネルギー線８を金属部材４の先端部６（凸状部７）に照射する具体的な方法としては、図７に示すように、金属部材４を、その先端部６が接合端縁２近傍の側面部１３に垂直に交差するように配置し、エネルギー線８を、側面部１３に垂直に交差する線をエネルギー線発生装置により走査、すなわち金属部材４の先端部６（凸状部７）を走査して照射する方法を挙げることが出来る。このとき、エネルギー線８を、金属箔体１の側面部１３を含む面の法線３に対して、角度θ（０°≦θ≦３０°）で先端部６に照射するという上述の条件に加え、エネルギー線８を、側面部１３に垂直に交差する線に対して、角度が垂直で先端部６に照射することが好ましい。これらの方法により、ろう材を必要とせずに金属箔体１と金属部材４の溶解体とを溶着させて、金属箔体１と金属部材４との接合体１１を形成することが出来るためにコストを低減することが出来る。また隣り合う金属箔体１が平行に並んでいなくてもその大略端縁を揃えて配列されていれば、複数枚の金属箔体１を一度の照射によって金属部材４と接合できるために生産性の向上を図ることが出来る。さらに、上述した条件によれば、金属箔体１に損傷を与えずに、金属部材４の先端部６（凸状部７）のみを溶解させて金属箔体１と金属部材４とを溶着・接合することが出来、接合の機械的強度を向上させることが出来るために信頼性の向上を図ることが出来る。
【００７６】
本発明の接合体の製造方法においては、照射点におけるパワー密度が６ｋＷ／ｍｍ^２以上となるように、金属部材の凸状の先端部にエネルギー線を照射することが好ましく、７ｋＷ／ｍｍ^２以上となるように照射することがさらに好ましく、８ｋＷ／ｍｍ^２以上となるように照射することが特に好ましい。６ｋＷ／ｍｍ^２未満であると、接合状態が良好ではなく、得られる接合体の機械的強度が不充分となる場合が想定されるためである。なお、前記パワー密度の上限については特に限定されないが、金属部材やこれに接合される金属箔への損傷発生の回避等の観点からは、適宜決定すればよく、例えば６０ｋＷ／ｍｍ^２以下であればよい。
【００７７】
また、本発明の接合体の製造方法においては、凸状の先端部の厚みをＬ_２（ｍｍ）、前述のパワー密度をＥ（ｋＷ／ｍｍ^２）としたとき、下記式（１０）を満足するようにエネルギー線を照射することが好ましい。下記式（１０）を満足するような条件でエネルギー線を照射することにより、金属箔体への損傷が抑制され、接合部分の機械的強度も強い接合体を製造することが出来る。
【００７８】
【数１０】
Ｌ₂≦Ｅ／７ …（１０）
【００７９】
なお、より、接合の安定性を向上させ、接合部分の機械的強度にも信頼性を付与するといった観点からは、下記式（１１）、（１２）を満足することが好ましい。
【００８０】
【数１１】
Ｌ₂≦Ｅ／９ …（１１）
【００８１】
【数１２】
Ｌ₂≦Ｅ／１０ …（１２）
【００８２】
本発明の接合体の製造方法においては、エネルギー線の照射点が平面状である金属部材を用いることが好ましい。このことにより、エネルギー線の乱反射を抑制することが出来、特に金属箔体への損傷を抑制することが出来るために、良好な接合状態である接合体を得ることが出来る。なお、エネルギー線の乱反射を抑制するといった観点からは、少なくとも照射点よりも広い範囲で平面状であればよい。
【００８３】
さらに本発明の接合体の製造方法においては、照射点におけるスポット径が１ｍｍ以下となるようにエネルギー線を照射することが好ましい。このことにより、不要な箇所へのエネルギー線の照射を抑制することが出来、特に金属箔体への損傷を抑制することが出来るために、良好な接合状態である接合体を得ることが出来る。なお、本発明の接合体の製造方法においては、隣り合う金属箔体どうしに間隙を保持して配列する場合に特に好適である。
【００８４】
また、例えば図７に示す、かかるエネルギー線８としては、エネルギー密度が高く、発熱量も小さい、レーザー又は電子ビームを用いることが好ましく、また、連続波であるエネルギー線を用いることが好ましい。このことにより、凸状の先端部６の表面上にエネルギーを集中させて照射することが出来るために先端部６を効率的に溶解させることが出来、また金属箔体１の損傷を抑制することが出来る。なお、レーザーの中でも、ＹＡＧレーザーは、焦点をよりよく絞ることが出来、焦点からはずれた部分に配置された金属箔体１の位置では、エネルギー密度はより小さくなり、金属箔体１の損傷をよりよく抑制することが出来ることから、特に好ましい。
【００８５】
また、本発明の接合体の製造方法においては、エネルギー線８を連続照射が可能なエネルギー線発生装置を用いて照射することが好ましく、エネルギー線８を、側面部１３を含む面に平行な面上を移動して走査可能なエネルギー線発生装置を用いて照射することが好ましい（図７）。なお、照射するエネルギー線の走査速度は、０．１〜１００ｍ／ｍｉｎであることが好ましく、１〜３０ｍ／ｍｉｎであることがさらに好ましく、２〜１０ｍ／ｍｉｎであることが特に好ましい。また、凸状の先端部６をエネルギー線発生装置により走査することによりエネルギー線８を照射することが好ましい。さらに、本発明の接合体の製造方法においては、配列された金属箔体１の枚数に応じ、金属部材４を複数個用意し、複数の金属部材４を、それらの凸状部６が側面部１３に垂直に交差するようにして、連続的に配置することが好ましい。これらのことにより、複数枚の金属箔体１を一度の照射によって接合することが出来るために、生産性の向上を図ることが出来る。
【００８６】
図３は、本発明の接合体の製造方法に用いることが出来る金属部材の一例を示す説明図である。
図３には、図７の金属部材４に比べ、凸状部３３に厚みを有する金属部材３１の例を示しており、この場合には、金属部材３１の上面側からエネルギー線３４を照射することによって、金属部材３１と金属箔体１の接合端縁２を溶着させて接合させることが出来る。
【００８７】
また、図８に示すように、本発明の金属箔体と金属部材との接合体の製造方法は、少なくとも１枚の金属箔体１の端縁２と金属部材５１を接合して金属箔体１と金属部材５１との接合体５５を製造する方法であって、金属部材５１の形状が、平坦部１２と、その厚みが平坦部１２に比して厚く、その先端に接合面を持った凸状部５２とを有する形状であり、金属箔体１の端縁のうちの金属部材５１と接合されるべく配列された端縁（接合端縁）２の側面部１３と、金属部材５１の接合面とを、接合端縁２近傍を屈曲することにより密着させて金属箔体１と金属部材５１を配置し、金属部材５１の凸状部５２にエネルギー線５３を照射し、それを溶解させて、溶解した金属部材５１の凸状部５２を金属箔体１の側面部１３に溶着させて、金属箔体１と金属部材５１との接合体５５を形成することを特徴とする。本発明における具体的な製造方法とその技術的効果は上述しているので、重複する部分は省略することとする。
【００８８】
本発明の接合体の製造方法によれば、図８に示すような、金属部材の先端部ではない所定箇所に凸状部５２を有する場合に、その凸状部５２を設けた金属部材５１の背面にエネルギー線５３を照射することにより、その金属部材５１と金属箔体１の接合端縁２とを溶着させて接合体５５を製造することが出来る。
【００８９】
【実施例】
以下、本発明を実施例により具体的に説明するが、本発明はこれら実施例に限定されるものではない。
（実施例１〜３、比較例１、２）
エネルギー線として連続波のＹＡＧレーザーを使用し、金属部材の接合部（凸状部）の形状、金属箔体と金属部材の接触のさせ方、及びＹＡＧレーザーの出力、走査速度等の種々の接合条件を設定して接合試験を実施し、得られた接合体の断面を顕微鏡観察した。なお、金属箔体と金属部材を構成する金属は銅（ＪＩＳ
Ｃ１１００）である。結果を図９〜１３に示す。
【００９０】
（考察）
金属部材と金属箔体との接合状態が良好な接合体では、金属箔体側から金属部材の方向へと形成されている柱状晶を観察することが出来た（実施例１〜３）。一方、比較例１のように金属部材と金属箔体とが接合されていない箇所においては柱状晶を観察することは出来ず、代わりに等軸晶を観察することが出来た。
【００９１】
さらに、比較例２では柱状晶は観察されないものの、部分的に金属箔体と金属部材との接合が起こっていることが判明した。しかし、実施例に比して、接合面積が小さく、安定的な接合状態ではないことが判明した。
以上のことから、金属箔体と金属部材との接合部分において、金属箔体から金属部材の方向へ柱状晶が形成されるような条件であれば、良好な接合状態である接合体を製造できることが判明した。
【００９２】
【発明の効果】
以上説明したように、本発明によって、ろう材を必要としないためにコスト性に優れ、また、金属箔体に損傷を与えずに金属部材のみを溶解させて金属箔体と金属部材とを溶着・接合させることにより、接合体の機械的強度が強く信頼性に優れた金属箔体と金属部材との接合体を提供することが出来る。さらに、本発明によって、ろう材を必要としないためにコストが低減され、また、隣り合う金属箔体が平行に並んでいなくてもその大略端縁を揃えて配列されていれば、複数枚の金属箔体を一度の照射によって金属部材と接合することが出来るために生産性に優れ、さらに、金属箔体に損傷を与えずに金属部材のみを溶解させて金属箔体と金属部材とを溶着・接合することが出来、接合の機械的強度を向上させることが出来るために信頼性に優れた金属箔体と金属部材との接合体の製造方法を提供することが出来る。
【図面の簡単な説明】
【図１】本発明の接合体の一実施例を模式的に示す斜視図である。
【図２】本発明の接合体の製造に用いられる金属部材の一例を模式的に示す斜視図である。
【図３】本発明の接合体の製造に用いられる金属部材の別の例を模式的に示す斜視図である。
【図４】本発明の接合体の製造に用いられる金属部材のさらに別の一例を模式的に示す斜視図である。
【図５】本発明の接合体の製造に用いられる金属部材の、凸状部の形状の一例を示す模式図である。
【図６】本発明の接合体の製造に用いられる金属部材の、凸状部の形状の別の例を示す模式図である。
【図７】本発明の接合体の製造方法の一実施例を模式的に示す説明図である。
【図８】本発明の接合体の製造方法の別の実施例を模式的に示す説明図である。
【図９】実施例１の接合体の断面における金属組織を示す顕微鏡写真である。
【図１０】実施例２の接合体の断面における金属組織を示す顕微鏡写真である。
【図１１】実施例３の接合体の断面における金属組織を示す顕微鏡写真である。
【図１２】比較例１の接合体の断面における金属組織を示す顕微鏡写真である。
【図１３】比較例２の接合体の断面における金属組織を示す顕微鏡写真である。
【符号の説明】
１…金属箔体、２…端縁（接合端縁）、３…側面部を含む面の法線、４…金属部材、５…接合部、６…先端部、７…凸状部、８…エネルギー線、９…接合面、１０…間隙、１１…接合体、１２…平坦部、１３…側面部、３１…金属部材、３２…先端部、３３…凸状部、３４…エネルギー線、３５…エネルギー線、５１…金属部材、５２…凸状部、５３…エネルギー線。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a joined body (hereinafter also simply referred to as “joined body”) of a metal foil body and a metal member, and a method for manufacturing the same. More specifically, the present invention relates to a bonded body excellent in cost and reliability, and a manufacturing method thereof excellent in productivity.
[0002]
[Prior art]
Conventionally, in order to join a metal foil body and a metal member, a brazing material is applied to the joint portion of the metal member, or a brazing material is sandwiched between the metal foil body and the metal member, and these are put in an electric furnace. In general, a method of heating the whole or a method of heating a bonding portion using an electron beam or the like is generally used.
[0003]
However, since these joining methods require a brazing material, there is a problem that the manufacturing cost is high. In addition, in order to suppress damage to the metal foil body when irradiating energy rays, only brazing material with a considerably lower melting point than the metal foil body can be used for welding. In addition, the metal foil body and the metal member are both dissolved, so that the metal foil may be damaged, and the mechanical strength of the joined portion of the obtained joined body tends to be low. was there.
[0004]
[Problems to be solved by the invention]
The present invention has been made in view of such conventional problems. The object of the present invention is to provide a metal member that is excellent in cost because no brazing material is required, and that does not damage the metal foil body. The metal foil body and metal member are welded and bonded to each other, and the mechanical strength of the bonded body is strong. Another object of the present invention is to provide a method for producing a joined body of a metal foil body and a metal member.
[0005]
[Means for Solving the Problems]
  That is, according to the present invention, it is a joined body of a metal foil body and a metal member formed by joining an edge of at least one metal foil body and a metal member,The shape of the metal member is a shape having a flat portion and a convex portion having a thickness larger than that of the flat portion and having a bonding surface at the tip thereof.Of the edges of the metal foilBeforeEdges arranged to be joined to the metal member (joint edges))ofSide andOf the metal memberThe joint surfaceBy bending the vicinity of the joining edgeCloseBy irradiating the convex part with energy rays in a state where the convex part is melted, the convex part and the side part are welded.A joined body of a metal foil body and a metal member is provided.
[0006]
  In the present invention, the metal foil body and the metal member are preferably composed of copper or a copper alloy.,MoneyIt is preferable that columnar crystals are formed from the metal foil body toward the metal member at the joint portion between the metal foil body and the metal member.
[0008]
  In the present invention, ConvexThickness (L₂) And the thickness of the flat part (L₁) Is preferably 0.1 mm or more, and the thickness of the flat portion (L₁) Is preferably 0.2 mm or more, and the thickness (L₂) Is preferably 0.4 mm or more.
[0009]
  It is preferable that the energy ray is irradiated at a predetermined position at an angle θ (0 ° ≦ θ ≦ 30 °) with respect to the normal line of the surface including the side surface portion of the metal foil body. Metal partMaterialConvex part is,Side partDrippingIt is preferable that they are arranged so as to intersect each other directly. Energy rays are on the sideDrippingAn angle with respect to a straight lineGagIt is preferable to irradiate the convex part directly. It is preferable that the energy rays do not directly irradiate the metal foil body.
[0010]
In the present invention, the power density at the irradiation point of the energy beam is 6 kW / mm.²Preferably, the thickness of the convex portion is L₂(Mm), power density is E (kW / mm²), It is preferable to satisfy the following formula (4).
[0011]
[Expression 4]
L₂≦ E / 7 (4)
[0012]
In this invention, it is preferable that the spot diameter in the irradiation point of an energy ray is 1 mm or less, and it is preferable that the irradiation point of the energy ray in a metal member is planar.
[0013]
In the present invention, it is preferable that adjacent metal foils are arranged with a gap between them, and the energy beam is preferably generated by a laser or an electron beam. Further, the energy beam is preferably a continuous wave, and the laser is preferably a YAG laser.
[0014]
  Furthermore, the bonding material for assisting the bonding between the metal member and the metal foil is a metal foil and / orOr convex partApplied to theOrMetal foil andConvex partSandwiched betweenConvex partAnd irradiating the bonding material with energy rays, dissolving them and dissolvingConvex partFurther, it may be formed by welding a bonding material to the bonding edge of the metal foil body.
[0015]
These constituent conditions are preferably employed for the metal foil body and the metal member, which are respectively used in the electrochemical element. Moreover, according to this invention, the electrochemical element formed using the conjugate | zygote of a metal foil body and a metal member is provided.
[0016]
  Further, according to the present invention, there is provided a method for producing a joined body of a metal foil body and a metal member by joining an edge of at least one metal foil body and a tip portion of the metal member,The shape of the metal member is a shape having a flat portion and the tip portion having a convex shape whose thickness is thicker than that of the flat portion.Of the edges of the metal foilofAn edge arranged to be joined to the tip of the metal member (joining edge))ofSide andThe metal foil body and the metal member are brought into close contact with the tip of the metal member by bending the vicinity of the joining edge.Place, irradiate the tip with energy rays, dissolve it, dissolveBeforeThe tipSide partA method for producing a joined body of a metal foil body and a metal member, characterized in that a joined body of the metal foil body and the metal member is formed.
[0017]
  In the present invention, a metal foil body and a metal member made of copper or a copper alloy are used.PreferGood.
[0018]
  In the present invention,tipPart thickness (L₂) And the thickness of the flat part (L₁It is preferable to use a metal member having a difference from 0.1 mm or more and a flat portion thickness (L₁) Is preferably a metal member of 0.2 mm or more,TipThickness (L₂) Is preferably 0.4 mm or more.
[0019]
  Moreover, it is preferable to irradiate a front-end | tip part with an angle (theta) (0 degree <= theta <= 30 degree) with respect to the normal line of the surface containing a side part. Metal partThe tip of the materialSide partDrippingIt is preferable to arrange so that it intersects directly. ~ sideFaceDrippingIntersects directlyenergyLine,It is preferable to scan and irradiate with an energy beam generator. Energy rays on the sideDrippingAn angle with respect to a straight lineGagStraightTipIs preferably irradiated. It is preferable not to directly irradiate the metal foil with energy rays.
[0020]
  In the present invention, the power density at the irradiation point is 6 kW / mm.²It is preferable to irradiate energy rays so thatTipThe thickness of L₂(Mm), the power density is E (kW / mm)²), It is preferable to irradiate the energy beam so as to satisfy the following formula (5).
[0021]
[Equation 5]
L₂≦ E / 7 (5)
[0022]
In the present invention, it is preferable to use a metal member having a planar irradiation point of energy rays, and it is preferable to irradiate the energy rays so that the spot diameter at the irradiation point is 1 mm or less.
[0023]
In the present invention, it is preferable to arrange the metal foils adjacent to each other while maintaining a gap, and it is preferable to use a laser or an electron beam as the energy ray.
[0024]
  In the present invention, it is preferable to use a YAG laser as the laser, and it is more preferable to irradiate the energy beam using an energy beam generator capable of continuous irradiation. It is preferable to irradiate the energy beam using an energy beam generator capable of moving and scanning on a plane parallel to the plane including the side surface.. DWith energy generator, Energy rays at the tipIt is preferable to scan and irradiate. Prepare a plurality of metal members according to the number of arranged metal foil bodies, and attach a plurality of metal members to those metal members.TipSideDrippingIt is preferable to arrange them continuously so as to intersect each other.
[0025]
  Moreover, according to the present invention, a method for producing a joined body of a metal foil body and a metal member by joining an edge of at least one metal foil body and the metal member,The shape of the metal member is a shape having a flat portion and a convex portion having a thickness larger than that of the flat portion and having a bonding surface at the tip thereof.Among the edges of the metal foil body, the edges arranged to be joined to the metal member (joint edges))ofSide andThe metal foil body and the metal member are brought into close contact with the joint surface of the metal member by bending the vicinity of the joint edge.Arrange, irradiate the convex part with energy rays, dissolve it, dissolveBeforeConvex partBeforeRecordSide partA method for producing a joined body of a metal foil body and a metal member, characterized in that a joined body of the metal foil body and the metal member is formed.
[0026]
  In the present invention, a metal foil body and a metal member made of copper or a copper alloy are used.PreferGood. In the present invention, ConvexThickness (L₂) And the thickness of the flat part (L₁) Is preferably a metal member having a difference of 0.1 mm or more, and the thickness of the flat portion (L₁) Is preferably 0.2 mm or more, and the thickness of the convex portion (L₂) Is preferably 0.4 mm or more.
[0027]
  Moreover, it is preferable to irradiate the convex portion with an energy ray at an angle θ (0 ° ≦ θ ≦ 30 °) with respect to the normal of the surface including the side surface portion. Metal partMaterialConvex partTheSide partDrippingIt is preferable to arrange so that it intersects directly. ~ sideFaceDrippingIntersects directlyenergyLine,It is preferable to scan and irradiate with an energy beam generator. Energy rays on the sideDrippingAn angle with respect to a straight lineGagIt is preferable to irradiate the convex part directly. It is preferable not to directly irradiate the metal foil with energy rays.
[0028]
In the present invention, the power density at the irradiation point is 6 kW / mm.²It is preferable to irradiate energy rays so that the thickness is as described above.₂(Mm), power density is E (kW / mm²), It is preferable to irradiate energy rays so as to satisfy the following formula (6).
[0029]
[Formula 6]
L₂≦ E / 7 (6)
[0030]
In the present invention, it is preferable to irradiate the energy beam so that the spot diameter at the irradiation point is 1 mm or less, and it is preferable to use the metal member where the irradiation point of the energy beam is planar.
[0031]
In the present invention, it is preferable to arrange the metal foils adjacent to each other while maintaining a gap, and it is preferable to use a laser or an electron beam as the energy ray.
[0032]
  In the present invention, it is preferable to use a YAG laser as the laser, and it is more preferable to irradiate the energy beam using an energy beam generator capable of continuous irradiation. It is preferable to irradiate the energy beam using an energy beam generator capable of moving and scanning on a plane parallel to the plane including the side surface.. DWith energy generator, The energy ray on the convex partIt is preferable to scan and irradiate. Prepare a plurality of metal members according to the number of arranged metal foil bodies, and the plurality of metal members, the convex portions of which are side portionsDrippingIt is preferable to arrange them continuously so as to intersect each other.
[0033]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
[0034]
  As shown in FIG. 1, the metal foil of the present invention1And metal parts4Conjugate with11As described above, at least one metal foil body1Edge of2And metal parts4And joinContactCoalescedTheIn addition, the metal material which comprises the metal foil body 1 and the metal member 4 which are the constituent materials of the joined body of the metal foil body and metal member which concern on this invention is comprised by the general metal or its alloy etc. Specifically, it is preferably composed of titanium, copper, or an alloy thereof, and in particular, composed of copper or a copper alloy provides a bonded body with a good bonding state. It is preferable because it is possible.
  AlsoAs shown in FIG. 2, the joined body of the present invention isThe shape of the metal member 4 is a shape having a flat portion and a convex portion 7 having a thickness larger than that of the flat portion and having a bonding surface at the tip thereof. In the state where the side surface portion 13 of 2 and the joint surface of the metal member 4 are brought into close contact with each other by bending the vicinity of the joint edge 2, the convex portion 7 is irradiated with energy rays to melt the convex portion 7. It is formed by welding the convex portion 7 and the side surface portion 13 together.ThingsThe
[0035]
  The number of metal foil bodies used in the joined body of the present invention may be one or plural. When the number of metal foils is 1, the edge of the metal member isConvex partThe metal foil body is configured to be joined at a plurality of locations. Although there is no restriction | limiting in particular in the structure, For example, winding one metal foil body concentrically or bending several places is mentioned. In the case where there are a plurality of metal foil bodies, the joining edges are arranged so as to be substantially aligned. Even when there are a plurality of metal foil bodies, one or a plurality of the metal foil bodies may be concentrically wound or a plurality of places may be bent.
[0036]
There is no restriction | limiting in particular as a metal member used for the joined body of this invention, For example, what was obtained by the general-purpose shaping | molding method can be used.
[0037]
  For example, the metal member 4 shown in FIG.As long as the shape is a shape having a flat part and a convex part 7 whose thickness is thicker than that of the flat part and having a joint surface at its tip.There is no particular limitation.
  Specific examples of the shape of the convex portion are shown in FIGS. The shape of the convex portion 7 of the metal member 4 used in the joined body of the present invention may be a trapezoidal shape as shown in FIG. 5 or a spire shape as shown in FIG.
  In FIGS. 5 and 6, L₁Is the thickness of the flat part 12, L₂Indicates the thickness of the convex portion 7.
[0038]
  In the joined body of the present invention, as shown in FIGS.The flat portion 12 is thicker than the flat portion 12 and has a joint surface at the tip.Convex part 7AndThe thickness of the convex portion 7 (L₂) And the thickness (L₁) Is preferably 0.1 mm or more, more preferably 0.6 mm or more, and particularly preferably 0.8 mm or more. When the difference in thickness between the convex portion 7 and the flat portion 12 is less than 0.1 mm, the shape characteristic of the convex portion 7 is not exhibited, and the contact between the convex portion 7 and the metal foil body 1 is not achieved. This is not preferable because the state becomes unstable. Further, in the joined body of the present invention, the upper limit value of the difference in thickness between the convex portion 7 and the flat portion 12 is not particularly limited, but may be set as appropriate from the processing accuracy and strength of the metal member, for example, 3 mm. The following is sufficient.
[0039]
From the viewpoint of preventing deformation and damage of the metal member when the metal member is pressed against the metal foil during joining, the thickness of the flat portion (L₁) Is preferably 0.2 mm or more, more preferably 0.3 mm or more, and particularly preferably 0.4 mm or more. The upper limit value of the thickness of the flat portion is not particularly limited, but may be appropriately set from the strength and weight of the metal member because it is a portion not directly related to the welded portion, for example, 2 mm or less. I just need it.
[0040]
Further, the thickness of the convex portion (L₂) Is preferably 0.4 mm or more, more preferably 0.5 mm or more, and particularly preferably 0.6 mm or more. Thereby, it can be set as the joined body joined more firmly. In addition, although it does not specifically limit about the upper limit of the thickness of a convex-shaped part, What is necessary is just to set suitably from the limit of the power of the energy ray irradiated.
[0041]
With respect to the shape of the metal member used in the joined body of the present invention, the following shapes can be given as preferred examples.
FIG. 2 shows an example of the metal member 4 having the convex portion 7 at the tip end portion 6. In this case, the metal member 4 is irradiated with an energy ray 8 from the upper surface side to thereby form the metal member 4. The member 4 and the joining edge 2 of the metal foil body 1 can be welded and joined.
[0042]
FIG. 3 shows an example of a metal member 31 having a convex portion 33 that is thicker than the metal member 4 of FIG. In this case, by irradiating the energy beam 34 from the upper surface side of the metal member 31, the metal member 31 and the joining edge 2 of the metal foil body 1 can be welded and joined.
[0043]
FIG. 4 shows an example in which a convex portion 52 is provided at a predetermined position, not the tip portion of the metal member. In this case, energy rays are provided on the back surface of the metal member 51 provided with the convex portion 52. By irradiating 53, the metal member 51 and the metal foil body 1 can be joined.
[0044]
In the present invention, it is preferable that the metal foil body and the metal member are made of the same type of metal, and this allows the metal foil body and the metal member to be better welded. Strength is high and reliability can be improved.
[0045]
  The following method can be mentioned as a manufacture example of the joined body of this invention. That is, as shown in FIG.A metal member 4 having a shape having a flat part and a convex part 7 having a thickness larger than that of the flat part and having a joint surface at the tip thereof is prepared.Of the edges of the metal foil 1ofEdges arranged to be joined to the metal member 4 (joining edges)2 nearSide side 13 andBy bending the joint surface of the metal member 4 in the vicinity of the joint edge 2Arrange for close contactTo do.The convex portion 7 of the metal member 4 is irradiated with energy rays 8 and melted, and the melted convex portion 7 of the metal member 4 is welded to the joining edge 2 of the metal foil body 1 to form a metal foil body. A method of forming a joined body 11 of 1 and the metal member 4 can be mentioned.
[0046]
  At this time, by bending the vicinity of the joining edge 2,Side surface 13 and, Convex7Joint surfaceAnd closelyRu. In order to bend the vicinity of the joining edge 2, in addition to bending the vicinity of the joining edge 2 by an appropriate method in advance, the metal member 4 to be joined to the joining edge 2 is pressed with an appropriate pressure. Examples include a method of bending.
[0047]
In the joined body of the present invention, it is preferable that columnar crystals are formed in the joining portion between the metal foil body and the metal member in the direction from the metal foil body to the metal member. In general, a weld metal grows (epitaxial growth) with the same crystal orientation on the crystal grains of the base metal (unmelted portion). The solid phase thus formed grows inside the weld bead (molten portion) as the heat source moves. This growth is easy to grow in the direction of the largest temperature gradient, and grows in a form extending almost in one direction in the direction, and the crystal thus grown is called a columnar crystal.
[0048]
The molten part of the metal member recrystallizes as it cools, but the heat of the molten part diffuses rapidly through the metal foil. That is, it is considered that the temperature of the molten metal in the portion in close contact with the metal foil body decreases, and columnar crystals are easily formed from the metal foil body to the metal member with the interface between the metal foil body and the molten metal as a nucleus. Furthermore, in the present invention, the side surface portion in the vicinity of the joining edge of the metal foil body is in close contact with the metal member and has a good contact state, so that a columnar crystal is easily formed by the cooling effect through the metal foil body. It becomes. The joined body of the present invention in which columnar crystals are formed from the metal foil body to the metal member in the joined portion has a good joined state between the metal foil body and the metal member, that is, the mechanical strength of the joined portion is strong and reliable. It is a bonded body with excellent properties.
[0049]
Moreover, in the joined body of the present invention, as shown in FIG. 2, the energy ray 8 is at an angle θ (with respect to the normal 3 of the surface including the side surface portion 13 near the joining edge 2 of the metal foil body 1. The projection 7 is preferably irradiated at 0 ° ≦ θ ≦ 30 °, more preferably at an angle θ (0 ° ≦ θ ≦ 10 °), and the angle θ (0 ° ≦ θ It is particularly preferable that irradiation is performed at ≦ 5 °. In addition, the energy rays 8 are preferably focused on the surface of the convex portion 7 of the metal member or in the vicinity of the front and back thereof, and the energy rays 8 are preferably not directly irradiated onto the metal foil body 1.
[0050]
  Furthermore, metal membersFourConvex 7,Side 13DrippingThe energy rays 8 are arranged so as to cross each other directly, and the side surface 13DrippingIt is preferable to irradiate a line that intersects directly with an energy beam generator, that is, by scanning the convex portion 7 of the metal member 4. At this time, the energy rays 8 described above are applied to the convex portion 7 at an angle θ (0 ° ≦ θ ≦ 30 °) with respect to the normal 3 of the surface including the side surface portion 13 of the metal foil body 1. In addition to that, the energy ray 8 is connected to the side portion 13.DrippingAn angle with respect to a straight lineGagIt is preferable that the projection 7 is directly irradiated.
  As a result, as shown in FIG. 1, the metal foil body 1 and the melted metal member 4 are welded to form a joined body 11 of the metal foil body 1 and the metal member 4 without using a brazing material. Therefore, the cost can be reduced. Moreover, even if the adjacent metal foil bodies 1 are not arranged in parallel, a plurality of metal foil bodies 1 can be joined to the metal member 4 by a single irradiation as long as the edges are aligned substantially. . Further, the metal foil body 1 and the metal member 4 can be welded and joined by dissolving only a predetermined portion (convex portion) of the metal member 4 without damaging the metal foil body 1. Therefore, the reliability can be improved.
[0051]
In addition, the "joining edge" as used in the field of this invention is the joining of each metal foil body over several places in the edge where several places in one metal foil body or a plurality of metal foil bodies is joined. Means the edge to be. Further, “crossing the side surface portion substantially perpendicularly” means that all of the side surface portions in the vicinity of the plurality of joining edges intersect substantially perpendicularly.
[0052]
In the joined body of the present invention, when the energy beam is irradiated to the convex portion of the metal member, the power density at the irradiation point of the energy beam is 6 kW / mm.²Preferably, it is 7 kW / mm²More preferably, 8 kW / mm²The above is particularly preferable. 6kW / mm²This is because the bonding state is not good and the mechanical strength is insufficient if it is less than 1. The upper limit of the power density is not particularly limited, and may be determined as appropriate from the viewpoint of avoiding damage to the metal member and the metal foil joined thereto, for example, 60 kW / mm.²The following is sufficient. Here, the “power density” of the energy beam referred to in the present invention means the energy (kW) of the energy beam, which is the spot area (mm) of the irradiation point irradiated with the energy beam at a predetermined location of the metal member.²) Means the value obtained by dividing by.
[0053]
In the joined body of the present invention, the thickness of the convex portion is set to L.₂(Mm), the power density mentioned above is E (kW / mm)²), It is preferable that the following formula (7) is satisfied. By irradiating energy rays under conditions that satisfy the following formula (7), the bonded body of the present invention is characterized in that damage to the metal foil body is suppressed and the mechanical strength of the bonded portion is also strong. It is a joined body which has.
[0054]
[Expression 7]
L₂≦ E / 7 (7)
[0055]
Note that it is preferable to satisfy the following formulas (8) and (9) from the viewpoint of obtaining a joined body having characteristics such as further improving the stability of joining and strong mechanical strength of the joined portion.
[0056]
[Equation 8]
L₂≦ E / 9 (8)
[0057]
[Equation 9]
L₂≦ E / 10 (9)
[0058]
In the joined body of the present invention, the irradiation point of the energy beam in the metal member is preferably flat. Thereby, irregular reflection of energy rays is suppressed, and particularly damage to the metal foil body is suppressed. Therefore, the bonded body of the present invention has a characteristic of being in a good bonded state. In addition, from the viewpoint of suppressing the irregular reflection of the energy rays, it may be flat at least in a range wider than the irradiation point.
[0059]
Furthermore, in the joined body of the present invention, the spot diameter at the irradiation point is preferably 1 mm or less. Thereby, irradiation of energy rays to unnecessary portions is suppressed, and particularly damage to the metal foil body is suppressed. Therefore, the bonded body of the present invention has a characteristic of being in a good bonded state. The joined body of the present invention is particularly suitable when adjacent metal foil bodies are arranged with a gap therebetween.
[0060]
Further, for example, such an energy ray 8 shown in FIG. 2 is preferably a laser or electron beam having a high energy density and a small calorific value, and the energy ray is preferably a continuous wave. Thereby, since energy can be concentrated and irradiated on the surface of the convex portion 7, the convex portion 7 can be efficiently dissolved, and damage to the metal foil body 1 can be suppressed. . Of the lasers, the YAG laser can focus better, and the energy density becomes smaller at the position of the metal foil body 1 arranged in a portion deviated from the focus, and the damage to the metal foil body 1 is better. Since it can suppress, it is especially preferable.
[0061]
  Moreover, when manufacturing the joined body which concerns on this invention, it is preferable to irradiate the energy beam 8 shown, for example in FIG. 2 using the energy beam generator which can be irradiated continuously, and the energy beam 8 is irradiated to the side surface part 13. Irradiation is preferably performed using an energy beam generator capable of scanning a plane parallel to the plane including the. In addition, it is preferable that the scanning speed | velocity | rate of the energy ray to irradiate is 0.1-100 m / min, It is further more preferable that it is 1-30 m / min, It is especially preferable that it is 2-10 m / min. Also,Energy beam generatorConvex part 7InEnergy raysTheIt is preferable to scan and irradiate. Furthermore, in the present invention, a plurality of metal members 4 are prepared according to the number of the arranged metal foil bodies 1, and the plurality of metal members 4 are formed with the convex portions 7 having the side surface portions 13.DrippingIt is preferable to arrange them continuously so as to intersect each other. By these things, the several metal foil body 1 can be joined by one irradiation.
[0062]
  When manufacturing the joined body of the present invention, a joining auxiliary material such as a brazing material is not necessary, but it may be used as a matter of course. In that case, the joining auxiliary material for assisting the joining of the metal member and the metal foil body is the metal foil body and / orOrMetal partsConvex partApplied to theOrOf metal foil and metal partsConvex partSandwiched betweenConvex partAnd irradiating the bonding material with energy rays, dissolving them and dissolvingConvex partAnd welding the joining material to the joining edge of the metal foil bodyIs joinedIt is preferable.
[0063]
Although there is no restriction | limiting in particular in the use of the conjugate | zygote of this invention, The thing used for an electrochemical element can be mentioned as a suitable example. Specifically, the metal foil is applied as a current collecting substrate for an electrochemical element, and the metal member is applied as a current collecting member for deriving current from the current collecting substrate. Moreover, there is no restriction | limiting in particular as this electrochemical element, However, A laminated type electrochemical element and a wound-type electrochemical element can be mentioned as a suitable example. In the case where the metal constituting the metal foil body and the metal member is copper or a copper alloy, the joined body of the present invention is suitable as a negative electrode material for a lithium secondary battery including a wound electrochemical element, for example. Can be used. In this case, the thickness of the metal foil body made of copper or a copper alloy is preferably 7 μm to 15 μm.
[0064]
Next, an embodiment of a method for producing a joined body of a metal foil body and a metal member according to the present invention will be specifically described with reference to the drawings.
[0065]
  As shown in FIG. 7, the manufacturing method of the joined body of the metal foil body and the metal member of the present invention joins the edge 2 of at least one metal foil body 1 and the tip 5 of the metal member 4. A method for manufacturing a joined body 10, comprising:The shape of the metal member 4 is a shape having a flat part and a convex tip part 6 (convex part 7) whose thickness is thicker than that of the flat part,Of the edges of the metal foil 1ofThe tip of the metal member 46Edges arranged to be joined with (joint edges)2Side surface 13 andThe metal foil body 1 and the metal member 4 are brought into close contact with the front end portion 6 of the metal member 4 by bending the vicinity of the joining edge 2.Arrange and irradiate the tip part 5 of the metal member 4 with the energy ray 7, dissolve it, and the tip part of the melted metal member 46Of the metal foil 1Side 13Bonded to the metal foil body 1 and the metal member 411It is characterized by forming. In the present invention, a general metal or an alloy thereof may be used as the metal material constituting the metal foil body 1 and the metal member 4, and specifically, from titanium, copper, or an alloy thereof. It is preferable to use a metal foil body and a metal member, and it is particularly preferable to use a metal foil body and a metal member made of copper or a copper alloy in order to obtain a bonded body with a good bonding state.
[0066]
  In the manufacturing method of the joined body of this invention, the metal member 4 which has the convex part 6 which protrudes in the joining edge side in the front-end | tip part 5 is used, and the side surface of the convex part 6 and at least 1 or more joining edge 2 vicinity. The metal member 4 is arranged so that the part 13 is in close contactThe
[0067]
  At this time, by bending the vicinity of the joining edge 2,Side part 13 and joint surfaceHaveTip 6(Convex part 7)And closelyRu. In order to bend the vicinity of the joining edge 2, in addition to bending the vicinity of the joining edge 2 by an appropriate method in advance, the metal member 4 to be joined to the joining edge 2 is pressed with an appropriate pressure. Examples include a method of bending.
[0068]
The number of metal foil bodies used in the method for producing a joined body of the present invention may be one or a plurality. When the number of the metal foil bodies is one, the metal foil body is configured so that the edge thereof is joined to the tip portion of the metal member at a plurality of locations. Although there is no restriction | limiting in particular in the structure, For example, winding one metal foil body concentrically or bending several places is mentioned. In the case where there are a plurality of metal foil bodies, the joining edges are arranged so as to be substantially aligned. Even when there are a plurality of metal foil bodies, one or a plurality of the metal foil bodies may be concentrically wound or a plurality of places may be bent.
[0069]
There is no restriction | limiting in particular as a metal member used for the manufacturing method of the conjugate | zygote of this invention, For example, what was obtained by the general-purpose shaping | molding method can be used.
[0070]
  For example, the metal member 4 shown in FIG.As long as the shape is a shape having a flat portion and a convex tip portion 6 having a thickness larger than that of the flat portion and having a joint surface at the tip thereof.There is no particular limitation.
[0071]
  In the manufacturing method of the joined body of the present invention, as shown in FIGS.The flat portion 12 is thicker than the flat portion 12 and has a joint surface at the tip.Convex part 7AndThe thickness of the convex portion (L₂) And the thickness of the flat part (L₁It is preferable to use a metal member 4 that is 0.1 mm or more, more preferably to use a metal member 4 that is 0.6 mm or more, and to use a metal member 4 that is 0.8 mm or more. It is particularly preferred. When the difference in thickness between the convex portion and the flat portion is less than 0.1 mm, the shape characteristic of the convex portion 7 is not exhibited, and the contact state between the convex portion 7 and the metal foil body 1 is Unstable because it becomes unstable. Further, in the method for manufacturing a joined body of the present invention, the upper limit value of the difference in thickness between the convex portion and the flat portion is not particularly limited, but may be set as appropriate from the processing accuracy and strength of the metal member, for example, 3 mm. The following is sufficient.
[0072]
From the viewpoint of preventing deformation and damage of the metal member when the metal member is pressed against the metal foil during joining, the thickness of the flat portion (L₁) Is preferably 0.2 mm or more, more preferably 0.3 mm or more, and particularly preferably 0.4 mm or more. The upper limit value of the thickness of the flat portion is not particularly limited, but may be set as appropriate based on the strength and weight of the metal member because it is a portion not directly related to the welded portion, for example, 2 mm or less. That's fine.
[0073]
  Also convexTip ofPart thickness (L₂) Is preferably 0.4 mm or more, more preferably 0.5 mm or more, and particularly preferably 0.6 mm or more. This makes it possible to obtain a joined body that is more firmly joined. In addition,TipThe upper limit value of the thickness is not particularly limited, but may be set as appropriate from the limit of the power of the irradiated energy beam.
[0074]
  In the manufacturing method of the joined body of the present invention, as shown in FIG.8Of the metal member 4 at an angle θ (0 ° ≦ θ ≦ 30 °) with respect to the normal 3 of the surface including the side surface portion 13 in the vicinity of the joining edge 2 of the metal foil body 1.6Is preferably irradiated at an angle θ (0 ° ≦ θ ≦ 10 °), more preferably at an angle θ (0 ° ≦ θ ≦ 5 °). Also energy rays8The tip of the metal member 46(Convex part7It is preferable to focus on the surface of or near the front and back of the8It is preferable not to irradiate the metal foil body 1 directly.
[0075]
  Energy rays8Of the metal member 4Tip 6 (Convex part7)As a specific method of irradiating the metal member 4, as shown in FIG.Tip6 is a side surface portion 13 in the vicinity of the joining edge 2.DrippingArrange so as to intersect directly, energy rays8The side portion 13DrippingA line that intersects directly is scanned by the energy beam generator, that is, the tip of the metal member 46(Convex part7) And irradiating with scanning. At this time, energy rays8At an angle θ (0 ° ≦ θ ≦ 30 °) with respect to the normal 3 of the surface including the side surface portion 13 of the metal foil body 1.TipIn addition to the above conditions of irradiating 68The side portion 13DrippingAn angle with respect to a straight lineGagStraightTip6 is preferably irradiated. By these methods, the metal foil 1 and the melted metal member 4 are welded without using a brazing material, and the joined body of the metal foil 1 and the metal member 411Therefore, the cost can be reduced. In addition, even if adjacent metal foil bodies 1 are not arranged in parallel, they can be produced because a plurality of metal foil bodies 1 can be joined to the metal member 4 by a single irradiation as long as their edges are aligned. The improvement of property can be aimed at. Furthermore, according to the above-described conditions, the tip of the metal member 4 is not damaged without damaging the metal foil body 1.6(Convex part7The metal foil body 1 and the metal member 4 can be welded and bonded together, and the mechanical strength of the bonding can be improved, so that the reliability can be improved.
[0076]
  In the manufacturing method of the joined body of the present invention, the power density at the irradiation point is 6 kW / mm.²As described above, the convex shape of the metal memberTip ofIt is preferable to irradiate the part with energy rays, 7 kW / mm²It is more preferable to irradiate so that it becomes the above, 8 kW / mm²It is particularly preferable to irradiate so as to achieve the above. 6kW / mm²This is because the bonding state is not good, and it is assumed that the obtained bonded body has insufficient mechanical strength. The upper limit of the power density is not particularly limited, but may be determined as appropriate from the viewpoint of avoiding damage to the metal member and the metal foil joined thereto, for example, 60 kW / mm.²The following is sufficient.
[0077]
  Moreover, in the manufacturing method of the joined body of this invention, it is convex.Tip ofThe thickness of the part is L₂(Mm), the power density mentioned above is E (kW / mm)²), It is preferable to irradiate energy rays so as to satisfy the following formula (10). By irradiating energy rays under conditions that satisfy the following formula (10), it is possible to manufacture a bonded body in which damage to the metal foil body is suppressed and the mechanical strength of the bonded portion is strong.
[0078]
[Expression 10]
L₂≦ E / 7 (10)
[0079]
Note that it is preferable to satisfy the following formulas (11) and (12) from the viewpoint of further improving the stability of bonding and imparting reliability to the mechanical strength of the bonded portion.
[0080]
## EQU11 ##
L₂≦ E / 9 (11)
[0081]
[Expression 12]
L₂≦ E / 10 (12)
[0082]
In the method for producing a joined body of the present invention, it is preferable to use a metal member having a planar irradiation point of energy rays. Thereby, irregular reflection of energy rays can be suppressed, and particularly damage to the metal foil body can be suppressed, so that a bonded body in a good bonded state can be obtained. In addition, from the viewpoint of suppressing the irregular reflection of energy rays, it may be planar at least in a range wider than the irradiation point.
[0083]
Furthermore, in the manufacturing method of the joined body of this invention, it is preferable to irradiate an energy ray so that the spot diameter in an irradiation point may be 1 mm or less. Thereby, irradiation of energy rays to unnecessary portions can be suppressed, and particularly damage to the metal foil body can be suppressed, so that a bonded body in a good bonded state can be obtained. In addition, in the manufacturing method of the conjugate | zygote of this invention, it is especially suitable when arrange | positioning holding | maintaining a clearance gap between adjacent metal foil bodies.
[0084]
  Further, for example, such energy rays shown in FIG.8As such, it is preferable to use a laser or an electron beam having a high energy density and a small calorific value, and it is preferable to use an energy beam which is a continuous wave. This makes it convexTip ofBecause the energy can be concentrated and irradiated on the surface of the part 6Tip6 can be efficiently dissolved, and damage to the metal foil 1 can be suppressed. Of the lasers, the YAG laser can narrow the focal point better, and the energy density becomes smaller at the position of the metal foil body 1 arranged in a portion deviated from the focus, and damage to the metal foil body 1 is caused. Since it can suppress more well, it is especially preferable.
[0085]
  In the method for producing a joined body according to the present invention, the energy beam8Is preferably irradiated using an energy ray generator capable of continuous irradiation.8Is preferably irradiated using an energy beam generator capable of scanning by moving on a plane parallel to the plane including the side surface portion 13 (FIG. 7). In addition, it is preferable that the scanning speed | velocity | rate of the energy ray to irradiate is 0.1-100 m / min, It is further more preferable that it is 1-30 m / min, It is especially preferable that it is 2-10 m / min. Also, ConvexConditionTip ofBy scanning the unit 6 with an energy beam generator, energy beams are scanned.8Is preferably irradiated. Furthermore, in the manufacturing method of the joined body of the present invention, a plurality of metal members 4 are prepared in accordance with the number of the arranged metal foil bodies 1, and the plurality of metal members 4 are formed such that their convex portions 6 are side portions. 13DrippingIt is preferable to arrange them continuously so as to intersect each other. By these things, since the metal foil body 1 of several sheets can be joined by one irradiation, the improvement of productivity can be aimed at.
[0086]
FIG. 3 is an explanatory view showing an example of a metal member that can be used in the method for producing a joined body of the present invention.
FIG. 3 shows an example of a metal member 31 having a thicker convex portion 33 than the metal member 4 of FIG. 7. In this case, the energy beam 34 is irradiated from the upper surface side of the metal member 31. By this, the joining edge 2 of the metal member 31 and the metal foil body 1 can be welded and joined.
[0087]
  Moreover, as shown in FIG. 8, the manufacturing method of the joined body of the metal foil body and metal member of this invention joins the edge 2 and the metal member 51 of at least 1 piece of metal foil body 1, and metal foil body. 1 and a metal member 51 for manufacturing a joined body 55,The shape of the metal member 51 is a shape having a flat portion 12 and a convex portion 52 having a thickness larger than that of the flat portion 12 and having a joint surface at the tip thereof.Of the edges of the metal foil 1ofEdges arranged to be joined to the metal member 51 (joint edges)2Side surface 13 andThe metal foil body 1 and the metal member 51 are brought into close contact with the joint surface of the metal member 51 by bending the vicinity of the joint edge 2.It arrange | positions, the energy ray 53 is irradiated to the convex part 52 of the metal member 51, it is melt | dissolved, and the convex part 52 of the melt | dissolved metal member 51 is made into the metal foil body 1.Side 13The bonded body 55 of the metal foil body 1 and the metal member 51 is formed by welding. Since the specific manufacturing method and its technical effect in the present invention have been described above, overlapping portions will be omitted.
[0088]
According to the method for manufacturing a joined body of the present invention, when the convex portion 52 is provided at a predetermined location that is not the tip portion of the metal member as shown in FIG. 8, the metal member 51 provided with the convex portion 52 is provided. By irradiating the energy beam 53 on the back surface, the metal member 51 and the bonding edge 2 of the metal foil body 1 can be welded to manufacture the bonded body 55.
[0089]
【Example】
EXAMPLES The present invention will be specifically described below with reference to examples, but the present invention is not limited to these examples.
(Examples 1 to 3, Comparative Examples 1 and 2)
A continuous wave YAG laser is used as the energy beam, and the bonding of the metal member (convex part), how to contact the metal foil and the metal member, and various bondings such as the output of the YAG laser and the scanning speed A joining test was performed with the conditions set, and the cross section of the obtained joined body was observed with a microscope. In addition, the metal which comprises a metal foil body and a metal member is copper (JIS).
C1100). The results are shown in FIGS.
[0090]
(Discussion)
In the joined body in which the joined state between the metal member and the metal foil body was good, columnar crystals formed from the metal foil body side toward the metal member could be observed (Examples 1 to 3). On the other hand, columnar crystals could not be observed in places where the metal member and the metal foil body were not joined as in Comparative Example 1, and equiaxed crystals could be observed instead.
[0091]
Further, in Comparative Example 2, although columnar crystals were not observed, it was found that the metal foil body and the metal member were partially joined. However, it has been found that the bonding area is smaller than that of the example and the bonding state is not stable.
From the above, it is possible to manufacture a bonded body in a good bonded state as long as columnar crystals are formed in the bonded portion between the metal foil body and the metal member in the direction from the metal foil body to the metal member. There was found.
[0092]
【The invention's effect】
As described above, according to the present invention, since the brazing material is not required, the cost is excellent, and only the metal member is melted without damaging the metal foil body, and the metal foil body and the metal member are welded. -By joining, the joined body of the metal foil body and metal member which has strong mechanical strength of the joined body and excellent reliability can be provided. Furthermore, according to the present invention, since the brazing material is not required, the cost is reduced, and even if the adjacent metal foil bodies are not arranged in parallel, the plurality of sheets can be used as long as the edges are arranged substantially in line. The metal foil body can be bonded to the metal member by a single irradiation, so that the productivity is excellent. Further, only the metal member is dissolved without damaging the metal foil body, so that the metal foil body and the metal member are Since it can weld and join and can improve the mechanical strength of joining, the manufacturing method of the joined body of the metal foil body and metal member excellent in reliability can be provided.
[Brief description of the drawings]
FIG. 1 is a perspective view schematically showing one embodiment of a joined body of the present invention.
FIG. 2 is a perspective view schematically showing an example of a metal member used for manufacturing the joined body of the present invention.
FIG. 3 is a perspective view schematically showing another example of a metal member used for manufacturing the joined body of the present invention.
FIG. 4 is a perspective view schematically showing still another example of the metal member used for manufacturing the joined body of the present invention.
FIG. 5 is a schematic view showing an example of the shape of a convex portion of a metal member used for manufacturing the joined body of the present invention.
FIG. 6 is a schematic view showing another example of the shape of the convex portion of the metal member used for manufacturing the joined body of the present invention.
FIG. 7 is an explanatory view schematically showing one embodiment of a method for producing a joined body according to the present invention.
FIG. 8 is an explanatory view schematically showing another embodiment of the method for producing a joined body according to the present invention.
9 is a photomicrograph showing the metal structure in the cross section of the joined body of Example 1. FIG.
10 is a photomicrograph showing the metal structure in the cross section of the joined body of Example 2. FIG.
11 is a photomicrograph showing the metal structure in the cross section of the joined body of Example 3. FIG.
12 is a photomicrograph showing the metal structure in the cross section of the joined body of Comparative Example 1. FIG.
13 is a photomicrograph showing the metal structure in the cross section of the joined body of Comparative Example 2. FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Metal foil body, 2 ... End edge (joining edge), 3 ... Normal of surface including a side part, 4 ... Metal member, 5 ... Joint part, 6 ... Tip part, 7 ... Convex part, 8 ... Energy ray, 9 ... joint surface, 10 ... gap, 11 ... joined body, 12 ... flat part, 13 ... side surface part, 31 ... metal member, 32 ... tip part, 33 ... convex part, 34 ... energy ray, 35 ... Energy rays 51... Metal member 52. Convex part 53. Energy rays.

Claims

A joined body of a metal foil body and a metal member formed by joining an edge of at least one metal foil body and a metal member,
The shape of the metal member is a shape having a flat portion and a convex portion having a thickness larger than that of the flat portion and having a bonding surface at the tip thereof.
And side portions of the array of edge (bonding edge) to be joined to the front Symbol metal member of the end edge of the metal foil, and the bonding surface of the metallic member, the joining edge near Irradiate energy rays to the convex portion in a state of being closely adhered by bending ,
A joined body of a metal foil body and a metal member, which is formed by melting the convex portion and welding the convex portion and the side surface portion .

The joined body of the metal foil body and the metal member according to claim 1, wherein the metal foil body and the metal member are made of copper or a copper alloy.

The joined body of the metal foil body and the metal member according to claim 1 or 2, wherein a columnar crystal is formed from the metal foil body toward the metal member at a joint portion between the metal foil body and the metal member. .

The joined body of the metal foil body and the metal member according to any one of claims 1 to 3, wherein the convex portion is formed at a tip portion of the metal member.

The thickness of the convex portion (L _2), metal foil and the metal member according to any one of claims 1 to 4 difference is 0.1mm or more and the thickness of the flat portion (L ₁₎ And zygote.

The joined body of the metal foil body and the metal member according to claim 5 , wherein a thickness (L ₁ ) of the flat portion is 0.2 mm or more .

The joined body of the metal foil body and the metal member according to claim 5 or 6, wherein a thickness (L ₂ ) of the convex portion is 0.4 mm or more .

The said energy ray is irradiated to the said convex-shaped part by angle (theta) (0 degree <= theta <= 30 degree) with respect to the normal line of the surface containing the said side part of the said metal foil body. A joined body of the metal foil body according to any one of the above and a metal member.

The joined body of the metal foil body and the metal member according to any one of claims 1 to 8 , wherein the convex portion of the metal member is disposed so as to intersect the side surface portion perpendicularly .

The metal foil body and the metal member according to any one of claims 1 to 9, wherein the energy ray is irradiated to the convex portion with an angle perpendicular to a line perpendicular to the side surface portion. And zygote.

The joined body of the metal foil body and the metal member according to any one of claims 1 to 10, wherein the energy ray is not directly irradiated onto the metal foil body.

The joined body of a metal foil body and a metal member according to any one of claims 1 to 11, wherein a power density at an irradiation point of the energy beam is 6 kW / mm ² or more .

The thickness of the convex portion _L 2 (mm), wherein, when the power density was set to E (kW / mm ^2), a metal according to any one of claims 1 to 12 which satisfies the following formula (1) A joined body of a foil body and a metal member.

The junction of the metal foil body and metal member as described in any one of Claims 1-13 whose irradiation point of the said energy beam in the said metal member is planar .

The spot diameter of the said irradiation point is 1 mm or less, The joined body of the metal foil body and metal member of Claim 14 .

The joined body of a metal foil body and a metal member according to any one of claims 1 to 15, wherein adjacent metal foil bodies are arranged with a gap therebetween.

The said energy ray is a thing by a laser or an electron beam , The joined body of the metal foil body and metal member as described in any one of Claims 1-16 .

The joined body of the metal foil body and the metal member according to claim 17 , wherein the energy beam is a continuous wave .

The joined body of a metal foil body and a metal member according to claim 17 or 18 , wherein the laser is a YAG laser .

A bonding material for assisting the bonding between the metal member and the metal foil is applied to the metal foil and / or the convex portion, or is sandwiched between the metal foil and the convex portion,
Irradiate energy rays to the convex part and the bonding material, dissolve them,
The joined body of a metal foil body and a metal member according to any one of claims 1 to 19, wherein the melted convex portion and the joining material are joined to each other by welding to the side face portion .

The metal foil body and the metal member according to any one of claims 1 to 20, wherein the metal foil body and the metal member are respectively a metal foil body and a metal member used for an electrochemical element .

An electrochemical element comprising the joined body of the metal foil body and the metal member according to claim 21.

A method of manufacturing a joined body of a metal foil body and a metal member by joining an edge of at least one metal foil body and a tip portion of the metal member,
The shape of the metal member is a shape having a flat portion and the tip portion having a convex shape that is thicker than the flat portion,
Of the edge of the metal foil body, a side surface portion of an edge (joining edge) arranged to be joined to the tip of the metal member and the tip of the metal member are connected to the joint end. Place the metal foil body and the metal member in close contact by bending the vicinity of the edge,
Irradiate the tip with energy rays, dissolve it,
A method for producing a joined body of a metal foil body and a metal member, wherein the melted tip portion is welded to the side surface portion to form a joined body of the metal foil body and the metal member.

The method for producing a joined body of a metal foil body and a metal member according to claim 23, wherein the metal foil body and the metal member made of copper or a copper alloy are used.

25. The metal foil body and the metal member according to claim 23 or 24, wherein the metal member having a difference between the thickness (L ₂ ) of the tip portion and the thickness (L ₁ ) of the flat portion is 0.1 mm or more. Method for manufacturing the joined body.

Method for producing a bonded body of the metal foil and the metal member according to claim 25, wherein the flat portion of the thickness (L ₁₎ uses the metal member is 0.2mm or more.

Method for producing a bonded body of the metal foil and the metal member according to claim 25 or 26 using the metal member thickness (L ₂₎ is 0.4mm or more of the tip.

The metal according to any one of claims 23 to 27, wherein the energy ray is irradiated to the tip portion at an angle θ (0 ° ≦ θ ≦ 30 °) with respect to a normal line of the surface including the side surface portion. A method for producing a joined body of a foil body and a metal member.

The method for producing a joined body of a metal foil body and a metal member according to any one of claims 23 to 28, wherein the tip end portion of the metal member is disposed so as to intersect the side surface portion perpendicularly .

30. The method of manufacturing a joined body of a metal foil body and a metal member according to any one of claims 23 to 29, wherein the energy beam perpendicularly intersecting the side surface portion is irradiated by scanning with an energy beam generator .

The joining of the metal foil body and the metal member according to any one of claims 23 to 30, wherein the energy ray is irradiated to the tip portion at an angle perpendicular to a line perpendicular to the side surface portion. Body manufacturing method.

The method for producing a joined body of a metal foil body and a metal member according to any one of claims 23 to 31 , wherein the energy ray is not directly irradiated onto the metal foil body.

The method for producing a joined body of a metal foil body and a metal member according to any one of claims 23 to 32 , wherein the energy beam is irradiated so that a power density at an irradiation point is 6 kW / mm ² or more .

The metal according to claim 33 , wherein the energy beam is irradiated so as to satisfy the following formula (2), where L ₂ (mm) is the thickness of the tip and E (kW / mm ² ) is the power density. A method for producing a joined body of a foil body and a metal member.

The method for producing a joined body of a metal foil body and a metal member according to any one of claims 23 to 34, wherein the metal member having a planar irradiation point of the energy rays is used .

The method for producing a joined body of a metal foil body and a metal member according to any one of claims 23 to 35 , wherein the energy beam is irradiated so that a spot diameter at an irradiation point is 1 mm or less .

37. The method for producing a joined body of a metal foil body and a metal member according to any one of claims 23 to 36, wherein the metal foil bodies are arranged while holding a gap between adjacent metal foil bodies .

The method for producing a joined body of a metal foil body and a metal member according to any one of claims 23 to 37, wherein a laser or an electron beam is used as the energy beam .

The method for producing a joined body of a metal foil body and a metal member according to claim 38 , wherein a YAG laser is used as the laser .

The method for producing a joined body of a metal foil body and a metal member according to any one of claims 23 to 39, wherein the energy beam is irradiated using an energy beam generator capable of continuous irradiation .

The metal foil body and metal according to any one of claims 23 to 40, wherein the energy beam is irradiated using an energy beam generator capable of moving and scanning on a plane parallel to a plane including the side surface portion. A method for producing a joined body with a member.

The method for manufacturing a joined body of a metal foil body and a metal member according to any one of claims 23 to 41, wherein the energy beam generator scans and irradiates the energy beam to the tip portion .

Prepare a plurality of the metal members according to the number of the arranged metal foil body,
43. A metal foil body and a metal member according to any one of claims 23 to 42, wherein a plurality of the metal members are continuously arranged such that the front end portions thereof perpendicularly intersect the side surface portions. Method for manufacturing the joined body.

A method of manufacturing a joined body of a metal foil body and a metal member by joining an edge of at least one metal foil body and a metal member,
The shape of the metal member is a shape having a flat portion and a convex portion having a thickness larger than that of the flat portion and having a bonding surface at the tip thereof.
Of the edge of the metal foil body, the side surface portion of the edge (joining edge) arranged to be joined to the metal member and the joining surface of the metal member are bent near the joining edge. By placing the metal foil body and the metal member in close contact with each other,
Irradiate the convex part with energy rays, dissolve it,
A method for producing a joined body of a metal foil body and a metal member, wherein the melted convex portion is welded to the side surface portion to form a joined body of the metal foil body and the metal member.

The manufacturing method of the joined body of the metal foil body and metal member of Claim 44 which uses the said metal foil body and the said metal member which consist of copper or a copper alloy .

The metal foil body and metal according to claim 44 or 45 , wherein the metal member having a difference between the thickness (L ₂ ) of the convex portion and the thickness (L ₁ ) of the flat portion is 0.1 mm or more. A method for producing a joined body with a member.

Method for producing a bonded body of the metal foil and the metal member according to claim 46, wherein the flat portion of the thickness (L ₁₎ uses the metal member is 0.2mm or more.

Method for producing a bonded body of the metal foil and the metal member according to claim 46 or 47 the thickness of the convex portion (L ₂₎ uses the metal member is 0.4mm or more.

49. The energy ray according to any one of claims 44 to 48, wherein the convex portion is irradiated with the energy ray at an angle θ (0 ° ≦ θ ≦ 30 °) with respect to a normal line of the surface including the side surface portion . A method for producing a joined body of a metal foil body and a metal member.

The method for producing a joined body of a metal foil body and a metal member according to any one of claims 44 to 49, wherein the convex portion of the metal member is disposed so as to intersect the side surface portion perpendicularly .

The method for producing a joined body of a metal foil body and a metal member according to any one of claims 44 to 50, wherein the energy beam perpendicularly intersecting the side surface portion is irradiated by scanning with an energy beam generator .

52. The metal foil body and the metal member according to any one of claims 44 to 51, wherein the energy ray is applied to the convex portion at an angle perpendicular to a line perpendicular to the side surface portion . Manufacturing method of joined body.

53. The method for producing a joined body of a metal foil body and a metal member according to any one of claims 44 to 52 , wherein the energy ray is not directly irradiated onto the metal foil body.

The method for producing a joined body of a metal foil body and a metal member according to any one of claims 44 to 53 , wherein the energy beam is irradiated so that a power density at an irradiation point is 6 kW / mm ² or more .

55. The energy beam according to claim 54 , wherein the energy beam is irradiated so as to satisfy the following formula (3), where L ₂ (mm) is the thickness of the convex portion and E (kW / mm ² ) is the power density . A method for producing a joined body of a metal foil body and a metal member.

The method for producing a joined body of a metal foil body and a metal member according to any one of claims 44 to 55, wherein the metal member having a planar irradiation point of the energy rays is used .

57. The method for producing a joined body of a metal foil body and a metal member according to claim 56 , wherein the energy beam is irradiated so that a spot diameter of the irradiation point is 1 mm or less .

The method for producing a joined body of a metal foil body and a metal member according to any one of claims 44 to 57, wherein the metal foil bodies are arranged while holding a gap between adjacent metal foil bodies .

The method for producing a joined body of a metal foil body and a metal member according to any one of claims 44 to 58 , wherein a laser or an electron beam is used as the energy beam .

60. The method for producing a joined body of a metal foil body and a metal member according to claim 59, wherein a YAG laser is used as the laser .

The method for producing a joined body of a metal foil body and a metal member according to any one of claims 44 to 60, wherein the energy beam is irradiated using an energy beam generator capable of continuous irradiation .

62. The metal foil body and metal according to any one of claims 44 to 61, wherein the energy beam is irradiated using an energy beam generator capable of moving and scanning on a plane parallel to a plane including the side surface portion. A method for producing a joined body with a member.

The method for manufacturing a joined body of a metal foil body and a metal member according to any one of claims 44 to 62, wherein the energy beam generator scans and irradiates the energy beam onto the convex portion .

Prepare a plurality of the metal members according to the number of the arranged metal foil body,
64. The metal foil body and the metal member according to any one of claims 44 to 63 , wherein a plurality of the metal members are continuously arranged such that the convex portions intersect perpendicularly with the side surface portions. And manufacturing method of joined body.