JP4175822B2

JP4175822B2 - Electrode foil with terminal and manufacturing method and apparatus thereof

Info

Publication number: JP4175822B2
Application number: JP2002084444A
Authority: JP
Inventors: 勝森小俣
Original assignee: ジェーシーシーエンジニアリング株式会社
Priority date: 2002-03-25
Filing date: 2002-03-25
Publication date: 2008-11-05
Anticipated expiration: 2022-03-25
Also published as: KR20030077954A; MY142461A; CN100380546C; KR100891476B1; SG117425A1; CN1447359A; JP2003282364A; TW564447B

Description

【０００１】
【発明の属する技術分野】
本発明は、端子付き電極箔並びにその製造方法及び装置に係り、特に電極箔に穴をあけた後、該穴上にリード線付き端子のタブを重ね合わせ、タブ側からグサリ針を穴内に挿通して、電極箔自体のバリの発生を防止し、タブのバリを電極箔の裏面側に形成させて電極箔とタブとを固着することによって、電極箔の地金をタブに確実に接触させて導通抵抗を極めて小さくすると共に、該導通抵抗のばらつきを少なくした電気特性の優れた端子付き電極箔の製造方法及び装置に関する。
【０００２】
【従来の技術】
従来、図２１において、電解コンデンサ素子は、リード線付き端子が固着された純度９９．９％程度、厚さ６０乃至１００μｍのエッチングアルミニウム箔の表面に酸化皮膜を形成した陽極用電極箔及び厚さ４０乃至６０μｍのエッチングアルミニウム箔である陰極用電極箔と電解紙とを交互に重ね合わせて円筒状に巻き上げて製作されている。
【０００３】
図２１から図２５において、リード線付き端子２は、リード素材２ａにアルミニウム製のタブ２ｂを溶接し、更に該タブ２ｂを平板状にプレス加工した後、トリミングして外形形状を一定の形に成形して製作されている。従来、アルミニウム箔１へのリード線付き端子２の固着は、グサリ加工によって固着されていた。具体的には、ワークテーブル３に載せたアルミニウム箔１上にリード線付き端子２のタブ２ｂを重ね合わせ（図２５（ａ））、押え具４で固定した後（図２５（ｂ））、先端部が四角錐の形状に成形されたグサリ針５をタブ２ｂ及びアルミニウム箔１に貫通させ（図２５（ｃ））、図２２及び図２３において、アルミニウム箔１及びタブ２ｂのバリ１ａ，２ｃをアルミニウム箔１の裏面側に形成し、更に該バリ１ａ，２ｃを矢印Ｒ及びＳ方向にプレス加工して固着していた。
【０００４】
図２２から図２４において、従来のグサリ加工により生じるアルミニウム箔１のバリ１ａ及びタブ２ｂのバリ２ｃは、アルミニウム箔１の裏面側に該アルミニウム箔１のバリ１ａが形成され、該バリ１ａの外側にタブ２ｂのバリ２ｃが形成された二重構造となっていた。一方、アルミニウム箔１とタブ２ｂとの固着の重要ポイントは、機械的に強固にアルミニウム箔１とタブ２ｂとが固着されていることは勿論のこと、該アルミニウム箔１とタブ２ｂとの電気的導通抵抗が極めて小さく、かつ該導通抵抗のばらつきが小さいことが、電解コンデンサの性能に直接影響することから重要な項目であり、特に微弱電流用の超小型電解コンデンサにおいては、該電気的導通抵抗の大きさは決定的な要素である。
【０００５】
アルミニウム箔１とタブ２ｂとの電気的導通抵抗を小さくするには、アルミニウム箔１の地金部とタブ２ｂとが直接接触して固着されていることが要求されるが、従来のグサリ加工によると、図２３において、アルミニウム箔１の表面に形成された化成皮膜が破れることなくバリ１ａとして形成され、更に該バリ１ａを包み込むようにしてバリ２ｃが形成されていた。従って、タブ２ｂは化成皮膜を介してアルミニウム箔１と接触することとなり、電気的導通抵抗は１．９ｍΩから２．２ｍΩとなって十分に小さくすることができない問題点があった。
【０００６】
また、タブ２ｂのバリ２ｃによってアルミニウム箔１の化成皮膜が一部破られ、アルミニウム箔１の地金とタブ２ｂとが直接接触するので、該現象が生じると電気的導通抵抗は小さくなる方向に作用するが、従来のグサリ加工では該地金との接触面積を制御することは不可能であり、これに起因して電気的導通抵抗がばらつく欠点があった。
【０００７】
また、近年超小型電解コンデンサの要求が多くなったが、これには、幅１ｍｍという極小幅の電極箔が使用される場合、非常に破れ易く、また従来以上に電気的導通抵抗の低減及びばらつきの低下が必要となること、更に従来のグサリ加工によると機械的強度の関係から２点のグサリ加工が必要となり、幅１ｍｍの電極箔に２点のグサリ加工は不可能であるから、１点のグサリ加工で十分な通電面積を確保しなければならない。しかし従来のグサリ加工では、上記の理由から１点のグサリ加工では十分な通電面積は確保できないから、幅１ｍｍ程度という極小幅の電極箔を用いる全高４ｍｍ以下の超小型電解コンデンサの要求に対応することができないという問題があった。
【０００８】
また、グサリ加工時に、アルミニウム箔１が強制的に破られることから、アルミニウム箔１に亀裂が発生し易く、該亀裂を起点としてアルミニウム箔１が破断されてしまうという大きな問題があった。
【０００９】
【発明が解決しようとする課題】
本発明は，上記した従来技術の欠点を除くためになされたものであって、その目的とするところは、表面に化成皮膜処理が施された電極箔にあけられた穴上にリード線付き端子のタブを重ね合わせ、該タブ側からグサリ針を穴内に挿通してタブのバリを電極箔の裏面側に形成して電極箔とリード線付き端子のタブとを固着し、電極箔自体のバリの発生を防止することによって、電極箔の地金とタブとを直接、かつ安定して接触させて固着することができるようにすることであり、またこれによって電極箔とタブとの電気的導通抵抗を小さくすると共に、ばらつきを小さくして１点のグサリ加工でも十分な通電面積が確保できるようにして幅１ｍｍ程度の極小幅の電極箔へのグサリ加工を可能とし、電気特性の優れた全高５ｍｍ以下、具体的には座板を含めた全高が３．２５ｍｍという世界最小の超小型電解コンデンサを、グサリ加工方式によっても製作できるようにすることである。
【００１０】
また他の目的は、表面に化成皮膜処理が施された電極箔に４つの隅部が夫々電極箔の長手方向及び幅方向に向けられた角穴をあけた後、該角穴上にリード線付き端子のタブを重ね合わせ、該タブ側から断面角形に形成されたグサリ針の４つの角部を角穴の夫々の隅部に一致させて角穴内に挿通してグサリ加工し、電極箔とリード線付き端子とを圧縮して固着することによって、グサリ加工時に電極箔を強制的に破ることによる亀裂の発生を防止し、電極箔へのダメージを最小にすることであり、またこれによって電極箔の機械的強度の低下を防止し、該電極箔の破断の発生をなくすことができるようにすることである。
【００１１】
更に他の目的は、上記構成によって、１点グサリ加工を可能とし、１点グサリ加工でありながら、電極箔の地金とタブとを直接接触させて電極箔とタブとの電気的導通抵抗及び抵抗値のばらつきを小さくし、かつ機械的強度を向上させて幅１ｍｍ程度の極小幅の電極箔にもリード線付き端子のタブを固着することができるようにすることであり、またこれによって微弱電流用の超小型電解コンデンサを製作できるようにすることである。
【００１２】
また他の目的は、電極箔の一方の面側に配設され抜き穴が設けられたダイスと、該ダイスと対向して電極箔の他方の面側に配設されたパンチとからなり抜き穴内にパンチを突出させて電極箔に穴を形成するプレス型と、電極箔の穴上にリード線付き端子のタブを重ね合わせ供給するリード線付き端子供給機構と、ダイスの抜き穴内に出没自在に配設されタブ側から電極箔の穴内に挿通してタブのバリを電極箔の裏面側に形成するグサリ針とを備えた端子付き電極箔の製造装置により、電極箔に穴をあけた後、該穴上にタブを重ね合わせてリード線付き端子を供給し、該タブ側からグサリ針を穴内に挿通してグサリ加工して電極箔とリード線付き端子とを固着することによって、電極箔のバリを発生させずにグサリ加工して電気的導通抵抗の小さな電気的性能の優れた端子付き電極箔を効率よく製造することができるようにすることである。
【００１３】
【課題を解決するための手段】
【００１４】
要するに本発明方法（請求項１）は、表面に化成皮膜処理が施されてリールに巻き取られた電極箔を前記リールから引き出し、前記電極箔に４つの隅部が夫々前記電極箔の長手方向及び幅方向に向けられた角穴をあけた後、該角穴上にリード線付き端子のタブを重ね合わせ、該タブ側から断面角形に形成されたグサリ針の４つの角部を前記角穴の前記４つの隅部に一致させて前記角穴内に挿通し、前記タブのバリを前記電極箔の裏面側に形成するようにグサリ加工して前記電極箔と前記リード線付き端子の前記タブとを圧縮して固着することを特徴とするものである。
【００１６】
また本発明端子付き電極箔（請求項２）は、表面に化成皮膜処理が施されてリールに巻き取られた電極箔を前記リールから引き出し、前記電極箔に４つの隅部が夫々前記電極箔の長手方向及び幅方向に向けられた角穴をあけた後、該角穴上にリード線付き端子のタブを重ね合わせ、該タブ側から断面角形に形成されたグサリ針の４つの角部を前記角穴の前記４つの隅部に一致させて前記角穴内に挿通し、前記タブのバリを前記電極箔の裏面側に形成するようにグサリ加工し、プレス加工により前記電極箔と前記リード線付き端子の前記タブとを圧縮して固着してなることを特徴とするものである。
【００１８】
また本発明装置（請求項３）は、表面に化成皮膜処理が施され巻き取られたリールから引き出された電極箔の一方の面側に配設され抜き穴が設けられたダイスと該ダイスと対向して前記電極箔の他方の面側に配設されたパンチとからなり前記抜き穴内に前記パンチを突出させて前記電極箔に穴を形成するプレス型と、前記電極箔の前記穴上にリード線付き端子のタブを重ね合わせ供給するリード線付き端子供給機構と、前記ダイスの抜き穴内に出没自在に配設され前記タブ側から前記電極箔の前記穴内に挿通して前記タブのバリを前記電極箔の裏面側に形成するグサリ針とを備え、前記電極箔に前記穴をあけた後、該穴上に前記タブを重ね合わせて前記リード線付き端子を供給し、該タブ側から前記グサリ針を前記穴内に挿通してグサリ加工して前記電極箔と前記リード線付き端子の前記タブとを固着するように構成したことを特徴とするものである。
【００１９】
【発明の実施の形態】
以下本発明を図面に示す実施例に基いて説明する。本発明に係る端子付き電極箔の製造装置１０は、図１及び図２において、表面にエッチング処理及び化成皮膜処理が施された電極箔１３にリード線付き端子１４のタブ１４ｂを重ね合わせてグサリ加工し、バリ１４ｃを電極箔１３の裏面側に形成し、電極箔１３とリード線付き端子１４とを固着させて端子付き電極箔１５を製造するための装置であり、図３から図８において、プレス型１１と、リード線付き端子供給機構（図示せず）と、グサリ針１２とを備えている。
【００２０】
プレス型１１は、電極箔１３に４つの隅部１３ｂが夫々電極箔１３の長手方向及び幅方向に向けられた角穴１３ａをあけるためのものであって、図３において、リール１７から引き出されガイドローラ１６に案内されて供給された電極箔１３の上方に配設されたダイス１８と、該電極箔１３の下方に配設されたパンチ１９とから構成されている。
【００２１】
ダイス１８は、基台２７に嵌合して上下方向（矢印Ｂ又はＥ方向）に移動自在に配設されたダイスホルダ２０に固定されている。ダイスホルダ２０には、ロッドエンド２１を介してカムフォロワ２２が配設され、図示しないカム装置により該カムフォロワ２２を押圧して矢印Ｂ又はＥ方向（図５，図６）に移動させてダイス１８を端子付き電極箔の製造装置１０のワークテーブル２３に押圧するように構成されている。またダイス１８には、角形の抜き穴１８ａが設けられている。
【００２２】
パンチ１９は、角形の抜き穴１８ａと同一形状の断面を持ち、該抜き穴１８ａに対向配置されたピンであり、パンチホルダ２４に固定されてパンチガイド２５の穴に摺動可能に嵌合しており、該パンチホルダ２４と共に上下方向（矢印Ｃ又はＦ方向）に移動できるようになっている。そして、該パンチ１９をダイス１８の角形の抜き穴１８ａ内に突出させて電極箔１３に４つの隅部１３ｂを夫々電極箔１３の長手方向及び幅方向に向けた角形の角穴１３ａをあけるようになっている。
【００２３】
リード線付き端子供給機構（図示せず）は、図１９及び図２０において、リード素材１４ａにアルミニウム製のタブ１４ｂが溶接されたリード線付き端子１４の該タブ１４ｂを、電極箔１３の角穴１３ａ上に重ね合わせるように供給するためのものであって、リード線付き端子１４を所定の方向に揃えて搬送する整列搬送機構（図示せず）と、該整列搬送機構から順次リード線付き端子１４を受け取り、タブ１４ｂを電極箔１３の角穴１３ａに一致させて搬送する搬送装置（図示せず）とから構成されており、その具体的機構は、従来公知の機構を組み合わせて達成されている。
【００２４】
またパンチガイド２５の上方には、図３において、箔押え２８が箔押えホルダ２９に固定されて配設され、該箔押えホルダ２９は基台２７に嵌合して上下方向に移動可能となっている。箔押えホルダ２９の上端には、カムフォロワ３０が配設され、図示しないカム装置により該カムフォロワ３０を押圧して矢印Ｈ方向（図７）に移動させ、パンチガイド２５との間で電極箔１３を挟持して固定するようになっている。
【００２５】
グサリ針１２は、グサリ加工して電極箔１３とリード線付き端子１４のタブ１４ｂとを固着するためのものであって、図１４をも参照して、先端が四角錐形状１２ａに成形されたピンであり、ダイス１８の角形の抜き穴１８ａに摺動自在に嵌合して針ホルダ３１に固定されている。針ホルダ３１は、上下方向に移動可能に基台２７に嵌合し、該針ホルダ３１の上端に配設されたカムフォロワ３２を図示しないカム装置で押圧して矢印Ｊ方向（図８）に移動させ、グサリ針１２を矢印Ｌ方向に下降させてグサリ加工するようになっている。
【００２６】
そして、端子付き電極箔の製造装置１０によって製造される端子付き電極箔１５は、図１９及び図２０において、電極箔１３にあけられた角穴１３ａ上に重ね合わせてリード線付き端子１４のタブ１４ｂを配置し、該タブ１４ｂ側からグサリ針１２を角穴１３ａ内に挿通させてタブ１４ｂのバリ１４ｃを電極箔１３の裏面側に形成し、圧縮して電極箔１３とタブ１４ｂとを固着した構造となっている。
【００２８】
そして本発明方法（請求項１）は、表面に化成皮膜処理が施されてリール１７に巻き取られた電極箔１３を前記リール１７から引き出し、前記電極箔１３に４つの隅部１３ｂが夫々前記電極箔１３の長手方向及び幅方向に向けられた角穴１３ａをあけた後、該角穴１３ａ上にリード線付き端子１４のタブ１４ｂを重ね合わせ、該タブ１４ｂ側から断面角形に形成されたグサリ針１２の４つの角部を前記角穴１３ａの前記４つの隅部１３ｂに一致させて前記角穴１３ａ内に挿通し、前記タブ１４ｂのバリ１４ｃを前記電極箔１３の裏面側に形成するようにグサリ加工して前記電極箔１３と前記リード線付き端子１４の前記タブ１４ｂとを圧縮して固着することを特徴とする方法である。
【００２９】
本発明は、上記のように構成されており、以下その作用について説明する。図４から図１６において電極箔１３にタブ１４ｂをグサリ加工して固着させる工程について説明する。図４及び図９において、表面に化成皮膜処理が施された電極箔１３をガイドローラ１６でガイドしながらリール１７から引き出し、ダイス１８とパンチガイド２５との間に配置する。
【００３０】
図５、図１０及び図１１において、図示しないカム装置により該カムフォロワ２２を矢印Ａ方向に押圧してダイス１８をダイスホルダ２０と共に矢印Ｂ方向に下降させ、ダイス１８とパンチガイド２５とで、例えば幅１ｍｍ程度の極小幅の電極箔１３を挟持した後、パンチホルダ２４を矢印Ｃ方向に上昇させてパンチ１９をダイス１８の角形の抜き穴１８ａ内に突出させて電極箔１３に１個の角穴１３ａをあける。
【００３１】
図６及び図１２において、ダイスホルダ２０を矢印Ｄ方向に移動させることによってダイス１８を矢印Ｅ方向に上昇させると共に、パンチ１９を矢印Ｆ方向に下降させると、電極箔１３には、４つの隅部１３ｂが夫々電極箔１３の長手方向及び幅方向に向けられた角穴１３ａがあけられている。このとき、電極箔１３の角穴１３ａの縁には、ごく小さなバリ１３ｃが上方に向かって形成され、また角穴１３ａの端面は、化成皮膜のないアルミニウムの地金が露出した状態となっている。またダイス１８の抜き穴１８ａ内には、角穴１３ａが打ち抜かれた角形の打抜き粕（図示せず）が残っているが、ダイス１８が矢印Ｅ方向に上昇することによって、抜き穴１８ａ内に残っていた該打抜き粕は、グサリ針１２によって抜き穴１８ａから突き出される。
【００３２】
図７及び図１３において、カム装置によりカムフォロワ３０を矢印Ｈ方向に押圧して箔押え２８を下降させ、電極箔１３を押圧固定した後、リード線付き端子供給機構（図示せず）によってリード線付き端子１４を矢印Ｇ方向に搬送し、タブ１４ｂを電極箔１３の角穴１３ａに一致させて位置決めする。
【００３３】
次いで、図８、図１４及び図１５において、カム装置によりカムフォロワ２２を矢印Ｉ方向に、またカムフォロワ３２を矢印Ｊ方向に押圧してダイス１８を矢印Ｋ方向に下降させ、リード線付き端子１４のタブ１４ｂを電極箔１３の角穴１３ａに一致させた状態で押圧した後、グサリ針１２を矢印Ｌ方向に下降させて四角錐形状の先端１２ａをタブ１４ｂ側から電極箔１３の角穴１３ａ内に挿通することによって、タブ１４ｂのバリ１４ｃを電極箔１３の裏面側（図１５において下方）に形成させた後、図１６において、グサリ針１２及びダイス１８を夫々矢印Ｍ及びＮ方向に上昇させる。
【００３４】
図１７において、グサリ加工に際して、電極箔１３には予め角穴１３ａが形成されているので、グサリ針１２が角穴１３ａ内に挿通されても電極箔１３自身のバリ１３ｃが発生することはない。また該角穴１３ａに露出しているアルミニウム地金がタブ１４ｂのバリ１４ｃに直接接触した状態でグサリ加工されており、電極箔１３とタブ１４ｂとの電気的導通抵抗は、極めて小さくなっているが、更にタブ１４ｂのバリ１４ｃは、矢印Ｏ及びＰ方向に圧縮されて電極箔１３に密着させられ（図１８）、電気的導通抵抗は更に低減すると共に、電極箔１３とタブ１４ｂとの機械的結合強度が向上した端子付き電極箔１５が、１点グサリ加工によっても製造できるようになる（図１９，図２０）。
【００３５】
【発明の効果】
本発明は、上記のように表面に化成皮膜処理が施された電極箔にあけられた穴上にリード線付き端子のタブを重ね合わせ、該タブ側からグサリ針を穴内に挿通してタブのバリを電極箔の裏面側に形成して電極箔とリード線付き端子のタブとを固着し、電極箔自体のバリの発生を防止するようにしたので、電極箔の地金とタブとを直接、かつ安定して接触させて固着することができるようになり、またこの結果電極箔とタブとの電気的導通抵抗を小さくすることができると共に、ばらつきが小さくなって１点のグサリ加工で十分な通電面積が確保できるようになるため、幅１ｍｍ程度の極小幅の電極箔へのグサリ加工が可能となり、電気特性の優れた全高５ｍｍ以下、具体的には座板を含めた全高が３．２５ｍｍという世界最小の超小型電解コンデンサを、グサリ加工方式によっても製作できるという画期的な効果が得られる。
【００３６】
また表面に化成皮膜処理が施された電極箔に４つの隅部が夫々電極箔の長手方向及び幅方向に向けられた角穴をあけた後、該角穴上にリード線付き端子のタブを重ね合わせ、該タブ側から断面角形に形成されたグサリ針の４つの角部を角穴の夫々の隅部に一致させて角穴内に挿通してグサリ加工し、電極箔とリード線付き端子とを圧縮して固着するようにしたので、グサリ加工時に電極箔を強制的に破ることによる亀裂の発生を防止し得、電極箔へのダメージを最小にすることができ、またこの結果電極箔の機械的強度の低下を防止でき、該電極箔の破断の発生をなくすことができるという効果がある。
【００３７】
更には、上記構成によって、１点グサリ加工を可能とし、１点グサリ加工でありながら、電極箔の地金とタブとを直接接触させて電極箔とタブとの電気的導通抵抗及び抵抗値のばらつきを小さくし、かつ機械的強度を向上させて幅１ｍｍ程度の極小幅の電極箔にもリード線付き端子のタブを固着することができるようになり、またこの結果微弱電流用の超小型電解コンデンサを製作できるという効果がある。
【００３８】
また電極箔の一方の面側に配設され抜き穴が設けられたダイスと、該ダイスと対向して電極箔の他方の面側に配設されたパンチとからなり抜き穴内にパンチを突出させて電極箔に穴を形成するプレス型と、電極箔の穴上にリード線付き端子のタブを重ね合わせ供給するリード線付き端子供給機構と、ダイスの抜き穴内に出没自在に配設されタブ側から電極箔の穴内に挿通してタブのバリを電極箔の裏面側に形成するグサリ針とを備えた端子付き電極箔の製造装置により、電極箔に穴をあけた後、該穴上にタブを重ね合わせてリード線付き端子を供給し、該タブ側からグサリ針を穴内に挿通してグサリ加工して電極箔とリード線付き端子とを固着したので、電極箔のバリを発生させずにグサリ加工して電気的導通抵抗の小さな電気的性能の優れた端子付き電極箔を効率よく製造することができるという効果が得られる。
【００３９】
【実施例１】
幅１．０８ｍｍ、箔の厚さ８０μｍ、箔の種類８０ＬＪ（４４ＦＶ）のアルミニウム電極箔と、タブの厚さ０．１８ｍｍのリード線付き端子を用い、パンチ径０．４３ｍｍ角のパンチで電極箔の幅方向中央に角穴をあけ、針径０．４３ｍｍφのグサリ針で１ヵ所グサリ加工した後、タブのバリの対角線寸法が約０．７９ｍｍとなるように圧縮した端子付き電極箔を２０個製作して電極箔とリード線付き端子間の電気的導通抵抗を測定した。測定結果は、平均値が１．３７ｍΩであり、最大値１．４９ｍΩ、最小値１．２８ｍΩであった。
【００４０】
【実施例２】
また幅１．０８ｍｍ、箔の厚さ８０μｍ、箔の種類８０ＬＪ（１２．５ＦＶ）のアルミニウム電極箔と、タブの厚さ０．１８ｍｍのリード線付き端子を用い、パンチ径０．４３ｍｍ角のパンチで電極箔の幅方向中央に角穴をあけ、針径０．４３ｍｍφのグサリ針で１ヵ所グサリ加工した後、タブのバリの対角線寸法が約０．８２ｍｍとなるように圧縮して端子付き電極箔を１７個製作し、電極箔とリード線付き端子間の電気的導通抵抗を測定した。測定結果は、平均値が１．１９ｍΩであり、最大値１．３２ｍΩ、最小値１．１４ｍΩであった。
【００４１】
【実施例３】
また幅１．０８ｍｍ、箔の厚さ１００μｍ、箔の種類Ａ０６Ｓのアルミニウム電極箔と、タブの厚さ０．１８ｍｍのリード線付き端子を用い、パンチ径０．４３ｍｍ角のパンチで電極箔の幅方向中央に角穴をあけ、針径０．４３ｍｍφのグサリ針で１ヵ所グサリ加工した後、タブのバリの対角線寸法が約０．８６ｍｍとなるように圧縮した端子付き電極箔を２０個製作して電極箔とリード線付き端子間の電気的導通抵抗を測定した。測定結果は、平均値が１．１４ｍΩであり、最大値１．３８ｍΩ、最小値０．９９ｍΩであった。
【００４２】
【実施例４】
表１は、化成電圧８Ｖの高倍率エッチングアルミニウム電極箔、５０Ｖ化成高倍率エッチングアルミニウム電極箔及び６８Ｖ化成高倍率エッチングアルミニウム電極箔の３種類の箔を用いて、本発明による圧着かしめ接続（ぐさり加工）による接続方法と、従来方法による接続抵抗の比較を示す。この例は、従来品共に圧着かしめ接続による機械的接続で最も厳しい１点接続方法によるものである。
【００４３】
【表１】

【００４４】
表２は、アジピン酸アンモニウム１０％液の６０℃保温槽に本発明品と従来品とを浸漬し、化成電圧に等しい電圧を印加し、４８時間後の接続抵抗を測定した結果であり、変化の差が著しいことを示している。
【００４５】
【表２】

【００４６】
【実施例５】
実施例１と同様に、化成電圧８Ｖの高倍率エッチングアルミニウム電極箔を用いて、６Ｖ１０μF の電解コンデンサを製造し、１０５℃中で定格電圧６Ｖを１０００時間連続通電した結果を表３及び表４に示す。本発明品は、１０００時間通電後もほとんど特性変化がなく安定しているが、従来品はオープン不良、特性不安定等、特性劣化が著しい。
【００４７】
【表３】

【００４８】
【表４】

【００４９】
表１及び表２に示すように、従来品の初期接続抵抗は、本発明品の約２倍近い値であり、化成液中における強制劣化テストの試験後の値は、本発明品の変化が約１．７倍以下と安定しているのに対して、従来品は約５倍と大きな変化を示している。
【００５０】
また表３の製品高温ライフテスト（Life Test ）では、本発明品の特性変化はほとんどなく、良好な結果を示している。従来品はオープン不良、特性不安定等の特性劣化が著しいことを示している。
【００５１】
以上のように、本発明は、製品の歩留まり向上、信頼性向上に貢献できるものであり、実用価値が非常に高く、また以上の測定結果が示すように、１ヵ所のグサリ加工であるにもかかわらず、電気的導通抵抗は、最大でも１．５ｍΩ以下の極めて小さい抵抗値であり、従来の加工方法で得られる約２．２ｍΩの抵抗値と比較して、本発明の端子付き電極箔の加工方法が有効であることが証明された。また、極めて小さい抵抗値を１ヵ所のグサリ加工で得ることができるので、電気的性能を低下させることなく、幅１ｍｍ程度の電極箔にリード線付き端子を固着することができ、従来グサリ加工では不可能であった、例えば座板を含めた全高が３．２５ｍｍという世界最小の超小型電解コンデンサの製作が可能となる。
【図面の簡単な説明】
【図１】図１から図２０は本発明の実施例に係り、図１は端子付き電極箔の斜視図である。
【図２】端子付き電極箔の分解斜視図であり、（ａ）はリード線付き端子の斜視図である。（ｂ）はリールに巻き取られた電極箔の斜視図である。
【図３】端子付き電極箔の製造装置の全体正面図である。
【図４】端子付き電極箔の製造装置の初期状態を示す正面図である。
【図５】プレス型を作動させて電極箔に角穴をあける状態を示す正面図である。
【図６】角穴があけられた電極箔からダイス及びパンチが離間する状態を示す正面図である。
【図７】箔押えホルダが下降して電極箔を固定すると共に、リード線付き端子が供給される状態を示す正面図である。
【図８】グサリ針が下降してグサリ加工する状態を示す正面図である。
【図９】図９から図１８は電極箔にリード線付き端子のタブがグサリ加工されて固着される工程に係り、図９はダイスとパンチの間に電極箔が供給された状態を示す要部拡大縦断面図である。
【図１０】ダイスが下降して電極箔を挟持した状態を示す要部拡大縦断面図である。
【図１１】パンチが上昇してダイスの抜き穴内に進入し、電極箔に角穴をあけた状態を示す要部拡大縦断面図である。
【図１２】角穴があけられた電極箔を示し、（ａ）は電極箔からダイス及びパンチが離間して状態を示す要部拡大縦断面図である。（ｂ）は角穴があけられた電極箔の部分平面図である。
【図１３】電極箔の角穴上にタブを一致させてリード線付き端子が供給された状態を示す要部拡大縦断面図である。
【図１４】再びダイスを下降させて電極箔とタブとを挟持した状態を示す要部拡大縦断面図である。
【図１５】グサリ針を下降させてタブのバリを電極箔の裏面側に形成させる状態を示す要部拡大縦断面図である。
【図１６】グサリ針及びダイスを上昇させてグサリ加工が終了した状態を示す要部拡大縦断面図である。
【図１７】グサリ加工によってタブのバリが電極箔の裏面側に形成される状態を示す要部拡大縦断面図である。
【図１８】タブのバリを圧縮して電極箔に強固に固着させた端子付き電極箔の要部拡大縦断面図である。
【図１９】端子付き電極箔の部分平面図である。
【図２０】端子付き電極箔の斜視図である。
【図２１】図２１から図２５は従来例に係り、図２１は電極箔及びリード線付き端子のタブにグサリ針を下降させてグサリ加工する状態を示す斜視図である。
【図２２】グサリ加工によって形成された電極箔及びタブのバリの状態であって、電極箔のバリの方がタブのバリよりも大きいことを示す要部拡大縦断面図である。
【図２３】電極箔及びタブのバリを圧縮して電極箔にリード線付き端子を固着した状態であって、電極箔のバリを介してタブのバリが電極箔に接触している状態を示す要部拡大縦断面図である。
【図２４】電極箔及びタブのバリの状態であって、電極箔のバリの方がタブのバリよりも大きく広がっている状態を示す端子付き電極箔の部分平面図である。
【図２５】グサリ加工して電極箔とタブとを固着する工程を示す要部拡大縦断面図であり、（ａ）は電極箔とタブとが所定の位置に供給された状態を示す要部拡大縦断面図である。（ｂ）はダイスを下降させて電極箔とタブとを挟持し、グサリ針を下降させる状態を示す要部拡大縦断面図である。（ｃ）はグサリ針を電極箔とタブとに貫通させてグサリ加工した状態を示す要部拡大縦断面図である。
【符号の説明】
１０端子付き電極箔の製造装置
１１プレス型
１２グサリ針
１３電極箔
１３ａ角穴
１３ｂ隅部
１３ｃ電極箔のバリ
１４リード線付き端子
１４ｂタブ
１４ｃタブのバリ
１５端子付き電極箔
１７リール
１８ダイス
１８ａ抜き穴
１９パンチ[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an electrode foil with a terminal and a method and apparatus for manufacturing the electrode foil, and in particular, after making a hole in the electrode foil, a tab of a terminal with a lead wire is overlaid on the hole, and a wedge needle is inserted into the hole from the tab side. Then, the burr of the electrode foil itself is prevented, the burr of the tab is formed on the back side of the electrode foil, and the electrode foil and the tab are firmly fixed, so that the metal foil of the electrode foil is securely in contact with the tab. The present invention relates to a method and an apparatus for manufacturing an electrode foil with a terminal having excellent electrical characteristics in which conduction resistance is extremely reduced and variation in the conduction resistance is reduced.
[0002]
[Prior art]
Conventionally, in FIG. 21, the electrolytic capacitor element has an anode electrode foil in which an oxide film is formed on the surface of an etching aluminum foil having a purity of about 99.9% and a thickness of 60 to 100 μm to which a terminal with a lead wire is fixed, and a thickness thereof. It is manufactured by alternately laminating electrode foils for cathodes, which are 40 to 60 μm etched aluminum foil, and electrolytic paper, and winding them up into a cylindrical shape.
[0003]
21 to 25, the lead wire-equipped terminal 2 is formed by welding a tab 2b made of aluminum to a lead material 2a, pressing the tab 2b into a flat plate shape, and then trimming the outer shape into a certain shape. Molded and manufactured. Conventionally, the lead wire-attached terminal 2 has been fixed to the aluminum foil 1 by a rubbing process. Specifically, the tab 2b of the terminal 2 with the lead wire is superimposed on the aluminum foil 1 placed on the work table 3 (FIG. 25 (a)), and fixed with the presser 4 (FIG. 25 (b)), A gusset needle 5 whose tip is shaped like a quadrangular pyramid is passed through the tab 2b and the aluminum foil 1 (FIG. 25 (c)), and in FIGS. 22 and 23, burrs 1a and 2c of the aluminum foil 1 and the tab 2b are formed. Was formed on the back side of the aluminum foil 1, and the burrs 1a and 2c were pressed in the directions of arrows R and S to be fixed.
[0004]
22 to 24, the burr 1a of the aluminum foil 1 and the burr 2c of the tab 2b generated by the conventional rubbing process are formed on the back side of the aluminum foil 1, and the burr 1a of the aluminum foil 1 is formed outside the burr 1a. The burrs 2c of the tab 2b are formed in a double structure. On the other hand, the important point of the fixation between the aluminum foil 1 and the tab 2b is that the aluminum foil 1 and the tab 2b are fixed mechanically and strongly, and the electrical connection between the aluminum foil 1 and the tab 2b is not limited. An extremely small conduction resistance and a small variation in the conduction resistance is an important item because it directly affects the performance of the electrolytic capacitor. Especially in a micro electrolytic capacitor for weak current, the electrical conduction resistance The size of is a decisive factor.
[0005]
In order to reduce the electrical conduction resistance between the aluminum foil 1 and the tab 2b, it is required that the metal base portion of the aluminum foil 1 and the tab 2b are fixed in direct contact with each other. In FIG. 23, the chemical conversion film formed on the surface of the aluminum foil 1 was formed as a burr 1a without breaking, and a burr 2c was formed so as to enclose the burr 1a. Therefore, the tab 2b comes into contact with the aluminum foil 1 through the chemical conversion film, and there is a problem that the electrical conduction resistance cannot be sufficiently reduced from 1.9 mΩ to 2.2 mΩ.
[0006]
Further, the chemical conversion film of the aluminum foil 1 is partially broken by the burr 2c of the tab 2b, and the metal base of the aluminum foil 1 and the tab 2b are in direct contact with each other. Although it works, it is impossible to control the contact area with the base metal by the conventional rubbing, and there is a drawback that the electric conduction resistance varies due to this.
[0007]
In recent years, there has been an increasing demand for ultra-small electrolytic capacitors. For this reason, when an electrode foil with a width as small as 1 mm is used, it is very easy to break, and the electrical conduction resistance is reduced and dispersed more than ever. In addition, according to the conventional rubbing process, two points of rubbing are necessary because of mechanical strength, and two points of rubbing cannot be performed on an electrode foil having a width of 1 mm. A sufficient energizing area must be secured by the lapping process. However, in the conventional rubbing process, a sufficient energization area cannot be secured by the one-point rubbing process for the above-mentioned reasons. There was a problem that I could not.
[0008]
Further, since the aluminum foil 1 is forcibly broken at the time of rubbing, there is a big problem that the aluminum foil 1 is easily cracked and the aluminum foil 1 is broken starting from the crack.
[0009]
[Problems to be solved by the invention]
The present invention has been made in order to eliminate the above-mentioned drawbacks of the prior art, and the object of the present invention is to provide a terminal with a lead wire on a hole formed in an electrode foil having a surface subjected to a chemical conversion film treatment. The tab of the tab is overlapped, and a gusset needle is inserted into the hole from the tab side to form a burr of the tab on the back side of the electrode foil, and the electrode foil and the tab of the terminal with the lead wire are fixed. Is to allow the metal foil and the tab of the electrode foil to be directly and stably brought into contact with each other and to fix the electrode foil and the electric conduction between the electrode foil and the tab. The resistance is reduced and the variation is reduced, so that a sufficient energizing area can be secured even with one point of rubbing. 5mm or less, specifically The miniature electrolytic capacitor overall height of the world's smallest of 3.25mm, including a seat plate, is to be able to manufacture by Gusari machining strategy.
[0010]
Another object of the present invention is to form a square hole in which four corners are directed in the longitudinal direction and the width direction of the electrode foil, respectively, on the surface of the electrode foil that has been subjected to a chemical conversion film treatment. The tabs of the attached terminals are overlapped, and the four corners of the wedge needle formed in a square cross section from the tab side are aligned with the respective corners of the square holes to be inserted into the square holes, and then subjected to a rubbing process. By compressing and fixing the terminal with lead wire, it is possible to prevent cracking due to forcible tearing of the electrode foil during rubbing, and to minimize damage to the electrode foil. It is intended to prevent the mechanical strength of the foil from being lowered and to prevent the electrode foil from being broken.
[0011]
Still another object of the present invention is to enable one-point rubbing by the above-mentioned configuration, and while the one-point rubbing is performed, the metal foil of the electrode foil and the tab are brought into direct contact with each other, and the electric conduction resistance between the electrode foil and the tab and It is intended to reduce the variation in resistance value and improve the mechanical strength so that the tab of the lead wire terminal can be fixed to an extremely small electrode foil having a width of about 1 mm. It is to be able to manufacture a micro electrolytic capacitor for electric current.
[0012]
Another object of the present invention is to provide a die having a die provided on one surface side of the electrode foil and provided with a punch hole and a punch provided on the other surface side of the electrode foil so as to face the die. A press die that forms a hole in the electrode foil by protruding the punch, a terminal supply mechanism with a lead wire that superimposes the tab of the terminal with the lead wire on the hole of the electrode foil, and a die that can be freely inserted into the die hole After drilling a hole in the electrode foil by a manufacturing apparatus for electrode foil with a terminal, which is provided with a gusset needle that is arranged and inserted into the hole of the electrode foil from the tab side and forms a burr of the tab on the back side of the electrode foil, By supplying a terminal with a lead wire by superimposing a tab on the hole, and inserting a rubbing needle into the hole from the tab side to fix the electrode foil and the terminal with the lead wire, Low electrical continuity resistance by rubbing without generating burrs It is to be able to efficiently produce excellent with terminal electrode foil of an electrical performance.
[0013]
[Means for Solving the Problems]
[0014]
in short The method of the present invention (claims) 1 ) Pulls out from the reel the electrode foil that has been subjected to a chemical conversion film treatment on its surface and wound on a reel, and the corners of the electrode foil are oriented in the longitudinal and width directions of the electrode foil, respectively. After making a hole, the tab of the terminal with lead wire is overlaid on the square hole, and the four corners of the wedge needle formed in a square cross section from the tab side coincide with the four corners of the square hole And inserting into the square hole, crushing so as to form a burr of the tab on the back side of the electrode foil, and compressing and fixing the electrode foil and the tab of the terminal with lead wire It is a feature.
[0016]
Further, the present invention terminal electrode foil (claims) 2 ) Pulls out from the reel the electrode foil that has been subjected to a chemical conversion film treatment on its surface and wound on a reel, and the corners of the electrode foil are oriented in the longitudinal and width directions of the electrode foil, respectively. After making a hole, the tab of the terminal with lead wire is overlaid on the square hole, and the four corners of the wedge needle formed in a square cross section from the tab side coincide with the four corners of the square hole The tab is inserted into the square hole, and the tab burr is formed on the back side of the electrode foil, and the electrode foil and the tab of the terminal with lead wire are compressed and fixed by pressing. It is characterized by being formed.
[0018]
The apparatus of the present invention (claims) 3 ) Is formed on one surface side of the electrode foil drawn out from the reel that has been subjected to the chemical conversion film treatment on the surface, and a die provided with a punch hole and the other of the electrode foil facing the die. And a punch for forming a hole in the electrode foil by projecting the punch into the punched hole and a tab of a terminal with a lead wire on the hole of the electrode foil. A terminal supply mechanism with lead wires to be fed together, and a burr of the tab formed on the back side of the electrode foil by being inserted into the hole of the electrode foil from the tab side so as to be able to protrude and retract in the die hole A stylus needle that pierces the electrode foil, and then feeds the terminal with the lead wire by overlapping the tab on the hole, and the gusset needle is inserted into the hole from the tab side. The electrode foil and the lead It is characterized in that it has configured to fix the said tab of the line with the terminal.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described based on embodiments shown in the drawings. The electrode foil manufacturing apparatus 10 according to the present invention has a gusset by overlapping the tab 14b of the terminal 14 with lead wire on the electrode foil 13 whose surface has been subjected to etching treatment and chemical conversion film treatment in FIGS. This is an apparatus for manufacturing the electrode foil 15 with a terminal by forming a burr 14c on the back side of the electrode foil 13 and fixing the electrode foil 13 and the terminal 14 with a lead wire, as shown in FIGS. , A press die 11, a lead wire-equipped terminal supply mechanism (not shown), and a wedge needle 12.
[0020]
The press die 11 is for making a square hole 13a in which four corners 13b are directed in the longitudinal direction and width direction of the electrode foil 13, respectively, in the electrode foil 13, and is pulled out from the reel 17 in FIG. The die 18 is disposed above the electrode foil 13 guided and supplied by the guide roller 16, and the punch 19 is disposed below the electrode foil 13.
[0021]
The dice 18 is fixed to a dice holder 20 that is fitted to the base 27 and arranged to be movable in the vertical direction (arrow B or E direction). The die holder 20 is provided with a cam follower 22 via a rod end 21. The cam follower 22 is pressed by a cam device (not shown) and moved in the direction of arrow B or E (FIGS. 5 and 6) to connect the die 18 to a terminal. It is comprised so that it may press on the work table 23 of the manufacturing apparatus 10 of an attached electrode foil. The die 18 is provided with a square punch hole 18a.
[0022]
The punch 19 is a pin having the same shape as that of the square punch hole 18a and disposed opposite to the punch hole 18a. The punch 19 is fixed to the punch holder 24 and is slidably fitted into the hole of the punch guide 25. The punch holder 24 can move in the vertical direction (arrow C or F direction). Then, the punch 19 is protruded into the rectangular punch hole 18a of the die 18, and the square corner hole 13a is formed in the electrode foil 13 with the four corners 13b facing the longitudinal direction and the width direction of the electrode foil 13, respectively. It has become.
[0023]
19 and 20, the lead wire-attached terminal supply mechanism (not shown) is formed by connecting the tab 14b of the lead wire terminal 14 in which the aluminum tab 14b is welded to the lead material 14a to the square hole of the electrode foil 13. 13a for supplying the terminal 14 with the lead wire so as to be superposed on it, and an aligning / conveying mechanism (not shown) for conveying the terminal 14 with the lead wire aligned in a predetermined direction, and the terminal with the lead wire sequentially from the aligning / conveying mechanism 14 and a transporting device (not shown) for transporting the tab 14b in alignment with the square hole 13a of the electrode foil 13, and the specific mechanism is achieved by combining conventionally known mechanisms. Yes.
[0024]
Further, in FIG. 3, a foil presser 28 is fixed to a foil presser holder 29 and disposed above the punch guide 25. The foil presser holder 29 is fitted to a base 27 and can be moved in the vertical direction. ing. A cam follower 30 is disposed at the upper end of the foil holder 29. The cam follower 30 is pressed by a cam device (not shown) to move in the direction of arrow H (FIG. 7), and the electrode foil 13 is moved between the punch guide 25 and the foil guide holder 29. It is designed to be pinched and fixed.
[0025]
The rubbing needle 12 is for rubbing and fixing the electrode foil 13 and the tab 14b of the terminal 14 with the lead wire. The tip is also formed into a quadrangular pyramid shape 12a with reference to FIG. A pin, which is slidably fitted into a rectangular hole 18 a of the die 18 and fixed to the needle holder 31. The needle holder 31 is fitted to the base 27 so as to be movable in the vertical direction, and the cam follower 32 disposed at the upper end of the needle holder 31 is pressed by a cam device (not shown) to move in the arrow J direction (FIG. 8). Then, the rubbing needle 12 is lowered in the direction of the arrow L to perform the rubbing process.
[0026]
And the electrode foil 15 with a terminal manufactured with the manufacturing apparatus 10 of the electrode foil with a terminal is piled up on the square hole 13a opened in the electrode foil 13, and the tab of the terminal 14 with a lead wire in FIG.19 and FIG.20. 14b is arranged, and the bristle needle 12 is inserted into the square hole 13a from the tab 14b side to form a burr 14c of the tab 14b on the back side of the electrode foil 13, and the electrode foil 13 and the tab 14b are fixed by compression. It has a structure.
[0028]
And The method of the present invention (claims) 1 ) Pulls out from the reel 17 the electrode foil 13 that has been subjected to a chemical conversion film treatment on its surface and wound on the reel 17, and the electrode foil 13 has four corners 13 b in the longitudinal direction and width of the electrode foil 13, respectively. After opening the square hole 13a directed in the direction, the tab 14b of the terminal 14 with the lead wire is superimposed on the square hole 13a, and the four corners of the wedge needle 12 having a square cross section formed from the tab 14b side. Is inserted into the square hole 13a so as to coincide with the four corners 13b of the square hole 13a, and the burr 14c of the tab 14b is crushed so as to be formed on the back side of the electrode foil 13, and the electrode In this method, the foil 13 and the tab 14b of the lead wire-equipped terminal 14 are compressed and fixed.
[0029]
The present invention is configured as described above, and the operation thereof will be described below. A process of rubbing and fixing the tab 14b to the electrode foil 13 in FIGS. 4 to 16 will be described. In FIG. 4 and FIG. 9, the electrode foil 13 whose surface is subjected to the chemical conversion film treatment is pulled out from the reel 17 while being guided by the guide roller 16, and is disposed between the die 18 and the punch guide 25.
[0030]
5, 10, and 11, the cam follower 22 is pressed in the direction of arrow A by a cam device (not shown) to lower the die 18 together with the die holder 20 in the direction of arrow B. After sandwiching the electrode foil 13 having a very small width of about 1 mm, the punch holder 24 is raised in the direction of the arrow C so that the punch 19 protrudes into the rectangular hole 18a of the die 18 so that one square hole is formed in the electrode foil 13. Open 13a.
[0031]
6 and 12, when the die holder 20 is moved in the arrow D direction to raise the die 18 in the arrow E direction and the punch 19 is lowered in the arrow F direction, the electrode foil 13 has four corners. Square holes 13a are formed in which 13b is directed in the longitudinal direction and the width direction of the electrode foil 13, respectively. At this time, a very small burr 13c is formed upward at the edge of the square hole 13a of the electrode foil 13, and the end surface of the square hole 13a is in a state where an aluminum base metal without a chemical conversion film is exposed. Yes. Further, a square punching punch (not shown) in which the square hole 13a is punched remains in the punching hole 18a of the die 18, but when the die 18 is raised in the direction of arrow E, the punching hole 18a is moved into the punching hole 18a. The remaining punching rod is protruded from the punching hole 18 a by the gusset needle 12.
[0032]
7 and 13, the cam follower 30 is pressed in the direction of arrow H by the cam device to lower the foil presser 28 and press and fix the electrode foil 13, and then the lead wire is connected by a terminal supply mechanism (not shown) with a lead wire. The attached terminal 14 is conveyed in the direction of the arrow G, and the tab 14 b is aligned with the square hole 13 a of the electrode foil 13 and positioned.
[0033]
Next, in FIGS. 8, 14 and 15, the cam follower 22 is pressed in the direction of arrow I by the cam device, and the cam follower 32 is pressed in the direction of arrow J to lower the die 18 in the direction of arrow K. After pressing the tab 14b in a state where the tab 14b is aligned with the square hole 13a of the electrode foil 13, the rubbing needle 12 is lowered in the arrow L direction so that the quadrangular pyramid tip 12a is inserted into the square hole 13a of the electrode foil 13 from the tab 14b side. After the burr 14c of the tab 14b is formed on the back surface side of the electrode foil 13 (downward in FIG. 15), the rubbing needle 12 and the die 18 are raised in the directions of arrows M and N, respectively, in FIG. .
[0034]
In FIG. 17, since the square holes 13a are formed in the electrode foil 13 in advance during the rubbing process, the burr 13c of the electrode foil 13 itself does not occur even when the wedge needle 12 is inserted into the square holes 13a. . Further, the aluminum ingot exposed in the square hole 13a is crushed in a state where it is in direct contact with the burr 14c of the tab 14b, and the electrical conduction resistance between the electrode foil 13 and the tab 14b is extremely small. However, the burr 14c of the tab 14b is compressed in the directions of arrows O and P to be brought into close contact with the electrode foil 13 (FIG. 18), and the electrical conduction resistance is further reduced, and the mechanical force between the electrode foil 13 and the tab 14b is reduced. The terminal-attached electrode foil 15 with improved mechanical coupling strength can be manufactured by one-point rubbing (FIGS. 19 and 20).
[0035]
【The invention's effect】
The present invention superimposes a tab of a terminal with a lead wire on a hole formed in an electrode foil having a chemical conversion film treatment on the surface as described above, and inserts a gusset needle into the hole from the tab side to insert the tab. A burr was formed on the back side of the electrode foil to secure the electrode foil and the tab of the terminal with lead wire to prevent the burr of the electrode foil itself. In addition, it is possible to stably contact and fix, and as a result, the electrical conduction resistance between the electrode foil and the tab can be reduced, and the variation is reduced, so that one-point rubbing is sufficient. As a result, it is possible to process the electrode foil with an extremely small width of about 1 mm. The total height is 5 mm or less with excellent electrical characteristics. Specifically, the total height including the seat plate is 3. The world's smallest ultra-small electrolysis co The capacitor, revolutionary effect that can be manufactured by Gusari machining strategy.
[0036]
In addition, after making a square hole with four corners oriented in the longitudinal direction and width direction of the electrode foil, respectively, on the surface of the electrode foil that has been subjected to a chemical conversion film treatment, a tab of a terminal with a lead wire is placed on the square hole. Overlapping, and aligning the four corners of the wedge needle formed in a square cross section from the tab side with each corner of the square hole, and inserting into the square hole, and processing the electrode foil and lead wire terminal Compressed and fixed to prevent cracking due to forcible tearing of the electrode foil during rubbing, minimizing damage to the electrode foil. It is possible to prevent the mechanical strength from being lowered and to eliminate the occurrence of breakage of the electrode foil.
[0037]
Furthermore, the above-described configuration enables one-point rubbing, and while the one-point rubbing is performed, the metal foil and the tab of the electrode foil are brought into direct contact with each other, and the electric conduction resistance and resistance value between the electrode foil and the tab are reduced. By reducing the variation and improving the mechanical strength, it becomes possible to fix the tab of the terminal with the lead wire to the electrode foil having a width as small as about 1 mm. As a result, the micro electrolysis for weak current can be achieved. There is an effect that a capacitor can be manufactured.
[0038]
Further, the punch is made up of a die provided on one surface side of the electrode foil and provided with a punch hole, and a punch provided on the other surface side of the electrode foil so as to face the die. A press die that forms a hole in the electrode foil, a terminal supply mechanism with a lead wire that superimposes a tab of a terminal with a lead wire on the hole of the electrode foil, and a tab side that can be freely projected and retracted in a die hole After making a hole in the electrode foil with a terminal foil manufacturing device provided with a gusseted needle that is inserted into the hole in the electrode foil to form a burr of the tab on the back side of the electrode foil, the tab is placed on the hole. Since the terminal with lead wire is supplied by superimposing, and the rubbing needle is inserted into the hole from the tab side, and the electrode foil and the terminal with lead wire are fixed, the burr of the electrode foil does not occur. Excellent electrical performance with low electrical conduction resistance by rubbing Effect that can be produced efficiently with terminal electrode foil.
[0039]
[Example 1]
Using an aluminum electrode foil with a width of 1.08 mm, a foil thickness of 80 μm, a foil type of 80 LJ (44 FV), and a terminal with a lead wire with a tab thickness of 0.18 mm, a punch with a 0.43 mm square punch electrode foil After drilling a square hole in the center in the width direction and processing one point with a gusseted needle with a needle diameter of 0.43 mmφ, 20 electrode foils with terminals compressed so that the diagonal dimension of the tab burr is about 0.79 mm The electrical conduction resistance between the electrode foil and the terminal with lead wire was measured. As for the measurement results, the average value was 1.37 mΩ, the maximum value was 1.49 mΩ, and the minimum value was 1.28 mΩ.
[0040]
[Example 2]
A punch with a 0.43 mm square punch diameter using an aluminum electrode foil with a width of 1.08 mm, a foil thickness of 80 μm, a foil type of 80 LJ (12.5 FV), and a terminal with a lead wire having a tab thickness of 0.18 mm After drilling a square hole in the center in the width direction of the electrode foil and processing one point with a gusset needle with a needle diameter of 0.43 mmφ, compress the tab burr so that the diagonal dimension of the tab burr is about 0.82 mm. Seventeen foils were produced, and the electrical conduction resistance between the electrode foil and the terminal with lead wire was measured. As for the measurement results, the average value was 1.19 mΩ, the maximum value was 1.32 mΩ, and the minimum value was 1.14 mΩ.
[0041]
[Example 3]
Also, using an aluminum electrode foil with a width of 1.08 mm, a foil thickness of 100 μm, and a foil type of A06S, and a lead wire terminal with a tab thickness of 0.18 mm, a punch with a 0.43 mm square punch diameter After drilling a square hole in the center of the direction and rubbing in one place with a 0.43mmφ needle needle, 20 electrode foils with terminals compressed so that the diagonal dimension of the tab burr is about 0.86mm are manufactured. The electrical conduction resistance between the electrode foil and the terminal with lead wire was measured. As for the measurement results, the average value was 1.14 mΩ, the maximum value was 1.38 mΩ, and the minimum value was 0.99 mΩ.
[0042]
[Example 4]
Table 1 shows a crimped caulking connection according to the present invention using three types of foils: a high magnification etched aluminum electrode foil with a conversion voltage of 8 V, a 50 V chemical conversion high magnification etching aluminum electrode foil, and a 68 V chemical conversion high magnification etching aluminum electrode foil. The comparison of the connection resistance by the conventional method and the connection method by) is shown. This example is based on the most strict one-point connection method by mechanical connection by crimping caulking for both conventional products.
[0043]
[Table 1]

[0044]
Table 2 shows the results of measuring the connection resistance after 48 hours by immersing the product of the present invention and the conventional product in a 60 ° C. heat retention bath of 10% ammonium adipate, applying a voltage equal to the formation voltage. It shows that the difference is remarkable.
[0045]
[Table 2]

[0046]
[Example 5]
Similarly to Example 1, a 6V 10 μF electrolytic capacitor was manufactured using a high-magnification etched aluminum electrode foil with a formation voltage of 8 V, and the results of continuous energization at 105 ° C. with a rated voltage of 6 V for 1000 hours are shown in Tables 3 and 4 Shown in The product of the present invention is stable with almost no change in characteristics even after 1000 hours of energization, but the conventional product has remarkable characteristics deterioration such as open defects and characteristic instability.
[0047]
[Table 3]

[0048]
[Table 4]

[0049]
As shown in Table 1 and Table 2, the initial connection resistance of the conventional product is nearly twice the value of the product of the present invention, and the value after the test of the forced deterioration test in the chemical conversion liquid is the change of the product of the present invention. While it is stable at about 1.7 times or less, the conventional product shows a large change of about 5 times.
[0050]
Moreover, in the product high temperature life test (Life Test) of Table 3, there is almost no change in the characteristics of the product of the present invention, and good results are shown. The conventional products show remarkable deterioration in characteristics such as open defects and unstable characteristics.
[0051]
As described above, the present invention can contribute to the improvement of product yield and reliability, has a very high practical value, and, as the above measurement results show, it is a single point of processing. Regardless, the electrical conduction resistance is an extremely small resistance value of 1.5 mΩ or less at the maximum, and compared with the resistance value of about 2.2 mΩ obtained by the conventional processing method, The processing method proved to be effective. In addition, an extremely small resistance value can be obtained by a single rubbing process, so that a terminal with a lead wire can be fixed to an electrode foil having a width of about 1 mm without degrading electrical performance. For example, the world's smallest ultra-small electrolytic capacitor with a total height of 3.25 mm including the seat plate can be manufactured.
[Brief description of the drawings]
FIG. 1 to FIG. 20 relate to an embodiment of the present invention, and FIG. 1 is a perspective view of a terminal-attached electrode foil.
FIG. 2 is an exploded perspective view of an electrode foil with a terminal, and (a) is a perspective view of a terminal with a lead wire. (B) is a perspective view of the electrode foil wound up on the reel.
FIG. 3 is an overall front view of an apparatus for producing electrode foil with terminals.
FIG. 4 is a front view showing an initial state of an apparatus for producing electrode foil with terminals.
FIG. 5 is a front view showing a state in which a press die is operated to make a square hole in an electrode foil.
FIG. 6 is a front view showing a state in which a die and a punch are separated from an electrode foil having a square hole.
FIG. 7 is a front view showing a state in which a foil press holder is lowered to fix an electrode foil and a terminal with a lead wire is supplied.
FIG. 8 is a front view showing a state in which the wedge needle is lowered and crushed.
9 to FIG. 18 are related to a process in which a tab of a terminal with a lead wire is glued and fixed to an electrode foil, and FIG. 9 is a diagram showing a state in which the electrode foil is supplied between a die and a punch. FIG.
FIG. 10 is an enlarged vertical cross-sectional view of the main part showing a state where the die is lowered and the electrode foil is sandwiched.
FIG. 11 is an enlarged vertical cross-sectional view of a main part showing a state in which a punch is raised and enters a die hole, and a square hole is made in an electrode foil.
FIG. 12 shows an electrode foil with square holes, and FIG. 12 (a) is an enlarged longitudinal sectional view of a main part showing a state in which a die and a punch are separated from the electrode foil. (B) is the fragmentary top view of the electrode foil by which the square hole was drilled.
FIG. 13 is an enlarged vertical cross-sectional view of a main part showing a state in which a terminal with a lead wire is supplied with a tab aligned on a square hole of an electrode foil.
FIG. 14 is an enlarged vertical sectional view of a main part showing a state where the die is lowered again and the electrode foil and the tab are sandwiched.
FIG. 15 is an enlarged vertical cross-sectional view of a main part showing a state in which a burr of a tab is formed on the back surface side of the electrode foil by lowering the needle.
FIG. 16 is an enlarged vertical cross-sectional view of a main part showing a state in which the processing is completed by raising the chain needle and the die.
FIG. 17 is an enlarged vertical cross-sectional view of a main part showing a state in which a burr of a tab is formed on the back side of an electrode foil by rubbing.
FIG. 18 is an enlarged vertical cross-sectional view of a main part of a terminal-attached electrode foil in which burrs of tabs are compressed and firmly fixed to the electrode foil.
FIG. 19 is a partial plan view of an electrode foil with a terminal.
FIG. 20 is a perspective view of an electrode foil with a terminal.
FIG. 21 to FIG. 25 relate to a conventional example, and FIG. 21 is a perspective view showing a state in which a wedge needle is lowered on a tab of an electrode foil and a terminal with a lead wire to perform a rubbing process.
FIG. 22 is an enlarged longitudinal sectional view of a main part showing a state of burr of an electrode foil and a tab formed by rubbing and showing that the burr of the electrode foil is larger than the burr of the tab.
FIG. 23 shows a state in which the burrs of the electrode foil and the tab are compressed and the terminal with the lead wire is fixed to the electrode foil, and the burrs of the tab are in contact with the electrode foil through the burrs of the electrode foil. It is a principal part expanded longitudinal cross-sectional view.
FIG. 24 is a partial plan view of an electrode foil with a terminal showing a state of burr on the electrode foil and the tab, where the burr on the electrode foil is larger than the burr on the tab.
FIG. 25 is an enlarged vertical cross-sectional view of a main part showing a step of fixing the electrode foil and the tab by rubbing, and (a) is a main part showing a state where the electrode foil and the tab are supplied to a predetermined position. It is an enlarged vertical sectional view. (B) is a principal part expansion longitudinal cross-sectional view which shows the state which lowers a die | dye, pinches | interposes an electrode foil and a tab, and lowers a gusset needle. (C) is a principal part expanded longitudinal sectional view which shows the state which penetrated the electrode needle | hook and the tab and carried out the rubbing process.
[Explanation of symbols]
10 Electrode foil manufacturing equipment with terminals
11 Press mold
12 gusset needle
13 Electrode foil
13a square hole
13b Corner
13c Electrode foil burr
14 Terminal with lead wire
14b tab
14c Tab burrs
15 Electrode foil with terminal
17 reel
18 dice
18a Punching hole
19 Punch

Claims

The electrode foil wound on the reel with a chemical conversion film applied to the surface is pulled out of the reel, and the electrode foil has square holes with the four corners directed in the longitudinal and width directions of the electrode foil, respectively. After that, the tabs of the terminals with lead wires are overlaid on the square holes, and the four corners of the wedge needle formed in a square cross section from the tab side are aligned with the four corners of the square holes. It is inserted into a square hole, and is crushed so as to form a burr of the tab on the back side of the electrode foil, and the electrode foil and the tab of the lead wire terminal are compressed and fixed. Manufacturing method of electrode foil with a terminal.

The electrode foil wound on the reel with a chemical conversion film applied to the surface is pulled out of the reel, and the electrode foil has square holes with the four corners directed in the longitudinal and width directions of the electrode foil, respectively. After that, the tabs of the terminals with lead wires are overlaid on the square holes, and the four corners of the wedge needle formed in a square cross section from the tab side are aligned with the four corners of the square holes. Inserted into a square hole, crushed to form a burr of the tab on the back side of the electrode foil, and pressed and fixed the electrode foil and the tab of the terminal with lead wire An electrode foil with a terminal.

A die provided on one surface side of an electrode foil drawn out from a reel that has been subjected to a chemical conversion film treatment on the surface and provided with a punch hole, and the other surface side of the electrode foil facing the die A press die that is formed in the punched hole and that forms a hole in the electrode foil, and a tab of a terminal with a lead wire is supplied over the hole of the electrode foil. A terminal supply mechanism with a lead wire, and a gusset that is arranged so as to be able to protrude and retract in the punched hole of the die and is inserted into the hole of the electrode foil from the tab side to form a burr of the tab on the back side of the electrode foil After the hole is made in the electrode foil, the tab is overlaid on the hole to supply the terminal with the lead wire, and the wedge needle is inserted into the hole from the tab side. Process the electrode foil and the lead wire Apparatus for producing a terminal with an electrode foil, characterized by being configured so as to fix the said tabs come terminal.