JP5367753B2 - 半田メッキ線の製造方法及び製造装置 - Google Patents
半田メッキ線の製造方法及び製造装置 Download PDFInfo
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- 229910000679 solder Inorganic materials 0.000 title claims description 70
- 238000004519 manufacturing process Methods 0.000 title claims description 62
- 238000004140 cleaning Methods 0.000 claims description 152
- 238000007747 plating Methods 0.000 claims description 135
- 238000004804 winding Methods 0.000 claims description 84
- 238000010438 heat treatment Methods 0.000 claims description 83
- 238000000034 method Methods 0.000 claims description 80
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 71
- 239000002253 acid Substances 0.000 claims description 69
- 238000000137 annealing Methods 0.000 claims description 59
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 54
- 230000000694 effects Effects 0.000 claims description 35
- 238000005406 washing Methods 0.000 claims description 22
- 238000011144 upstream manufacturing Methods 0.000 claims description 21
- 238000001816 cooling Methods 0.000 claims description 17
- 229910052802 copper Inorganic materials 0.000 claims description 14
- 239000010949 copper Substances 0.000 claims description 14
- 239000000463 material Substances 0.000 claims description 10
- 238000013020 steam cleaning Methods 0.000 claims description 4
- 239000007789 gas Substances 0.000 description 24
- 238000002474 experimental method Methods 0.000 description 15
- 239000000498 cooling water Substances 0.000 description 13
- 230000000052 comparative effect Effects 0.000 description 12
- 238000012790 confirmation Methods 0.000 description 9
- WABPQHHGFIMREM-UHFFFAOYSA-N lead(0) Chemical compound [Pb] WABPQHHGFIMREM-UHFFFAOYSA-N 0.000 description 8
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 6
- 239000004020 conductor Substances 0.000 description 6
- 239000012535 impurity Substances 0.000 description 6
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 5
- 229910001873 dinitrogen Inorganic materials 0.000 description 5
- 238000001514 detection method Methods 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 3
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 3
- 239000012459 cleaning agent Substances 0.000 description 3
- 239000000314 lubricant Substances 0.000 description 3
- 239000003921 oil Substances 0.000 description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 2
- 238000010924 continuous production Methods 0.000 description 2
- 238000011156 evaluation Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 238000002203 pretreatment Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000002210 silicon-based material Substances 0.000 description 1
- 238000011179 visual inspection Methods 0.000 description 1
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- B21C47/00—Winding-up, coiling or winding-off metal wire, metal band or other flexible metal material characterised by features relevant to metal processing only
- B21C47/003—Regulation of tension or speed; Braking
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
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- B21C47/00—Winding-up, coiling or winding-off metal wire, metal band or other flexible metal material characterised by features relevant to metal processing only
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B21C47/00—Winding-up, coiling or winding-off metal wire, metal band or other flexible metal material characterised by features relevant to metal processing only
- B21C47/02—Winding-up or coiling
- B21C47/10—Winding-up or coiling by means of a moving guide
- B21C47/12—Winding-up or coiling by means of a moving guide the guide moving parallel to the axis of the coil
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
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- B21C47/00—Winding-up, coiling or winding-off metal wire, metal band or other flexible metal material characterised by features relevant to metal processing only
- B21C47/34—Feeding or guiding devices not specially adapted to a particular type of apparatus
- B21C47/345—Feeding or guiding devices not specially adapted to a particular type of apparatus for monitoring the tension or advance of the material
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- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
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- C23C2/022—Pretreatment of the material to be coated, e.g. for coating on selected surface areas by heating
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- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
- C23C2/022—Pretreatment of the material to be coated, e.g. for coating on selected surface areas by heating
- C23C2/0224—Two or more thermal pretreatments
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
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- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
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- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
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- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
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- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/50—Controlling or regulating the coating processes
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Description
しかし、太陽電池セルが薄型化すると強度が弱くなり、太陽電池セルにおける太陽電池用リード線を半田接続した接続部分は、互いの膨張率の違いにより太陽電池セルに反りや破損が発生し易くなるという問題があった。
特許文献2における太陽電池用平角導体の製造方法は、導体を圧延などの工程により平角状に成形した後、熱処理工程により0.2%耐力を低減することや、導体の表面に半田メッキ膜を施す製造方法である。
本実施形態の半田メッキ線の製造装置10は、図1に示すように、被メッキ線1aに対してメッキ前処理を行うメッキ前処理手段2と、被メッキ線1aの表面に半田メッキを施すメッキ手段61と、表面にメッキを施したメッキ線1bを巻取る巻取り手段71とで構成している。
巻取り手段71は、巻取り張力調節機72、及び、ボビントラバース方式巻取り機75で構成している。
槽上方向転換ローラ65は、巻取り手段上流側配置ローラ73Aよりも高い位置に配置している。
半田メッキ線の製造方法は、被メッキ線1aに対してメッキ前処理を行うメッキ前処理工程と、被メッキ線1aの表面に半田メッキを施すメッキ工程と、表面にメッキを施したメッキ線1bを巻取る巻取り工程とを経て製造される。
軟化焼鈍工程では、内部を還元ガス雰囲気とした軟化焼鈍炉51の内部に被メッキ線1aを走行させることで該被メッキ線1aを軟化焼鈍して低耐力化するとともに、被メッキ線1aの表面の酸化層を還元する工程である。
半田メッキ線の製造装置10は、メッキ前処理手段2としてのサプライヤ11、加熱処理炉22、酸洗浄槽31、超音波水洗浄槽41、及び、軟化焼鈍炉51と、メッキ手段61としての溶融半田メッキ槽62と、巻取り手段71を、それぞれメッキ線1bの走行方向の上流側から下流側へこの順に一連配置している。
洗浄効果確認実験1では、上述した製造装置、及び製造方法によりメッキ線1bを製造する際において、表1に示すように、本発明例と比較例の2つの設定例の下で被メッキ線1aに対して加熱処理工程、酸洗浄工程、水洗浄工程をこの順で行った場合の洗浄効果の違いについて検証する実験を行った。
なお、洗浄効果確認実験では、被メッキ線1aの形状と線速以外の設定は、本発明例と比較例とで互いに同じ設定としている。
なお、図4は、本実験で用いる洗浄装置、及び、その周辺部分を模式的に示している。
なお、加熱処理工程では、加熱処理炉22の内部を蒸気雰囲気としているため、加熱処理炉22は、スチーマーとしても機能する。このため、加熱処理工程では、加熱により被メッキ線1aの表面に付着した付着物を加熱除去する効果も期待できるため、加熱処理工程を洗浄工程の一部と見なして本実験対象に含めている。
洗浄効果確認実験2では、上述した製造装置、及び製造方法によりメッキ線1bを製造する際において、本発明例と比較例の2つの設定例の下で被メッキ線1aに対してそれぞれ酸洗浄工程、水洗浄工程を行った場合の洗浄効果の違いについて検証する実験を行った。
他の実施形態として、加熱処理炉22と酸洗浄槽31との間に設置した冷却水槽23は、必須の構成ではなく、図5に示すように、これら加熱処理炉22と酸洗浄槽31との間に冷却水槽23を設置しなくてもよい。
水冷却手段は、冷却水槽23に対応し、
酸洗浄手段は、酸洗浄槽31に対応し、
水洗浄手段は、超音波水洗浄槽41に対応するものとし、本発明は、上述した実施形態に限定せず、様々な実施形態で構成することができる。
1b…メッキ線
2…メッキ前処理手段
10…メッキ線の製造装置
12…サプライヤ
22…加熱処理炉
30…洗浄手段
31…酸洗浄槽
41…超音波水洗浄槽
51…軟化焼鈍炉
57…還元ガス供給部
61…メッキ手段
63…溶融半田メッキ液
71…巻取り手段
72…巻取り張力調節機
75…ボビントラバース方式巻取り機
G…還元ガス
Claims (5)
- 銅線に対してメッキ前処理を行うメッキ前処理手段と、
銅線の表面に半田メッキを施すメッキ手段と、
表面にメッキを施した銅線を巻取る巻取り手段とで構成される半田メッキ線の製造装置であって、
前記銅線を、純銅系材料で形成し、
前記メッキ前処理手段に、銅線の表面を蒸気洗浄する加熱処理を行う加熱処理手段と、銅線を洗浄する洗浄手段と、銅線を軟化焼鈍して低耐力化する軟化焼鈍手段を備え、
低耐力化した前記銅線を、該銅線の耐力よりも低い巻取り力で前記巻取り手段により巻取る構成とし、
前記メッキ前処理手段、前記メッキ手段、及び、前記巻取り手段を、銅線の走行方向の上流側からこの順に一連配置し、
前記洗浄手段を、酸洗浄手段と水洗浄手段とで構成し、
前記メッキ前処理手段において、前記軟化焼鈍手段の上流側に、前記加熱処理手段、前記酸洗浄手段、及び、前記水洗浄手段を銅線走行方向に沿ってこの順に配置した
半田メッキ線の製造装置。 - 前記加熱処理手段と前記酸洗浄手段との間に、銅線の表面に酸化膜が形成され難いように、常温よりも高い酸洗浄効果を有する銅線表面温度を保つ範囲で冷却する水冷却手段を配置した
請求項1に記載の半田メッキ線の製造装置。 - 前記加熱処理手段と前記水冷却手段とを、加熱処理手段から導出した銅線が空気に触れないよう水冷却手段まで案内する連結管で互いに連結した
請求項2に記載の半田メッキ線の製造装置。 - 銅線に対してメッキ前処理を行うメッキ前処理工程と、
銅線の表面に半田メッキを施すメッキ工程と、
表面にメッキを施した銅線を巻取る巻取り工程とを経て製造される半田メッキ線の製造方法であって、
前記銅線には、純銅系材料で形成したものを用い、
前記メッキ前処理工程では、銅線の表面を蒸気洗浄する加熱処理を行う加熱処理工程と、銅線を洗浄する洗浄工程と、銅線を軟化焼鈍して低耐力化する軟化焼鈍工程を行い、
前記巻取り工程を、
低耐力化した前記銅線の耐力よりも低い巻取り力で巻取る工程とし、
前記巻取り工程の間、前記メッキ前処理工程と前記軟化焼鈍工程と前記メッキ工程とを連続して行い、
前記洗浄工程では、酸洗浄工程と水洗浄工程とを行い、
前記メッキ前処理工程において、前記軟化焼鈍工程の前に、前記加熱処理工程、前記酸洗浄工程、及び、前記水洗浄工程を、この順で行う
半田メッキ線の製造方法。 - 前記加熱処理工程と前記酸洗浄工程との間に、銅線の表面に酸化膜が形成され難いように、常温よりも高い酸洗浄効果を有する銅線表面温度を保つ範囲で冷却する水冷却工程を行う
請求項4に記載の半田メッキ線の製造方法。
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