US20030121131A1 - Apparatus for producing a grid for a battery plate, and method of producing the same - Google Patents
Apparatus for producing a grid for a battery plate, and method of producing the same Download PDFInfo
- Publication number
- US20030121131A1 US20030121131A1 US10/305,546 US30554602A US2003121131A1 US 20030121131 A1 US20030121131 A1 US 20030121131A1 US 30554602 A US30554602 A US 30554602A US 2003121131 A1 US2003121131 A1 US 2003121131A1
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- United States
- Prior art keywords
- disk
- disk cutter
- cutter rolls
- metal sheet
- grid
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/04—Processes of manufacture in general
- H01M4/043—Processes of manufacture in general involving compressing or compaction
- H01M4/0435—Rolling or calendering
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/14—Electrodes for lead-acid accumulators
- H01M4/16—Processes of manufacture
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/64—Carriers or collectors
- H01M4/70—Carriers or collectors characterised by shape or form
- H01M4/72—Grids
- H01M4/73—Grids for lead-acid accumulators, e.g. frame plates
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M2004/026—Electrodes composed of, or comprising, active material characterised by the polarity
- H01M2004/028—Positive electrodes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/10—Battery-grid making
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/18—Expanded metal making
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49108—Electric battery cell making
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/51—Plural diverse manufacturing apparatus including means for metal shaping or assembling
- Y10T29/5104—Type of machine
- Y10T29/5109—Lathe
- Y10T29/5111—Pulley or wheel
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/53—Means to assemble or disassemble
- Y10T29/5313—Means to assemble electrical device
- Y10T29/53135—Storage cell or battery
- Y10T29/53139—Storage cell or battery including deforming means
Definitions
- the present invention relates to an apparatus for producing a grid for a battery plate by using a rotary expander, and a method of producing such a grid.
- a battery plate of a lead storage battery is configured by filling an active material into meshes of a grid made of lead or a lead alloy.
- a grid is often produced by directly forming a grid-like shape by means of, for example, casting of lead or a lead alloy, or alternatively by forming meshes in a lead sheet made of lead or a lead alloy by an expander.
- Expanders for this purpose include an expander of the reciprocal type in which meshes are sequentially formed in a lead sheet with starting from both the ends of the sheet, by vertical motions of a die cutter, and that of the rotary type in which slits are formed in a lead sheet in a zigzag pattern by rotation of disk cutters (a slit forming step), and the lead sheet is stretched from both the sides to expand the slits into meshes (an expanding step).
- FIG. 3 shows a configuration example of a conventional production apparatus in a slit forming step in an expander of the rotary type (rotary expander).
- rotary expander on the right side of one disk cutter roll 1 in the figure, another disk cutter roll 2 is placed, and a further disk cutter roll 3 is placed below the disk cutter roll 2 in the figure.
- a lead sheet 4 made of lead or a lead alloy is passed between the three disk cutter rolls 1 to 3 .
- a large number of disk cutters 5 are arranged and fixed on a common rotation shaft with being separated from each other by a distance which is approximately equal to the thickness of one disk cutter 5 .
- Each of the disk cutters 5 is configured by a metal disk. As shown in FIG. 4, ridges 5 a in which the peripheral side face protrudes in a ridge-like shape toward the outer periphery from a reference circumferential face of a predetermined radius centered at the axis of the disk, and valleys 5 b in which the peripheral side face composed of a face substantially extending along the reference circumferential face is formed are alternately formed in a whole periphery in the circumferential direction.
- the disk cutters 5 of the disk cutter rolls 2 and 3 excluding the disk cutter roll 1 are configured in the following manner.
- a groove 5 c which is opened in the peripheral side face of the valley 5 b is formed in a radial direction so that the grooves which are formed in every pair of valleys 5 b adjacent to each other via the respective ridge 5 a are arranged so as to be alternate on peripheral edges of both the disk faces.
- FIGS. 4 ( b ) and 4 ( c ) the peripheral edge of one disk cutter 5 is shown in a partially enlarged manner while linearly developing the circumference.
- the three disk cutter rolls 1 to 3 in each of which the thus configured disk cutters 5 are arranged are placed so that the axes of the rolls horizontally elongate in parallel to one another and the ridges 5 a of the disk cutters 5 alternately engage each other.
- each ridge 5 a which reaches the right end enters between the ridges 5 a in the left end of the corresponding disk cutters 5 of the right disk cutter roll 2
- each ridge 5 a which reaches the lower end enters between the ridges 5 a in the upper end of the corresponding disk cutters 5 of the lower disk cutter roll 3 .
- the disk cutters 5 of the right and lower disk cutter roll 2 and 3 are placed so that the valleys 5 b of the disk cutters slightly overlap with each other.
- the portions where the slits 4 a which are arranged in the advancing direction of the lead sheet 4 are not connected to each other are formed as nodes 4 c .
- the slits 4 a formed in the lead sheet 4 are interrupted at intervals of a predetermined length along the advancing direction, and the nodes 4 c are formed between the slits, respectively.
- the portions which are to be formed as the nodes 4 c are formed with being shifted by a half pitch of the slits 4 a . Therefore, the large number of slits 4 a formed in the lead sheet 4 are arranged in a zigzag pattern as shown in the plan view in the circle C 2 of the one-dot chain line of FIG. 3.
- the lead sheet 4 in which the large number of slits 4 a have been formed in the slit forming step is stretched toward both the sides in the width direction in the subsequent step of the rotary expander.
- the slits 4 a are expanded so as to form meshes, whereby a lattice-like grid which is to be used as a battery plate of a lead storage battery is produced.
- the lead sheet 4 are passed between the disk cutter rolls 1 and 2 , and then between the disk cutter rolls 2 and 3 , or processed two times. Therefore, the rotary expander has a problem in that, as compared with a grid which is processed by an expander of the reciprocal type, a whole grid is corroded in a larger amount and the life performance is lower. Since the lead sheet is passed two times between the three disk cutter rolls 1 to 3 , shavings are produced in a large amount during the process. This causes many production disadvantages such as that a production line must be frequently cleaned. Specifically, many whisker-like lead shavings adhere to a grid which is produced by a conventional rotary expander.
- the present inventor developed a technique in which, as shown in FIG. 5, the lead sheet 4 is processed by using only two disk cutter rolls 2 and 3 that are vertically arranged.
- the lead sheet 4 which has been passed through between the upper and lower disk cutter rolls 2 and 3 is horizontally pulled out and then carried out, and hence the lead sheet 4 is in an unstable condition in a carrying-out portion. Consequently, there arise problems in that the sheet faces are undulated, and that meshes of an expanded grid often have irregular shapes.
- the ridges 5 a perform not only a function of cutting the lead sheet 4 to form the slits 4 a , but also that of vertically protruding the wires 4 b by ridge-like protrusions of the ridges 5 a .
- the ridges 5 a When the ridges 5 a are moved to the lower or upper end in accordance with the rotation of the disk cutters 5 , therefore, the ridges 5 a vertically penetrate the lead sheet 4 to bite between the slits 4 a .
- FIG. 6 shows the state in which the lead sheet 4 is caught by the ridges 5 a of the lower disk cutters 5 and tends to be once moved downward in a carrying-out portion A in accordance with the rotation of the disk cutters 5 .
- the horizontal direction in which the lead sheet 4 is pulled out is in parallel to the axes of the two upper and lower disk cutter rolls 2 and 3 , and elongates along the reference tangential plane which is perpendicular to the plane connecting the axes.
- the lead sheet 4 is separated simultaneously from the ridges 5 a of the upper and lower disk cutters 5 .
- the direction along which the lead sheet 4 is actually moved together with the ridges 5 a , or in either of the upward and downward directions is unstably changed at any time depending on the current manner of biting or catching the slits 4 a by the ridges 5 a .
- the lead sheet 4 is pulled out to the carrying-out portion A while being undulated. Furthermore, the lead sheet 4 is horizontally pulled out toward the right side of FIG. 6. Even when the ridges 5 a are caught between the slits 4 a , therefore, the ridges will be suddenly separated from the slits in accordance with the rotation of the disk cutters 5 . As a result, each time when the ridges 5 a are separated from the slits 4 a , a vertical vibration occurs in the disk cutter rolls 2 and 3 . This also sometimes causes the phenomena in which the lead sheet 4 is undulated, and in which meshes of an expanded grid often have irregular shapes.
- the invention has been conducted in order to solve the above-discussed problems. It is an object of the invention to provide an apparatus for producing a grid for a battery plate in which slits are formed in a metal sheet while maintaining the axis-to-axis distance of two disk cutter rolls to an adequate value, and meshing edges of disk cutters by an appropriate overlapping dimension, whereby production of shaving and wear of the disk cutters are reduced, and in which the metal sheet is pulled out to be carried out after transported along one of the two disk cutter rolls, whereby a grid having meshes of a uniformly regular shape can be stably produced, and also a method of producing such a grid.
- the invention set forth in claim 1 provides an apparatus for producing a grid for a battery plate in which two disk cutter rolls are opposed to each other, and a metal sheet is passed between the disk cutter rolls to form a large number of slits in a zigzag pattern in the metal sheet, wherein each of the disk cutter rolls is configured by placing a plurality of disk cutters on a same shaft with forming a gap therebetween, each of the disk cutters is configured by: alternately forming, in a whole periphery of a peripheral edge of a disk, ridges in which a peripheral side face protrudes in a ridge-like shape toward an outer periphery from a reference circumferential face of a radius r (mm), and valleys in which a peripheral side face composed of a face extending along the reference circumferential face is formed, the reference circumferential face being centered at an axis of the disk; and, for each of the valleys, forming a groove which is opened in a peripheral side face of the valley
- a metal sheet is passed only one time between the two disk cutter rolls to form slits in the metal sheet. Therefore, metal shavings are produced in a less amount, so that, when a grid which is produced by expanding the metal sheet is used as a positive plate, the formation efficiency and the life performance of the plate can be improved. Moreover, the load of the disk cutters is reduced, and hence the replacement frequency of the disk cutter rolls can be lowered.
- the invention set forth in claim 2 is characterized in that the apparatus comprises transporting means for once transporting the metal sheet which has been passed through between the two disk cutter rolls, along a peripheral face of one of the disk cutter rolls, and carrying out the metal sheet with pulling out the metal sheet from a position of the peripheral face in a tangential direction.
- a metal sheet is once transported along the peripheral face of one of the disk cutter rolls.
- the angle at which the metal sheet passed through between the two disk cutter rolls is pulled out to be carried out is set to be along the reference tangential plane, the metal sheet is separated simultaneously from the peripheral faces of the two disk cutter rolls, and hence unstably carried out.
- a metal sheet is pulled out and carried out at an angle which is inclined with respect to the reference tangential plane. After the metal sheet is passed through between the two disk cutter rolls, therefore, the metal sheet is first transported along the peripheral face of the one disk cutter roll on the inclined side.
- the metal sheet is surely separated from the peripheral face of the other disk cutter roll.
- the metal sheet which is transported along the peripheral face of the one disk cutter roll is pulled out as it is in the tangential direction, so that the metal sheet can be smoothly separated also from the one disk cutter roll.
- the metal sheet is sequentially separated in a stepwise manner from the peripheral faces of the two disk cutter rolls, whereby the metal sheet can be prevented from entering into an unstable state or being undulated or causing vibrations.
- the invention set forth in claim 3 provides a method of producing a grid for a battery plate in which two disk cutter rolls are opposed to each other, and a metal sheet is passed between the disk cutter rolls to form a large number of slits in a zigzag pattern in the metal sheet, wherein the metal sheet which has been passed through between the two disk cutter rolls is once transported along a peripheral face of one of the disk cutter rolls, and the metal sheet is then pulled out from a position of the peripheral face in a tangential direction to be carried out.
- a metal sheet is first transported along the peripheral face of one of the disk cutter rolls, and then pulled out in a tangential direction from a position of the peripheral face of the disk cutter roll. Therefore, the metal sheet is first surely separated from the peripheral face of the other disk cutter roll, and thereafter can be smoothly separated also from the one disk cutter roll.
- the metal sheet is sequentially separated in a stepwise manner from the peripheral faces of the two disk cutter rolls, whereby the metal sheet can be prevented from entering into an unstable state or being undulated or causing vibrations.
- the invention set forth in claim 4 is characterized in that disk cutters of the disk cutter rolls which are opposed to each other are placed with making reference circumferential faces of the disk cutters in contact with each other, to cause valleys of the disk cutters overlap with each other by a dimension d (mm) (0 ⁇ d ⁇ 0.3).
- a metal sheet is passed only one time between the two disk cutter rolls to form slits in the metal sheet. Therefore, metal shavings are produced in a less amount, so that, when a grid which is produced by expanding the metal sheet is used as a positive plate, the formation efficiency and the life performance of the plate can be improved. Moreover, the load of the disk cutters is reduced, and hence the replacement frequency of the disk cutter rolls can be lowered.
- FIG. 1 is a side view showing a first embodiment of the invention, and showing a slit forming step in a rotary expander;
- FIG. 2 is a side view showing a second embodiment of the invention, and showing a slit forming step in a rotary expander;
- FIG. 3 is a side view showing a conventional art example, and showing a slit forming step in a rotary expander in which three disk cutter rolls are used;
- FIG. 4( a ) is a side view showing the configuration of a disk cutter
- FIG. 4( b ) is a partial enlarged plan view of a portion T
- FIG. 4( c ) is a partial enlarged side view of the portion T;
- FIG. 5 is a side view showing a slit forming step in a rotary expander in which two disk cutter rolls are used.
- FIG. 6 is a side view showing a manner in which, in the slit forming step in the rotary expander of FIG. 5, a lead sheet which has been passed through between the two disk cutter rolls is pulled out with being undulated.
- FIG. 1 is a side view showing a first embodiment of the invention, and showing a slit forming step in a rotary expander.
- the components having the same functions as those of the conventional art example shown in FIGS. 3 to 6 are denoted by the identical reference numerals.
- a slit forming step in a rotary expander for producing a grid which is used as a battery plate for a battery plate similar to that of the conventional art example will be described.
- the two disk cutter rolls 2 and 3 which are used in the slit forming step are configured in the same manner as those of the conventional art example. Namely, in each of the disk cutter rolls 2 and 3 , a large number of disk cutters 5 in which the ridges 5 a , the valleys 5 b , and the grooves 5 c are formed in peripheral edges of a metal disk are arranged and fixed on a common shaft.
- the two disk cutter rolls 2 and 3 are placed so that their axes horizontally elongate and are vertically parallel to each other.
- the disk cutters 5 of the upper disk cutter roll 2 are placed so that each ridge 5 a which reaches the lower end enters between the ridges 5 a in the upper end of the corresponding disk cutters 5 of the lower disk cutter roll 3
- the disk cutters 5 of the lower disk cutter roll 3 are placed so that each ridge 5 a which reaches the upper end enters between the ridges 5 a in the lower end of the corresponding disk cutters 5 of the upper disk cutter roll 2 .
- the upper and lower disk cutters 5 are placed so that their valleys 5 b slightly overlap with each other.
- the overlapping dimension d is set to be equal to or shorter than 0.3 mm (0.3 mm ⁇ d>0 mm). Therefore, the axis-to-axis distance L of the two disk cutter rolls 2 and 3 is in a range of 2r ⁇ 0.3 mm ⁇ L ⁇ 2r.
- the overlapping dimension d of the valleys 5 b of the disk cutters 5 of the two disk cutter rolls 2 and 3 is longer than 0 mm, and the valleys surely overlap with each other. Therefore, the slits 4 a can be formed in the lead sheet 4 of any thickness. Since the overlapping dimension d of the valleys 5 b does not exceed 0.3 mm, it is possible to suppress lead shavings from being produced in the process of forming the slits 4 a . When the overlapping dimension d exceeds 0.3 mm, shavings are produced in a large amount, and hence such a dimension is not preferable.
- the lead sheet 4 which has undergone the process of forming the slits 4 a in this way is stretched in the width direction in an expanding step which is the subsequent step of the rotary expander, and which is not shown.
- the slits 4 a are expanded so as to form meshes, whereby a lattice-like grid which is to be used as a battery plate of a lead storage battery is produced.
- FIG. 2 is a side view showing a second embodiment of the invention, and showing a slit forming step in a rotary expander.
- the components having the same functions as those of the first embodiment shown in FIG. 1 are denoted by the identical reference numerals.
- the disk cutter rolls 2 and 3 in the embodiment are placed in an oblique directional relationship as shown in FIG. 2.
- the axis O 1 which is the center of the rotation shaft of the disk cutter roll 2 and the axis O 2 which is the center of the rotation shaft of the disk cutter roll 3 horizontally elongate in parallel to each another, but the axis O 2 of the lower disk cutter roll 3 is not placed in a position which is straightly below the axis O 1 of the upper disk cutter roll 2 but is placed in a position which is oblique by an angle ⁇ toward the upstream side in the advancing direction of the lead sheet 4 .
- the axes O 1 and O 2 are positioned so as to obtain the axis-to-axis distance L at which the peripheral edges of the disk cutters 5 alternately enter the gaps to be engaged with each other, or more correctly the axis-to-axis distance L at which the valleys 5 b slightly overlap with each other.
- the lead sheet 4 is inserted between the disk cutter rolls 2 and 3 from an obliquely upper left side of FIG. 2, and then pulled out in the rightward and horizontal direction to be carried out.
- the lead sheet 4 is inserted at an angle in which the sheet is parallel to the axes O 1 and O 2 of the disk cutter rolls 2 and 3 , and which is along the reference tangential plane that is perpendicular to the plane connecting the axes O 1 and O 2 . This is because of the following reason.
- the reference tangential plane is a tangential plane which is common to the peripheral edges of both the disk cutter rolls 2 and 3 .
- the formations of the slits 4 a in both the faces of the lead sheet 4 by the upper and lower disk cutters 5 can be started at a substantially same timing.
- the lead sheet 4 can be inserted between the disk cutter rolls 2 and 3 at an angle which is inclined with respect to the reference tangential plane.
- the lower face of the lead sheet 4 is first in contact with the ridges 5 a of the disk cutters 5 of the lower disk cutter roll 3 , and under this state the sheet is transported by the angle ⁇ along the peripheral face of the lower disk cutter roll 3 .
- the formations of the slits 4 a by the disk cutters 5 of the upper and lower disk cutter rolls 2 and 3 are started.
- the lead sheet 4 is once transported by the angle ⁇ along the peripheral face of the upper disk cutter roll 2 . After the sheet reaches the lower end of the peripheral face of the upper disk cutter roll 2 , the sheet is pulled out in the tangential direction, i.e., the rightward and horizontal direction to be carried out. Namely, the lead sheet 4 is pulled out at a carrying-out angle which is upward inclined by the angle ⁇ with respect to the tangential plane of the two disk cutter rolls 2 and 3 .
- the lead sheet 4 which has undergone the process of forming the slits 4 a in this way is stretched in the width direction in an expanding step which is the subsequent step of the rotary expander, and which is not shown.
- the slits 4 a are expanded so as to form meshes, whereby a lattice-like grid which is to be used as a battery plate of a lead storage battery is produced.
- the lead sheet 4 when the lead sheet 4 has been passed through between the upper and lower disk cutter rolls 2 and 3 and the slits 4 a are formed by the disk cutters 5 , the lead sheet is once transported by the angle ⁇ along the peripheral face of the upper disk cutter roll 2 , and hence the sheet is surely separated from the peripheral face of the lower disk cutter roll 3 .
- the ridges 5 a of the upper and lower disk cutters 5 vertically penetrate the faces of the sheet to bite between the slits 4 a .
- the ridges 5 a of the disk cutters 5 of the lower disk cutter roll 3 are compulsively extracted from between the slits 4 a .
- the lead sheet 4 which is transported along the peripheral face of the upper disk cutter roll 2 reaches the lower end of the peripheral face, the sheet is pulled out in the rightward and horizontal direction. Therefore, it is required only to extract the ridges 5 a of the upper disk cutters 5 from between the slits 4 a , so that the sheet is smoothly separated in a stepwise manner from the roll to be carried out without causing an unstable condition. Consequently, the lead sheet 4 is sequentially separated from the peripheral faces of the two upper and lower disk cutter rolls 2 and 3 , whereby the lead sheet can be prevented from entering into an unstable state or being undulated or causing vibrations.
- the angle ⁇ which is equal to the carrying-out angle of the lead sheet 4 with respect to the reference tangential plane of the two disk cutter rolls 2 and 3 is shown as an angle of about 30°.
- the angle ⁇ may have any value as far as it is sufficiently larger than 0°. Practically, it is preferable to set the angle to be equal to or smaller than 90°.
- the two disk cutter rolls 2 and 3 may be placed in any directional relationship as far as the distance between the axes O 1 and O 2 can be maintained.
- the lead sheet 4 may be pulled out and carried out not in the rightward and horizontal direction but in a direction which is upward or downward inclined with respect to the horizontal direction.
- the configuration of the peripheral edges of the disk cutters 5 is not restricted as far as the slits 4 a can be formed in the lead sheet 4 in a zigzag pattern.
- a grid which is to be used as a battery plate of a lead storage battery is produced by processing the lead sheet 4 made of lead or a lead alloy
- the invention can be applied to a battery of any type including a lead storage battery as far as a similar grid is used as a current collector member of a battery plate.
- Such a grid can be produced by using a metal sheet of an appropriate material which is suitable to the kind of the battery.
- Lead sheets 4 (for example, Pb-0.065 wt. % Ca-1.3 wt. % Sn was used) were processed into grids by a rotary expander which uses the two disk cutter rolls 2 and 3 of the first embodiment, a rotary expander which uses the three disk cutter rolls 1 to 3 of the conventional art example, and a reciprocal expander, and the grids were compared with one another.
- the amount of lead shavings produced during the process was greatly reduced as compared with the grids produced by the rotary expander of the conventional art example.
- the production amount of PbO 2 in the case where formation was conducted at the same quantity of electricity was improved. Since stress acting on the lead sheet 4 is reduced, the corrosion resistance of the grids was enhanced, and the JIS light-load life performance was remarkably improved.
- the axis-to-axis distance L is shorter than 2r ⁇ 0.3 mm, however, the degree of elongation during formation of the slits 4 a is increased, and the nodes 4 c are largely deformed, so that the corrosion resistance was lowered.
- each disk cutter 5 is greatly prolonged.
- the disk cutters 5 of the two rolls, i.e., the disk cutter rolls 2 and 3 are used, and the disk cutters are therefore reduced in number to two thirds of those of the three rolls in the conventional art example. Consequently, it was seen that the embodiment achieves a very large economic effect.
- a vertical displacement gauge was disposed to measure an average vibration amplitude in the process of forming the slits 4 a .
- the ratios of vibration amplitudes of the examples having the various carrying-out angle ⁇ were investigated while setting the vibration amplitude of the first embodiment as 100.
- Grids which were expanded to a predetermined degree after the slits 4 a were formed in the lead sheet 4 were investigated on a ratio of numbers of cracks of corrosion of grids of the examples respectively having the various carrying-out angles ⁇ while setting the ratio of the first embodiment as 100.
- an active material was filled into grids which were produced with adjusting the process speeds of the slit forming step and the expanding step so as not cause a crack of corrosion in the grids, and the grids were then cured and dried to be formed as positive plates.
- the positive plates were incorporated into lead storage batteries (Type 55D23 of JIS).
- a JIS overcharge life test was conducted on the lead storage batteries for one month. Thereafter, the corrosion amounts of the grids were checked, and ratios of corrosion amounts of the examples respectively having the various carrying-out angles ⁇ were obtained while setting the ratio of the first embodiment as 100.
- a battery plate which was produced according to the first embodiment was used as the negative plate, and a separator which is configured mainly by microporous polyethylene was interposed between the plates.
- the apparatus for producing a grid for a battery plate of the invention shavings produced during the process of forming slits can be greatly reduced, and the life performance can be extremely improved.
- the method of producing a grid for a battery plate of the invention after a metal sheet is passed through two disk cutter rolls, the metal sheet is sequentially separated in a stepwise manner from the peripheral faces of the disk cutter rolls. Therefore, the metal sheet can be prevented from entering into an unstable state or being undulated or causing vibrations.
Abstract
It is an object of the invention to provide an apparatus for producing a grid for a battery plate which can improve the life performance of a lead storage battery, and in which a lead sheet 4 is prevented from being undulated or causing vibrations in a carrying-out portion of disk cutter rolls 2 and 3, and also a method of producing such a grid.
As means for attaining the object, the axis-to-axis distance L (mm) of the two disk cutter rolls 2 and 3 in which a reference circumferential face has a radius r (mm), and which are opposed to each other is in a range of 2r−0.3 mm≦L<2r. The lead sheet 4 which has been passed through between the two disk cutter rolls 2 and 3 is once transported along the peripheral face of the lower disk cutter roll 3, and the lead sheet 4 which is transported only along the peripheral face of the disk cutter roll 3 is pulled out from a position of the peripheral face in a tangential direction to be carried out.
Description
- The present invention relates to an apparatus for producing a grid for a battery plate by using a rotary expander, and a method of producing such a grid.
- A battery plate of a lead storage battery is configured by filling an active material into meshes of a grid made of lead or a lead alloy. Such a grid is often produced by directly forming a grid-like shape by means of, for example, casting of lead or a lead alloy, or alternatively by forming meshes in a lead sheet made of lead or a lead alloy by an expander. Expanders for this purpose include an expander of the reciprocal type in which meshes are sequentially formed in a lead sheet with starting from both the ends of the sheet, by vertical motions of a die cutter, and that of the rotary type in which slits are formed in a lead sheet in a zigzag pattern by rotation of disk cutters (a slit forming step), and the lead sheet is stretched from both the sides to expand the slits into meshes (an expanding step).
- FIG. 3 shows a configuration example of a conventional production apparatus in a slit forming step in an expander of the rotary type (rotary expander). In the rotary expander, on the right side of one
disk cutter roll 1 in the figure, anotherdisk cutter roll 2 is placed, and a furtherdisk cutter roll 3 is placed below thedisk cutter roll 2 in the figure. Alead sheet 4 made of lead or a lead alloy is passed between the threedisk cutter rolls 1 to 3. In each of thedisk cutter rolls 1 to 3, a large number ofdisk cutters 5 are arranged and fixed on a common rotation shaft with being separated from each other by a distance which is approximately equal to the thickness of onedisk cutter 5. - Each of the
disk cutters 5 is configured by a metal disk. As shown in FIG. 4,ridges 5 a in which the peripheral side face protrudes in a ridge-like shape toward the outer periphery from a reference circumferential face of a predetermined radius centered at the axis of the disk, andvalleys 5 b in which the peripheral side face composed of a face substantially extending along the reference circumferential face is formed are alternately formed in a whole periphery in the circumferential direction. Although not sot shown in FIG. 4, thedisk cutters 5 of thedisk cutter rolls disk cutter roll 1 are configured in the following manner. In each of thevalleys 5 b, agroove 5 c which is opened in the peripheral side face of thevalley 5 b is formed in a radial direction so that the grooves which are formed in every pair ofvalleys 5 b adjacent to each other via therespective ridge 5 a are arranged so as to be alternate on peripheral edges of both the disk faces. In FIGS. 4(b) and 4(c), the peripheral edge of onedisk cutter 5 is shown in a partially enlarged manner while linearly developing the circumference. - The three disk cutter rolls1 to 3 in each of which the thus configured
disk cutters 5 are arranged are placed so that the axes of the rolls horizontally elongate in parallel to one another and theridges 5 a of thedisk cutters 5 alternately engage each other. Specifically, in each of thedisk cutters 5 of the leftdisk cutter roll 1, eachridge 5 a which reaches the right end enters between theridges 5 a in the left end of thecorresponding disk cutters 5 of the rightdisk cutter roll 2, and, in each of thedisk cutters 5 of the rightdisk cutter roll 2, eachridge 5 a which reaches the lower end enters between theridges 5 a in the upper end of thecorresponding disk cutters 5 of the lowerdisk cutter roll 3. Thedisk cutters 5 of the right and lowerdisk cutter roll valleys 5 b of the disk cutters slightly overlap with each other. - When the
lead sheet 4 is passed between the left and rightdisk cutter rolls ridges 5 a of thedisk cutters 5 overlap with each other to out thelead sheet 4, whereby a large number ofslits 4 a are formed as shown in a plan view in the circle C1 of the one-dot chain line of FIG. 3. The portions between theslits 4 a which are arranged in the width direction of thelead sheet 4 are pressed by theridges 5 a of thedisk cutters 5 to alternately protrude to both sides in a ridge-like shape from the faces of thelead sheet 4, and formed aswires 4 b. When thelead sheet 4 is passed between the upper and lowerdisk cutter rolls disk cutters 5 on the side where thegrooves 5 c of thevalleys 5 b are not formed vertically overlap with each other to cut thelead sheet 4, and theslits 4 a which are arranged in the advancing direction of thelead sheet 4 are connected to each other as shown in a plan view in the circle C2 of the one-dot chain line of FIG. 3. The portions where theslits 4 a which are arranged in the advancing direction of thelead sheet 4 are not connected to each other are formed as nodes 4 c. Therefore, theslits 4 a formed in thelead sheet 4 are interrupted at intervals of a predetermined length along the advancing direction, and the nodes 4 c are formed between the slits, respectively. In theslits 4 a which are adjacent to each other in the width direction, the portions which are to be formed as the nodes 4 c are formed with being shifted by a half pitch of theslits 4 a. Therefore, the large number ofslits 4 a formed in thelead sheet 4 are arranged in a zigzag pattern as shown in the plan view in the circle C2 of the one-dot chain line of FIG. 3. - The
lead sheet 4 in which the large number ofslits 4 a have been formed in the slit forming step is stretched toward both the sides in the width direction in the subsequent step of the rotary expander. As a result, theslits 4 a are expanded so as to form meshes, whereby a lattice-like grid which is to be used as a battery plate of a lead storage battery is produced. - In the conventional rotary expander, the
lead sheet 4 are passed between thedisk cutter rolls disk cutter rolls disk cutter rolls 1 to 3, shavings are produced in a large amount during the process. This causes many production disadvantages such as that a production line must be frequently cleaned. Specifically, many whisker-like lead shavings adhere to a grid which is produced by a conventional rotary expander. This is considered as one of causes of reduction of the formation efficiency in the case where a grid is used as a positive plate. Moreover, this increases the load of thedisk cutters 5, so that the disk cutters are often required to be replaced with new ones because of wear at intervals of one year at the shortest. - The present inventor developed a technique in which, as shown in FIG. 5, the
lead sheet 4 is processed by using only twodisk cutter rolls lead sheet 4 which has been passed through between the upper and lowerdisk cutter rolls lead sheet 4 is in an unstable condition in a carrying-out portion. Consequently, there arise problems in that the sheet faces are undulated, and that meshes of an expanded grid often have irregular shapes. - In the
disk cutters 5 of the upper and lowerdisk cutter rolls ridges 5 a perform not only a function of cutting thelead sheet 4 to form theslits 4 a, but also that of vertically protruding thewires 4 b by ridge-like protrusions of theridges 5 a. When theridges 5 a are moved to the lower or upper end in accordance with the rotation of thedisk cutters 5, therefore, theridges 5 a vertically penetrate thelead sheet 4 to bite between theslits 4 a. When theridges 5 a are further moved in an upward or downward separating direction in accordance with the rotation of thedisk cutters 5, thelead sheet 4 which is to be originally carried out in a horizontal direction is caught by theridges 5 a and tends to be moved upward or downward. For example, FIG. 6 shows the state in which thelead sheet 4 is caught by theridges 5 a of thelower disk cutters 5 and tends to be once moved downward in a carrying-out portion A in accordance with the rotation of thedisk cutters 5. Moreover, the horizontal direction in which thelead sheet 4 is pulled out is in parallel to the axes of the two upper and lowerdisk cutter rolls lead sheet 4 is separated simultaneously from theridges 5 a of the upper andlower disk cutters 5. The direction along which thelead sheet 4 is actually moved together with theridges 5 a, or in either of the upward and downward directions is unstably changed at any time depending on the current manner of biting or catching theslits 4 a by theridges 5 a. As a result, thelead sheet 4 is pulled out to the carrying-out portion A while being undulated. Furthermore, thelead sheet 4 is horizontally pulled out toward the right side of FIG. 6. Even when theridges 5 a are caught between theslits 4 a, therefore, the ridges will be suddenly separated from the slits in accordance with the rotation of thedisk cutters 5. As a result, each time when theridges 5 a are separated from theslits 4 a, a vertical vibration occurs in thedisk cutter rolls lead sheet 4 is undulated, and in which meshes of an expanded grid often have irregular shapes. - The invention has been conducted in order to solve the above-discussed problems. It is an object of the invention to provide an apparatus for producing a grid for a battery plate in which slits are formed in a metal sheet while maintaining the axis-to-axis distance of two disk cutter rolls to an adequate value, and meshing edges of disk cutters by an appropriate overlapping dimension, whereby production of shaving and wear of the disk cutters are reduced, and in which the metal sheet is pulled out to be carried out after transported along one of the two disk cutter rolls, whereby a grid having meshes of a uniformly regular shape can be stably produced, and also a method of producing such a grid.
- The invention set forth in
claim 1 provides an apparatus for producing a grid for a battery plate in which two disk cutter rolls are opposed to each other, and a metal sheet is passed between the disk cutter rolls to form a large number of slits in a zigzag pattern in the metal sheet, wherein each of the disk cutter rolls is configured by placing a plurality of disk cutters on a same shaft with forming a gap therebetween, each of the disk cutters is configured by: alternately forming, in a whole periphery of a peripheral edge of a disk, ridges in which a peripheral side face protrudes in a ridge-like shape toward an outer periphery from a reference circumferential face of a radius r (mm), and valleys in which a peripheral side face composed of a face extending along the reference circumferential face is formed, the reference circumferential face being centered at an axis of the disk; and, for each of the valleys, forming a groove which is opened in a peripheral side face of the valley, in a peripheral edge portion of one of disk faces in which valleys that are adjacent to each other via a ridge are formed in an oppositely reverse manner, and an axis-to-axis distance L (mm) of the disk cutter rolls satisfies a relationship of 2r−0.3≦L<2r. - According to the invention set forth in
claim 1, a metal sheet is passed only one time between the two disk cutter rolls to form slits in the metal sheet. Therefore, metal shavings are produced in a less amount, so that, when a grid which is produced by expanding the metal sheet is used as a positive plate, the formation efficiency and the life performance of the plate can be improved. Moreover, the load of the disk cutters is reduced, and hence the replacement frequency of the disk cutter rolls can be lowered. - The invention set forth in
claim 2 is characterized in that the apparatus comprises transporting means for once transporting the metal sheet which has been passed through between the two disk cutter rolls, along a peripheral face of one of the disk cutter rolls, and carrying out the metal sheet with pulling out the metal sheet from a position of the peripheral face in a tangential direction. - According to the invention set forth in
claim 2, after being passed through between the two disk cutter rolls, a metal sheet is once transported along the peripheral face of one of the disk cutter rolls. When the angle at which the metal sheet passed through between the two disk cutter rolls is pulled out to be carried out is set to be along the reference tangential plane, the metal sheet is separated simultaneously from the peripheral faces of the two disk cutter rolls, and hence unstably carried out. By contrast, in the invention set forth inclaim 2, a metal sheet is pulled out and carried out at an angle which is inclined with respect to the reference tangential plane. After the metal sheet is passed through between the two disk cutter rolls, therefore, the metal sheet is first transported along the peripheral face of the one disk cutter roll on the inclined side. Consequently, during the process in which the metal sheet is transported along the peripheral face of the one disk cutter roll, the metal sheet is surely separated from the peripheral face of the other disk cutter roll. The metal sheet which is transported along the peripheral face of the one disk cutter roll is pulled out as it is in the tangential direction, so that the metal sheet can be smoothly separated also from the one disk cutter roll. Namely, the metal sheet is sequentially separated in a stepwise manner from the peripheral faces of the two disk cutter rolls, whereby the metal sheet can be prevented from entering into an unstable state or being undulated or causing vibrations. - According to the invention, by the configuration of
claim 1, it is possible to provide an apparatus for producing a grid for a battery plate in which slits can be formed in a metal sheet while reducing shavings and wear of disk cutters, and a grid having meshes of a uniformly regular shape can be stably produced. - The invention set forth in
claim 3 provides a method of producing a grid for a battery plate in which two disk cutter rolls are opposed to each other, and a metal sheet is passed between the disk cutter rolls to form a large number of slits in a zigzag pattern in the metal sheet, wherein the metal sheet which has been passed through between the two disk cutter rolls is once transported along a peripheral face of one of the disk cutter rolls, and the metal sheet is then pulled out from a position of the peripheral face in a tangential direction to be carried out. - According to the invention set forth in
claim 3, after being passed through between the two disk cutter rolls, a metal sheet is first transported along the peripheral face of one of the disk cutter rolls, and then pulled out in a tangential direction from a position of the peripheral face of the disk cutter roll. Therefore, the metal sheet is first surely separated from the peripheral face of the other disk cutter roll, and thereafter can be smoothly separated also from the one disk cutter roll. The metal sheet is sequentially separated in a stepwise manner from the peripheral faces of the two disk cutter rolls, whereby the metal sheet can be prevented from entering into an unstable state or being undulated or causing vibrations. - The invention set forth in
claim 4 is characterized in that disk cutters of the disk cutter rolls which are opposed to each other are placed with making reference circumferential faces of the disk cutters in contact with each other, to cause valleys of the disk cutters overlap with each other by a dimension d (mm) (0<d≦0.3). - According to the invention set forth in
claim 4, a metal sheet is passed only one time between the two disk cutter rolls to form slits in the metal sheet. Therefore, metal shavings are produced in a less amount, so that, when a grid which is produced by expanding the metal sheet is used as a positive plate, the formation efficiency and the life performance of the plate can be improved. Moreover, the load of the disk cutters is reduced, and hence the replacement frequency of the disk cutter rolls can be lowered. - According to the invention, by the configuration of
claim 3, it is possible to provide a method of producing a grid for a battery plate in which a grid having meshes of a uniformly regular shape can be produced, and slits can be stably formed in a metal sheet while reducing shavings and wear of disk cutters. - FIG. 1 is a side view showing a first embodiment of the invention, and showing a slit forming step in a rotary expander;
- FIG. 2 is a side view showing a second embodiment of the invention, and showing a slit forming step in a rotary expander;
- FIG. 3 is a side view showing a conventional art example, and showing a slit forming step in a rotary expander in which three disk cutter rolls are used;
- FIG. 4(a) is a side view showing the configuration of a disk cutter, FIG. 4(b) is a partial enlarged plan view of a portion T, and FIG. 4(c) is a partial enlarged side view of the portion T;
- FIG. 5 is a side view showing a slit forming step in a rotary expander in which two disk cutter rolls are used; and
- FIG. 6 is a side view showing a manner in which, in the slit forming step in the rotary expander of FIG. 5, a lead sheet which has been passed through between the two disk cutter rolls is pulled out with being undulated.
- Hereinafter, embodiments of the invention will be described with reference to the accompanying drawings.
- FIG. 1 is a side view showing a first embodiment of the invention, and showing a slit forming step in a rotary expander. The components having the same functions as those of the conventional art example shown in FIGS.3 to 6 are denoted by the identical reference numerals.
- In the embodiment, a slit forming step in a rotary expander for producing a grid which is used as a battery plate for a battery plate similar to that of the conventional art example will be described. The two disk cutter rolls2 and 3 which are used in the slit forming step are configured in the same manner as those of the conventional art example. Namely, in each of the disk cutter rolls 2 and 3, a large number of
disk cutters 5 in which theridges 5 a, thevalleys 5 b, and thegrooves 5 c are formed in peripheral edges of a metal disk are arranged and fixed on a common shaft. - As shown in FIG. 1, the two disk cutter rolls2 and 3 are placed so that their axes horizontally elongate and are vertically parallel to each other. The
disk cutters 5 of the upperdisk cutter roll 2 are placed so that eachridge 5 a which reaches the lower end enters between theridges 5 a in the upper end of thecorresponding disk cutters 5 of the lowerdisk cutter roll 3, and thedisk cutters 5 of the lowerdisk cutter roll 3 are placed so that eachridge 5 a which reaches the upper end enters between theridges 5 a in the lower end of thecorresponding disk cutters 5 of the upperdisk cutter roll 2. The upper andlower disk cutters 5 are placed so that theirvalleys 5 b slightly overlap with each other. Specifically, when the axis-to-axis distance L of the two disk cutter rolls 2 and 3 is just twice (L=2r) the radius r of eachdisk cutter 5 or the distance between the axis of the disk cutter and the reference circumferential face, only theridges 5 a overlap with each other. Therefore, the axis-to-axis distance L is made slightly shorter than twice the radius r so that also thevalleys 5 b surely overlap with each other by the overlapping dimension d (d>0) shown in FIG. 1. The overlapping dimension d is set to be equal to or shorter than 0.3 mm (0.3 mm≧d>0 mm). Therefore, the axis-to-axis distance L of the two disk cutter rolls 2 and 3 is in a range of 2r−0.3 mm≦L<2r. - According to the configuration, the overlapping dimension d of the
valleys 5 b of thedisk cutters 5 of the two disk cutter rolls 2 and 3 is longer than 0 mm, and the valleys surely overlap with each other. Therefore, theslits 4 a can be formed in thelead sheet 4 of any thickness. Since the overlapping dimension d of thevalleys 5 b does not exceed 0.3 mm, it is possible to suppress lead shavings from being produced in the process of forming theslits 4 a. When the overlapping dimension d exceeds 0.3 mm, shavings are produced in a large amount, and hence such a dimension is not preferable. Thelead sheet 4 which has undergone the process of forming theslits 4 a in this way is stretched in the width direction in an expanding step which is the subsequent step of the rotary expander, and which is not shown. As a result, theslits 4 a are expanded so as to form meshes, whereby a lattice-like grid which is to be used as a battery plate of a lead storage battery is produced. - FIG. 2 is a side view showing a second embodiment of the invention, and showing a slit forming step in a rotary expander. The components having the same functions as those of the first embodiment shown in FIG. 1 are denoted by the identical reference numerals.
- Unlike the first embodiment in which the disk cutter rolls2 and 3 are placed in the strict vertical directional relationship, the disk cutter rolls 2 and 3 in the embodiment are placed in an oblique directional relationship as shown in FIG. 2. Specifically, the axis O1 which is the center of the rotation shaft of the
disk cutter roll 2, and the axis O2 which is the center of the rotation shaft of thedisk cutter roll 3 horizontally elongate in parallel to each another, but the axis O2 of the lowerdisk cutter roll 3 is not placed in a position which is straightly below the axis O1 of the upperdisk cutter roll 2 but is placed in a position which is oblique by an angle θ toward the upstream side in the advancing direction of thelead sheet 4. In the same manner as the first embodiment, the axes O1 and O2 are positioned so as to obtain the axis-to-axis distance L at which the peripheral edges of thedisk cutters 5 alternately enter the gaps to be engaged with each other, or more correctly the axis-to-axis distance L at which thevalleys 5 b slightly overlap with each other. - The
lead sheet 4 is inserted between the disk cutter rolls 2 and 3 from an obliquely upper left side of FIG. 2, and then pulled out in the rightward and horizontal direction to be carried out. In this case, preferably, thelead sheet 4 is inserted at an angle in which the sheet is parallel to the axes O1 and O2 of the disk cutter rolls 2 and 3, and which is along the reference tangential plane that is perpendicular to the plane connecting the axes O1 and O2. This is because of the following reason. The reference tangential plane is a tangential plane which is common to the peripheral edges of both the disk cutter rolls 2 and 3. When thelead sheet 4 is inserted between the upper and lower disk cutter rolls 2 and 3 along the reference tangential plane, therefore, the formations of theslits 4 a in both the faces of thelead sheet 4 by the upper andlower disk cutters 5 can be started at a substantially same timing. In the case where the contact of only theridges 5 a of thedisk cutters 5 of one of the disk cutter rolls 2 and 3 with the face of thelead sheet 4 immediately before the insertion is allowed, however, thelead sheet 4 can be inserted between the disk cutter rolls 2 and 3 at an angle which is inclined with respect to the reference tangential plane. When thelead sheet 4 is horizontally inserted between the disk cutter rolls 2 and 3 from the left side, for example, the lower face of thelead sheet 4 is first in contact with theridges 5 a of thedisk cutters 5 of the lowerdisk cutter roll 3, and under this state the sheet is transported by the angle θ along the peripheral face of the lowerdisk cutter roll 3. Immediately before this, the formations of theslits 4 a by thedisk cutters 5 of the upper and lower disk cutter rolls 2 and 3 are started. - When the formations of the
slits 4 a in thelead sheet 4 by the upper andlower disk cutters 5 of the upper and lower disk cutter rolls 2 and 3 are performed, thelead sheet 4 is once transported by the angle θ along the peripheral face of the upperdisk cutter roll 2. After the sheet reaches the lower end of the peripheral face of the upperdisk cutter roll 2, the sheet is pulled out in the tangential direction, i.e., the rightward and horizontal direction to be carried out. Namely, thelead sheet 4 is pulled out at a carrying-out angle which is upward inclined by the angle θ with respect to the tangential plane of the two disk cutter rolls 2 and 3. Thelead sheet 4 which has undergone the process of forming theslits 4 a in this way is stretched in the width direction in an expanding step which is the subsequent step of the rotary expander, and which is not shown. As a result, theslits 4 a are expanded so as to form meshes, whereby a lattice-like grid which is to be used as a battery plate of a lead storage battery is produced. - According to the embodiment, when the
lead sheet 4 has been passed through between the upper and lower disk cutter rolls 2 and 3 and theslits 4 a are formed by thedisk cutters 5, the lead sheet is once transported by the angle θ along the peripheral face of the upperdisk cutter roll 2, and hence the sheet is surely separated from the peripheral face of the lowerdisk cutter roll 3. In other words, in thelead sheet 4 between the disk cutter rolls 2 and 3, theridges 5 a of the upper andlower disk cutters 5 vertically penetrate the faces of the sheet to bite between theslits 4 a. When thelead sheet 4 is transported along the peripheral face of the upperdisk cutter roll 2, theridges 5 a of thedisk cutters 5 of the lowerdisk cutter roll 3 are compulsively extracted from between theslits 4 a. When thelead sheet 4 which is transported along the peripheral face of the upperdisk cutter roll 2 reaches the lower end of the peripheral face, the sheet is pulled out in the rightward and horizontal direction. Therefore, it is required only to extract theridges 5 a of theupper disk cutters 5 from between theslits 4 a, so that the sheet is smoothly separated in a stepwise manner from the roll to be carried out without causing an unstable condition. Consequently, thelead sheet 4 is sequentially separated from the peripheral faces of the two upper and lower disk cutter rolls 2 and 3, whereby the lead sheet can be prevented from entering into an unstable state or being undulated or causing vibrations. - In FIG. 2 of the embodiment, the angle θ which is equal to the carrying-out angle of the
lead sheet 4 with respect to the reference tangential plane of the two disk cutter rolls 2 and 3 is shown as an angle of about 30°. The angle θ may have any value as far as it is sufficiently larger than 0°. Practically, it is preferable to set the angle to be equal to or smaller than 90°. - Although the embodiment in which, in order to horizontally pull out the
lead sheet 4, the disk cutter rolls 2 and 3 are placed with being inclined by the angle θ has been described, the two disk cutter rolls 2 and 3 may be placed in any directional relationship as far as the distance between the axes O1 and O2 can be maintained. In the case where the disk cutter rolls 2 and 3 are placed in the strict vertical positional relationship as in the conventional art example, for example, thelead sheet 4 may be pulled out and carried out not in the rightward and horizontal direction but in a direction which is upward or downward inclined with respect to the horizontal direction. - Although the embodiments in which the
disk cutters 5 of the disk cutter rolls 2 and 3 have the configuration in which the large number of theridges 5 a are formed on the peripheral edge and thegrooves 5 c that are opened in thevalleys 5 b between theridges 5 a are formed alternately in the both disk faces have been described, the configuration of the peripheral edges of thedisk cutters 5 is not restricted as far as theslits 4 a can be formed in thelead sheet 4 in a zigzag pattern. - Although the embodiments in which a grid which is to be used as a battery plate of a lead storage battery is produced by processing the
lead sheet 4 made of lead or a lead alloy have been described, the invention can be applied to a battery of any type including a lead storage battery as far as a similar grid is used as a current collector member of a battery plate. Such a grid can be produced by using a metal sheet of an appropriate material which is suitable to the kind of the battery. - Lead sheets4 (for example, Pb-0.065 wt. % Ca-1.3 wt. % Sn was used) were processed into grids by a rotary expander which uses the two disk cutter rolls 2 and 3 of the first embodiment, a rotary expander which uses the three disk cutter rolls 1 to 3 of the conventional art example, and a reciprocal expander, and the grids were compared with one another.
- In the rotary expander of the first embodiment, grids were produced while the axis-to-axis distance L of the two disk cutter rolls2 and 3 was variously set. In the reciprocal expander, for the sake of comparison,
lead sheets 4 of the same lot were used, and grids which are identical in weight and mesh shape were produced. - After an active material was filled into the grids produced by these expanders, the grids were cured and dried to form positive plates. The positive plates, and negative plates which were produced by a conventional method were combined with separators which are configured mainly by microporous polyethylene to produce lead storage batteries of Type 55D23 (Japanese Industrial Standard JIS D 5301) for an automobile. A given amount of dilute sulfuric acid of a predetermined specific gravity was poured and formation was performed to complete the lead storage batteries.
- The thus produced lead storage batteries were investigated with respect to the rate of production of shavings during the production process of the grids, the formation efficiency after supplying the same quantity of electricity, the light-load life performance at 75° C. (tested by a method according to Japanese Industrial Standard JIS D 5301, and the shortest life of the
disk cutters 5 in a continuous production test. Table 1 below shows results of the comparisons.TABLE 1 Number axis dis- Rate of pro- Formation life perform- life of of tance duction of efficiency ance at 75° C. cutter rolls L (mm) shavings (%) (%) (cycle) (month) Remarks 3 — 100 100 2,000 12 Conventional art example 2 2r − 0.05 10 123 3,500 35 Example 2 2r − 0.2 12 122 3,600 36 Example 2 2r − 0.3 18 120 3,400 33 Example 2 2r − 0.4 25 118 2,900 27 Example 2 2r − 0.5 33 116 2,200 19 Example Recip- — — 102 2,800 — Comparative rocal example - As apparent from Table 1 above, the amount of lead shavings produced during the process was greatly reduced as compared with the grids produced by the rotary expander of the conventional art example. In accordance with the reduction of lead shavings, also the production amount of PbO2 in the case where formation was conducted at the same quantity of electricity was improved. Since stress acting on the
lead sheet 4 is reduced, the corrosion resistance of the grids was enhanced, and the JIS light-load life performance was remarkably improved. When the axis-to-axis distance L is shorter than 2r−0.3 mm, however, the degree of elongation during formation of theslits 4 a is increased, and the nodes 4 c are largely deformed, so that the corrosion resistance was lowered. The life of eachdisk cutter 5 is greatly prolonged. Thedisk cutters 5 of the two rolls, i.e., the disk cutter rolls 2 and 3 are used, and the disk cutters are therefore reduced in number to two thirds of those of the three rolls in the conventional art example. Consequently, it was seen that the embodiment achieves a very large economic effect. - The
slits 4 a were formed in thelead sheets 4 in the slit forming step by the rotary expander of the second embodiment, and in that by the rotary expander of the first embodiment, and compared with each other. Table 2 belowTABLE 2 Ratio of average Ratio of numbers Ratio of corro- Carrying vibration ampli- of cracks of sion amount af- out angle tudes of roll corrosion of ter overcharge η of lead pair (first grids (first em- test (first em- sheet embodiment = 100) bodiment = 100) bodiment = 100) Remarks 0° 100 100 100 First em- bodiment 5° 96 97 97 Example 15° 85 93 93 Example 30° 73 88 84 Example 45° 65 82 70 Example 60° 51 78 62 Example 75° 43 73 87 Example 90° 35 69 95 Example 105° 103 105 103 — 120° 110 110 120 — - The comparisons were conducted on the first embodiment and examples in the following manner. The
lead sheets 4 were always pulled out and carried out in the rightward and horizontal direction to be fed to the expanding step. By changing the angle θ of the disk cutter rolls 2 and 3, the carrying-out angle θ of thelead sheet 4 in the first embodiment was set to 0°, and that in the examples was changed from 5° to an angle which is larger than 90°. - In the disk cutter rolls2 and 3, a vertical displacement gauge was disposed to measure an average vibration amplitude in the process of forming the
slits 4 a. The ratios of vibration amplitudes of the examples having the various carrying-out angle θ were investigated while setting the vibration amplitude of the first embodiment as 100. Grids which were expanded to a predetermined degree after theslits 4 a were formed in thelead sheet 4 were investigated on a ratio of numbers of cracks of corrosion of grids of the examples respectively having the various carrying-out angles θ while setting the ratio of the first embodiment as 100. Furthermore, an active material was filled into grids which were produced with adjusting the process speeds of the slit forming step and the expanding step so as not cause a crack of corrosion in the grids, and the grids were then cured and dried to be formed as positive plates. The positive plates were incorporated into lead storage batteries (Type 55D23 of JIS). A JIS overcharge life test was conducted on the lead storage batteries for one month. Thereafter, the corrosion amounts of the grids were checked, and ratios of corrosion amounts of the examples respectively having the various carrying-out angles θ were obtained while setting the ratio of the first embodiment as 100. In all of the lead storage batteries, a battery plate which was produced according to the first embodiment was used as the negative plate, and a separator which is configured mainly by microporous polyethylene was interposed between the plates. - As a result of the comparison tests, with respect to the ratio of the average vibration amplitudes and that of the numbers of cracks of corrosion in the disk cutter rolls2 and 3, an example in which the carrying-out angle θ of the
lead sheet 4 is larger achieved a more excellent result while the minimum value was attained in the example of the carrying-out angle θ of 90°. With respect to the ratio of the corrosion amounts, the examples in which the carrying-out angle θ is 45° to 60° exhibited the minimum value. Even in the example of the carrying-out angle θ of 90°, the corrosion amount is smaller than that of the first embodiment. The phenomenon in which the ratio of the corrosion amounts of grids is larger as the carrying-out angle θ of thelead sheet 4 is larger is seemed to be caused because thelead sheet 4 is transported along the peripheral face of the upperdisk cutter roll 2 by a longer distance as the carrying-out angle θ is larger, and hence thelead sheet 4 is largely bent during this process to increase distortion. - As apparent from the above description, according to the apparatus for producing a grid for a battery plate of the invention, shavings produced during the process of forming slits can be greatly reduced, and the life performance can be extremely improved. According to the method of producing a grid for a battery plate of the invention, after a metal sheet is passed through two disk cutter rolls, the metal sheet is sequentially separated in a stepwise manner from the peripheral faces of the disk cutter rolls. Therefore, the metal sheet can be prevented from entering into an unstable state or being undulated or causing vibrations.
- It is a matter of course that, when the configurations of Examples 1 and 2 are combined with each other, the effects due to the respective configurations synergistically cooperate to realize an apparatus for producing a grid for a battery plate and a method of producing the same in which slits can be formed in a metal sheet while reducing shavings and wear of disk cutters, and a grid having meshes of a uniformly regular shape can be stably produced.
Claims (4)
1. An apparatus for producing a grid for a battery plate in which two disk cutter rolls are opposed to each other, and a metal sheet is passed between said disk cutter rolls to form a large number of slits in a zigzag pattern in said metal sheet, wherein
each of said disk cutter rolls is configured by placing a plurality of disk cutters on a same shaft with forming a gap therebetween, each of said disk cutters being configured by: alternately forming, in a whole periphery of a peripheral edge of a disk, ridges in which a peripheral side face protrudes in a ridge-like shape toward an outer periphery from a reference circumferential face of a radius r (mm), and valleys in which a peripheral side face composed of a face extending along said reference circumferential face is formed, said reference circumferential face being centered at an axis of said disk; and, for each of said valleys, forming a groove which is opened in a peripheral side face of said valley, in a peripheral edge portion of one of disk faces in which valleys that are adjacent to each other via a ridge are formed in an oppositely reverse manner, and
an axis-to-axis distance L (mm) of said two disk cutter rolls which are opposed to each other satisfies a relationship of 2r−0.3≦L<2r.
2. An apparatus for producing a grid for a battery plate according to claim 1 , wherein said apparatus comprises transporting means for once transporting said metal sheet which has been passed through between said two disk cutter rolls, along a peripheral face of one of said disk cutter rolls, and carrying out said metal sheet with pulling out said metal sheet from a position of said peripheral face in a tangential direction.
3. A method of producing a grid for a battery plate in which two disk cutter rolls are opposed to each other, and a metal sheet is passed between said disk cutter rolls to form a large number of slits in a zigzag pattern in said metal sheet, wherein
said metal sheet which has been passed through between said two disk cutter rolls is once transported along a peripheral face of one of said disk cutter rolls, and said metal sheet is then pulled out from a position of said peripheral face in a tangential direction to be carried out.
4. A method of producing a grid for a battery plate according to claim 3 , wherein disk cutters of said disk cutter rolls which are opposed to each other are placed with making reference circumferential faces of said disk cutters in contact with each other, to cause valleys of said disk cutters overlap with each other by a dimension d (mm) (0<d≦0.3).
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/229,812 US8142935B2 (en) | 2001-12-03 | 2008-08-27 | Apparatus for producing a battery plate expanded grid |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2001-368453 | 2001-12-03 | ||
JP2001368453A JP2003168440A (en) | 2001-12-03 | 2001-12-03 | Manufacturing device of lattice body for lead-acid battery |
JP2002-065640 | 2002-03-11 | ||
JP2002065640A JP4132885B2 (en) | 2002-03-11 | 2002-03-11 | Method for manufacturing grid for battery electrode plate |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/229,812 Division US8142935B2 (en) | 2001-12-03 | 2008-08-27 | Apparatus for producing a battery plate expanded grid |
US12/229,812 Continuation US8142935B2 (en) | 2001-12-03 | 2008-08-27 | Apparatus for producing a battery plate expanded grid |
Publications (1)
Publication Number | Publication Date |
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US20030121131A1 true US20030121131A1 (en) | 2003-07-03 |
Family
ID=26624836
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/305,546 Abandoned US20030121131A1 (en) | 2001-12-03 | 2002-11-27 | Apparatus for producing a grid for a battery plate, and method of producing the same |
US12/229,812 Expired - Lifetime US8142935B2 (en) | 2001-12-03 | 2008-08-27 | Apparatus for producing a battery plate expanded grid |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
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US12/229,812 Expired - Lifetime US8142935B2 (en) | 2001-12-03 | 2008-08-27 | Apparatus for producing a battery plate expanded grid |
Country Status (2)
Country | Link |
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US (2) | US20030121131A1 (en) |
CN (1) | CN1331254C (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20060239904A1 (en) * | 2003-07-30 | 2006-10-26 | Armando Marfisi | Utilization of lead shavings in abrasion mills for the production of lead oxide |
CN103296282A (en) * | 2012-03-05 | 2013-09-11 | 江阴市东顺机械有限公司 | Lead-acid storage battery grid with side teeth in processing |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2004015795A1 (en) * | 2002-08-09 | 2004-02-19 | Japan Storage Battery Co., Ltd. | Battery pole plate grid producing method, and battery producing method |
US8741487B1 (en) * | 2008-08-28 | 2014-06-03 | Greatbatch Ltd. | Electrode current collector with stress-relieving mesh structure |
CN105304927B (en) * | 2015-10-30 | 2017-11-03 | 天能电池(芜湖)有限公司 | Portable grid cuts brush machine |
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US5136762A (en) * | 1989-09-28 | 1992-08-11 | Fabrizio Gironi | Method of automatic drawing-in and machine for carrying out the said method |
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JP4030618B2 (en) * | 1997-02-06 | 2008-01-09 | 松下電器産業株式会社 | Manufacturing method of stretched mesh sheet |
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JP4288730B2 (en) * | 1998-09-28 | 2009-07-01 | パナソニック株式会社 | Lead storage battery manufacturing method and lead storage battery grid manufacturing apparatus |
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JP4686810B2 (en) * | 2000-04-24 | 2011-05-25 | パナソニック株式会社 | Lead acid battery |
JP4834912B2 (en) | 2001-03-01 | 2011-12-14 | パナソニック株式会社 | Manufacturing method of storage battery grid and manufacturing method of lead storage battery using storage battery grid manufactured by the manufacturing method |
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2002
- 2002-11-27 US US10/305,546 patent/US20030121131A1/en not_active Abandoned
- 2002-12-03 CN CNB021548889A patent/CN1331254C/en not_active Expired - Lifetime
-
2008
- 2008-08-27 US US12/229,812 patent/US8142935B2/en not_active Expired - Lifetime
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US4291443A (en) * | 1978-10-31 | 1981-09-29 | Cominco Ltd. | Forming expanded mesh sheet from deformable strip |
US5136762A (en) * | 1989-09-28 | 1992-08-11 | Fabrizio Gironi | Method of automatic drawing-in and machine for carrying out the said method |
US5216962A (en) * | 1990-01-16 | 1993-06-08 | Fimi S.P.A. Fabbrica Impianti Macchine Industriali | Shear for shearing laminar elements |
US6212744B1 (en) * | 1997-09-25 | 2001-04-10 | Matsushita Electric Industrial Co., Ltd. | Apparatus for expanding a metal sheet |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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US20060239904A1 (en) * | 2003-07-30 | 2006-10-26 | Armando Marfisi | Utilization of lead shavings in abrasion mills for the production of lead oxide |
CN103296282A (en) * | 2012-03-05 | 2013-09-11 | 江阴市东顺机械有限公司 | Lead-acid storage battery grid with side teeth in processing |
Also Published As
Publication number | Publication date |
---|---|
US20090000089A1 (en) | 2009-01-01 |
CN1331254C (en) | 2007-08-08 |
CN1423351A (en) | 2003-06-11 |
US8142935B2 (en) | 2012-03-27 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: JAPAN STORAGE BATTERY CO., LTD., JAPAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:FUJIWARA, YOSHIOMI;TANAKA, HIROYUKI;NISHIDA, TADASHI;REEL/FRAME:013554/0424 Effective date: 20021030 |
|
AS | Assignment |
Owner name: GS YUASA CORPORATION, JAPAN Free format text: CHANGE OF NAME;ASSIGNOR:JAPAN STORAGE BATTERY CO., LTD.;REEL/FRAME:017411/0445 Effective date: 20050720 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |