WO2006006430A1

WO2006006430A1 - Strap, casting mold, insert, casting device and casting method

Info

Publication number: WO2006006430A1
Application number: PCT/JP2005/012213
Authority: WO
Inventors: Kazuo Kamakura; Masayuki Morimoto
Original assignee: Gs Yuasa Corporation
Priority date: 2004-07-09
Filing date: 2005-07-01
Publication date: 2006-01-19
Also published as: TW200607588A

Abstract

A strap providing few causes for preventing a releasing operation and a high welding quality between cell-to-cell connections. A lead-storage-battery-use strap (1), wherein a cell-to-cell connection (2) by which cells adjoining with each other via a partition wall are welded in a lead storage battery and a connection (3) integrated with the lug of a pole plate group are formed into an L-shape forming an almost right angle, the opposite sides of the cell-to-cell connection (2) and the connection (3) are formed so as to straightly continue, and the cell-to-cell connection (2) is formed so as to make a tapering angle of 0.6˚-1.0˚.

Description

Specification

Strap, mold for molding, nesting, forging apparatus and method

Technical field

[0001] The present invention relates to, for example, a lead die battery (battery) strap mounted on various vehicles such as a single car, a passenger car, a truck, and a forklift, a forging mold, a nest, and a forging used for forging a strap. The present invention relates to an apparatus and a forging method.

Background art

[0002] In lead-acid batteries mounted on various vehicles, a cast-on-strap method (COS method) has been conventionally known as a method for connecting the ears of the electrode plate group via a strap (for example, Patent Documents 1 to 7). This COS method uses two methods. One of them is to immerse the bowl in molten metal (molten lead) in the melting tank manually or with an automatic machine to fill the melt in the cavity, and then lift the bowl from the melting tank to raise the ears of the electrode plate group. Is a method of forming a strap by immersing the material in a cavity to solidify the molten metal (see Patent Documents 1, 4, and 5).

[0003] In another method, a vertical mold is disposed in the vicinity of the melting tank, molten metal is injected into the cavity by transfer means such as a piston pump, and the injected molten metal is externally heated by heating means such as a heater (or a panner). While heating and keeping warm, the tip of the ear part of the electrode plate group that has been dried by flux treatment is immersed in the molten metal. In this state, the saddle is cooled to solidify the molten metal, and the ear part is strapped. (See Patent Documents 2, 3, 6, and 7). In addition, for the method of pouring molten metal into the cavity, a method is provided in which a weir is provided, the molten metal is pumped from the melting tank and the excess molten metal is returned to the melting tank, and between the molten metal surface and the mold. There are a method of creating a head (heavy method), a method of pouring directly with a pan, and so on.

[0004] On the other hand, the cavities of the strap forging mold used in the conventional COS method are generally formed into a bottomed shape by electric discharge machining. For example, as shown in FIGS. 51 is formed in an L shape so that the inter-cell connection portion 52 and the electrode plate group connection portion 53 correspond to substantially right angles, and the side surface of the inter-cell connection portion 52 has a good releasability. The width of the inter-cell connection portion 52 is set to be larger than the connection portion 53 with the electrode plate group, and The inter-cell connection part 52 was set to have a taper angle (draft angle) of 3 °. In addition, the ears of the electrode plate group are integrally formed in the connecting portion 53 with the electrode plate group in the forging process, and the inter-cell connecting portion 52 is joined to each other with the partition walls of the cells adjacent to each other by resistance welding. .

Patent Document 1: Japanese Patent Application Laid-Open No. 7-122259

Patent Document 2: Japanese Patent Laid-Open No. 9 199103

Patent Document 3: Japanese Patent Laid-Open No. 9-164469

Patent Document 4: Japanese Patent Laid-Open No. 10-294096

Patent Document 5: Japanese Unexamined Patent Publication No. 2002-0111562

Patent Document 6: Japanese Unexamined Patent Publication No. 2002-279965

Patent Document 7: Japanese Patent Laid-Open No. 2002-025534

Disclosure of the invention

Problems to be solved by the invention

[0006] There have been various problems with the conventional COS method strap manufacturing method as described above. That is, (1) due to the shape of the strap forging mold formed by electric discharge machining, an expensive boron-based mold release agent is required, and a cumbersome coating process to the cavity is required. On top of that, even when a mold release agent was applied, defective release often occurred. (2) When pumping up molten metal with a pump and injecting it into the cavity, troubles in the pouring system due to clogging of the molten metal in the pump and pipes occur and maintenance takes a lot of time and effort. For this reason, there was a problem that the operating rate might decrease and the running cost would increase.

[0007] (3) When the molten metal injected into the cavity is heated by a heater, troubles such as disconnection may occur. In addition, it was difficult to stably maintain the vertical heating and cooling temperatures, resulting in poor quality due to temperature variations, and it was easy to stabilize quality (quality control) immediately. Furthermore, since there are many opportunities for contact between the molten metal and the atmosphere (the contact area is wide), there were defects in that oxides and solidified products were easily generated. (4) When releasing a forged strap, an extrusion pin having an extrusion contact portion formed in a circular shape or a plate shape for extruding the strap with a saddle force is required, and the structure of the device is complicated. That extrusion on Since the abutment part does not abut against the entire bottom surface of the strap and can only be partially abutted, an equal pushing force cannot be applied to the bottom of the strap, and the release operation becomes unstable immediately. In addition, the push pin was easily deformed.

[0008] Since the strap 51 shown in FIGS. 11 (a) and 11 (b) has a stepped portion D that prevents a stable release operation, even if an expensive release agent is used, the strap 51 shown in FIG. There was a problem (related to item (1) above) that the corner portion R of the stepped portion D adhered to the mold and was difficult to release. In addition, as a draft for improving releasability, the inter-cell connection part 52 is provided with a taper angle with a taper of 3 ° (relative to the perpendicular drawn to the connection part 53 with the electrode plate group). In addition, between the back surfaces of the adjacent inter-cell connection portions 52, 52, a tapered gap of 6 ° in total is generated across the cell partition wall.

[0009] Therefore, when the connection portions 52, 52 between the cells are sandwiched between the electrode tips by the electrode tip and resistance welding is performed, the tapered gap is forcibly crushed and brought into a close contact state. Deformation is forced between the connection parts 53, 53 with the electrode plate group and the ear part of the electrode plate group. In order to improve the welding quality between the inter-cell connecting portions 52, 52, it is preferable that such deformation is small. For this purpose, the draft angle of the inter-cell connection 52 must be set as small as possible. However, since high machining accuracy cannot be obtained with an electric discharge cage, the draft angle must be set to at least about 3 ° as described above.

[0010] The present invention has been made in view of such a situation, and there are few factors that hinder the mold release operation and a high weld quality between the connection portions between cells, and an expensive mold release agent and extrusion pipe. The construction of the forging mold, insert, and the forging device that uses the forging mold and the pouring mechanism that can release the forged product without the need for a mold is simple and causes trouble. It is an object of the present invention to provide a float type forging apparatus and a forging method which can stably maintain the heating temperature and cooling temperature of the KUGUKU type and obtain a good forging quality.

Means for solving the problem

[0011] (1) The strap of the present invention is the lead-acid battery strap 1,

The inter-cell connection part 2 and the connection part 3 to the electrode plate group are formed in an L-shape corresponding to a substantially right angle, and both sides of the connection part 3 between the inter-cell connection part 2 and the electrode plate group 3 are strong. It is formed so as to be connected to the force straight, and the wall surfaces 2a, 2b, 2c of the inter-cell connecting part 2 are tapered taper angles. It is formed so that it may form.

[0012] According to such a configuration, since both side portions of the inter-cell connecting portion 2 and the connecting portion 3 to the electrode plate group are connected to the straight, there is a step that hinders the mold release operation as in the prior art. Eliminates mold release. In addition, since both sides of the connection part 3 between the cell connection part 2 and the electrode group 3 are straightened, it becomes easy to manufacture the cavity 6 for forming the strap 1 and the corner part (protrusion part). This eliminates the need for lead (raw material) and reduces the amount of light used.

[0013] (2) The taper angle is particularly preferably set to 0.6 ° to 1.0 °. In this way, it becomes easy to release the forged product (Strap 1). In addition, when resistance-welding the inter-cell connecting portions 2 and 2 facing each other with a partition wall therebetween, the gap between the inter-cell connecting portions 2 and 2 is reduced, so that the welding workability is improved and the remaining in the welded portion. Stress is less likely to occur and welding quality is improved. If the taper angle is smaller than 0.6 °, for example, when the strap 1 is formed by forging, it may be difficult to release the forged product from the mold. In addition, high machining accuracy is required to form cavity 6 and the machining conditions are too severe. On the other hand, if the taper angle is greater than 1.0 °, residual stress is likely to occur when resistance-welding the cell connection parts 2 and 2 together.

[0014] (3) In the forging die of the present invention, a through hole 5a having a draft upward and having no stepped portion is formed in the die body. The child 4 is detachably fitted upward, and a cavity 6 is formed on the child 4.

According to such a configuration, since the insert 4 fitted in the through hole 5a becomes the bottom of the cavity 6, it is not necessary to form the bottom of the cavity 6 in the forging mold 5. Therefore, the fabrication die 5 can be easily manufactured, and the through hole 5a can be formed by, for example, wire cutting. In that case, the surface finishing accuracy is remarkably improved, the draft angle can be set smaller than when the bottomed cavity is formed by conventional electric discharge machining, and the cost can be reduced. Since the insert 4 fitted to the bottom of the through hole 5a is in contact (contact) with the entire bottom of the manufactured product 1, the operation of releasing the insert 4 makes the manufactured product 1 stable. It can be released with good quality.

[0016] (4) The nesting of the present invention is the nesting 4 for forming the fabrication cavity 6;

Fitted to the bottom of the through-hole 5a formed in the forging mold 5 so as to be removable upward. Forming the cavity 6 thereon, and forming the fabricated article 1 with the cavity 6 and then releasing the fabricated article 1 when the insert 4 is removed from the through-hole 5a. It is characterized by.

According to such a configuration, since the bottom of the cavity 6 is formed by the insert 4, the forging die 5 can be formed only by forming the through hole 5 a in the forging die 5. For example, the through hole 5a can be formed by wire cutting. In that case, the surface finishing accuracy is significantly improved as compared with the case of the conventional discharge calorie, the draft angle can be set small, and the vertical shape can be formed at low cost.

[0018] Since the insert 4 can be detached from the through hole 5a in the mold release direction of the manufactured product 1, after the manufactured product 1 is manufactured, the insert 4 is removed from the through hole 5a (for example, by pushing up about 2 mm). With this operation, the manufactured product 1 can be released from the cavity 6. Since the insert 4 is in contact (contact) with the entire bottom of the manufactured product 1, the releasing operation of the manufactured product 1 when the insert 4 is released is stabilized, and the Releasability is greatly improved. Note that the forging die 5 may be moved downward to disengage the insert 4 from the through hole 5a. Examples of the manufactured product 1 include a lead-acid battery strap and a pole pole, but may be other parts and the like without being limited thereto.

[0019] (5) The forging apparatus of the present invention includes a mold supporting portion 23 for fixing and supporting the forging mold 5 described in the item (3), and a molten metal injection means 24 for injecting the molten metal 26 into the cavity 6. In addition, surplus molten metal removing means 25 for removing excess molten metal after pouring the molten metal 26 into the cavity 6 from the surface of the mold 5 for cooling, and cooling for cooling the molten metal 26 injected into the cavity 6 Cooling water supply means 12 for supplying water and release means 27 for separating the insert 4 from the through hole 5a are provided.

[0020] According to such a configuration, since the molten metal 26 is poured into the forging mold 5 fixedly supported, the injected molten metal 26 is spilled, and there is no poor injection of the molten metal 26. Since the insert 4 fitted into the bottom of the through hole 5a of the forging die 5 is in contact (contact) with the entire bottom of the manufactured product 1, the insert 1 is separated when the insert 4 is detached. The mold operation is stabilized, and the mold releasability of the fabricated product 1 is greatly improved. In addition, surplus molten metal removal means 25 removes molten metal burr 26 after pouring molten metal 26, so that surplus molten metal is removed. Product 1 releasability is improved. The mold release means 27 for separating the insert 4 from the through-hole 5a is used to fix the insert 5 and fix the insert 5 so that the insert 5 can be moved. Try moving child 4 4.

[0021] (6) The forging device of the present invention includes a melting tank 22 for storing the molten metal 26 in a heatable manner, and a mold support 23 for fixing and supporting the forging mold 5 in a floating island shape in the melting tank 22. And an elevating float 24 immersed in the molten metal 26 stored in the melting tank 22.

[0022] According to such a configuration, the molten metal 26 is poured into the cavity 6 by raising the molten metal surface by the operation of immersing the float 24 in the molten metal 26, so that the pouring mechanism is simple and the molten metal is pumped. Troubles such as clogging of molten metal in the pump and piping as in the conventional device that is pumped up and injected into the cavity do not occur. In addition, since the forging die 5 is fixed and supported in the melting tank 22, the operation of injecting the molten metal 26 into the cavity 6 is stabilized and the injection failure can be eliminated.

[0023] Further, since the molten metal 26 heated in the melting tank 22 is directly injected into the cavity 6, a heater (or a panner) for heating the molten metal 26 injected into the cavity 6 as in the prior art from outside. ) And other heating means are not required, the structure can be simplified, the occurrence of troubles can be reduced, and the heating temperature and cooling temperature of the forging mold 5 can be stably maintained. Quality is obtained. Since the molten metal 26 is not agitated, when the molten metal 26 is a Ca alloy, the generation of acid is suppressed. In addition, since all forging processes can be performed in the melting tank 22, the lead component (molten metal) is not taken out to the outside, and environmental measures are facilitated.

[0024] (7) The forging device of the present invention includes a melting tank 22 for storing the molten metal 26 in a heatable manner, and a mold support portion 23 for fixing and supporting the forging mold 5 in a floating island shape in the melting tank 22. The elevating float 24 that injects the molten metal 26 into the cavity 6 of the forging mold 5 by changing the degree of immersion in the molten metal 26 stored in the melting tank 22 and the cavity 6 A surplus melt removing means 25 for removing surplus melt after pouring the melt 26 from the surface of the mold 5 and cooling water for cooling the melt 26 poured into the cavity 6 are provided. The cooling water supply means 12 to be supplied and the fabricated product 1 formed in the cavity 6 are released from the mold. And a release means 27.

[0025] According to such a configuration, the molten metal 26 is poured into the cavity 6 by raising the surface of the molten metal by the operation of immersing the float 24 in the molten metal 26, so that the pouring mechanism is simple and the molten metal is pumped. Troubles such as clogging of molten metal in pumps and pipes, as in the case of conventional devices that are pumped up and injected into cavity 6, are eliminated. Also, since the forging die 5 is fixedly supported in the melting tank 22, the pouring operation of the molten metal 26 into the cavity 6 is stabilized and the injection failure can be solved.

[0026] Further, since the molten metal 26 heated in the melting tank 22 is directly injected into the cavity 6, a heater (or burner) for heating the molten metal injected into the cavity as in the prior art from the outside. It is possible to simplify the structure and reduce the occurrence of trouble, and it is possible to stably maintain the heating temperature and cooling temperature of the forging mold 5, thereby achieving good forging. Quality is obtained. Further, the surplus molten metal removing means 25 removes the surplus molten metal after pouring the molten metal 26 into the cavity 6 from the surface of the mold 5 for molding. Improves the forging quality. Since the molten metal 26 is not agitated and the float 24 is immersed in the molten metal 26, the contact area between the molten metal 26 and the atmosphere can be reduced. The generation of coagulum such as is suppressed. In addition, since all forging processes can be performed in the melting tank 22, it is easy to take environmental measures to prevent the lead component (molten metal) from being taken out.

(8) In the forging method of the present invention, the float 24 is immersed in the molten metal 26 stored in the melting tank 22 so as to be heatable, so that the floating method is fixedly supported in the melting tank 22 in a floating island shape. The molten metal 26 is injected into the cavity 6 of the mold 5.

[0028] According to such a method, the molten metal 26 is poured into the cavity 6 by raising the surface of the molten metal by the operation of immersing the float 24 in the molten metal 26, so that the pouring method is simple and the molten metal is pumped. Troubles such as clogging of molten metal in the pump and piping as in the conventional device that is pumped up and injected into the cavity do not occur. Since the forging mold 5 is fixedly supported in the melting tank 22, the mold is kept horizontal and the molten metal is poured into the cavity 6 by raising the molten metal surface. Because it can inject molten metal 26 around the whole area, The operation of pouring the molten metal 26 into the 6 is stable and the poor injection can be solved.

[0029] Further, since the molten metal 26 heated in the melting tank 22 is directly injected into the cavity 6, a heater (or burner) for heating the molten metal injected into the cavity as in the prior art from the outside. It is possible to simplify the structure and reduce the occurrence of trouble, and it is possible to stably maintain the heating temperature and cooling temperature of the forging mold 5, thereby achieving good forging. Quality is obtained. Since the molten metal 26 is not agitated, when the molten metal 26 is a Ca alloy, the generation of acid is suppressed. In addition, since all the forging processes can be performed in the melting tank 22, the lead component (molten metal) is not taken out to the outside, and environmental measures are facilitated.

[0030] (9) In the forging method of the present invention, the insert 4 is detachably fitted upward at the bottom of the through hole 5a formed in the mold body, and the cavity 6 is formed thereon, After pouring the molten metal 26 into the cavity 6 and forging the fabricated product 1, the fabricated article 1 is released from the cavity 6 by removing the insert 4 from the through hole 5 a. Features.

[0031] According to such a method, after the forged product 1 is forged, the insert 4 fitted in the through hole 5a is released from the through hole 5a, and the forged product 1 is released from the cavity 6. be able to . Since the insert 4 fitted to the bottom of the through-hole 5a is in contact (contact) with the entire bottom of the manufactured product 1, the mold 1 is released when the insert 4 is released. Will be stabilized and the releasability of the fabricated product 1 will be greatly improved. Further, since the through-hole 5a does not require a bottom, it is easy to form a saddle shape. For example, the through-hole 5a can be formed by wire cutting. In that case, the surface finishing accuracy is significantly improved compared to the case of forming a bottomed cavity by conventional electric discharge machining, the draft angle can be set small, and a vertical shape can be formed at a low cost. .

The invention's effect

[0032] In the strap according to the first aspect of the present invention, since both sides of the connection part between the inter-cell connection part and the electrode plate group are formed to be connected in a straight line, the conventional releasing operation is performed. There are no corners or steps that obstruct the process, making mold release easier. In addition, since both sides of the connection part between the inter-cell connection part and the electrode plate group are straightened, it is easy to manufacture the cavity for forming the strap and the corner part (protrusion part) is eliminated. Therefore, the amount of lead (raw material) used can be reduced, and light weight can be achieved. [0033] In the forging die of the present invention according to claim 3, the through hole for forging the forged product is formed without a step portion having a draft, so that the forming of the die is facilitated. For example, the through hole can be formed by wire cutting. In that case, the surface finishing accuracy can be significantly improved as compared with the case of the conventional electric discharge machining, and the cost can be reduced. However, since the insert fitted in the lower part of the through hole is in contact with the entire bottom of the manufactured product, the mold release operation of the manufactured product when the insert is released is stabilized. The releasability of the fabricated product is greatly improved. Therefore, a conventional extrusion pin and an expensive release agent are not required, and a forged product can be produced at a low cost.

[0034] In the insert according to the fourth aspect of the present invention, the bottom portion of the through hole in which the cavity is formed is detachably fitted in the mold release direction of the manufactured product, so that the bottom portion is formed in the through hole. Therefore, it becomes easy to form a saddle shape, and for example, a through hole can be formed by wire cutting. In that case, the surface finishing accuracy is remarkably improved as compared with the case of the conventional electric discharge machining, and the saddle shape can be formed at a low cost.

[0035] Since the insert can be removed in the mold release direction, the forged product can be released from the through-hole after the forged product has been manufactured. . However, since the insert is in contact (contact) with the entire bottom of the manufactured product, the release operation of the manufactured product is stable when the insert is released, and the release property of the manufactured product is stable. There is a marked improvement. Therefore, the conventional extrusion pin and expensive release agent are not required.

[0036] In the forging apparatus of the present invention according to claim 5, the molten metal is poured into the fixedly supported forging mold, so that the molten metal spills and the molten metal is not poorly injected. Since the insert fitted in the lower part of the through hole of the forging mold is in contact with the entire bottom of the forged product, the mold release operation of the forged product when the insert is released is stabilized. In addition, the mold releasability of forged products is significantly improved. In addition, surplus molten metal removal means the surface strength of the mold for casting after pouring the molten metal. The excess molten metal is removed, so that the occurrence of burrs can be suppressed, and the mold releasability of the fabricated product is improved and the quality of the fabrication is improved. To do.

[0037] In the forging device according to the sixth aspect of the present invention, the molten metal is poured into the cavity by raising the molten metal surface by the operation of immersing the float in the molten metal, so that the molten metal is pumped up and injected into the cavity. Trouble that clogs molten metal in the pump and piping No longer occurs. In addition, since the forging mold is fixedly supported in the melting tank, the molten metal pouring operation is stabilized and the poor pouring can be solved.

[0038] Further, since the molten metal heated in the melting tank is directly injected into the cavity, there is a heating means such as a heater (or a panner) for heating the molten metal injected into the cavity from the outside as in the prior art. This eliminates the need for simplification of the configuration, reduces the occurrence of trouble, and makes it possible to stably maintain the heating temperature and cooling temperature of the forging mold, thereby obtaining good forging quality. Since the molten metal is not agitated, when the molten metal is a Ca alloy, the generation of acid is suppressed. In addition, since all the forging processes can be performed in the melting tank, it is easy to take environmental measures that prevent the lead component (molten metal) from being taken out.

[0039] In the forging device of the present invention according to claim 7, the molten metal is pumped up by a pump and injected into the cavity to raise the molten metal surface by injecting the float into the molten metal and injecting the molten metal into the cavity. Therefore, the trouble that clogs the molten metal in the pump and the piping as in the conventional device does not occur. In addition, since the forging die is fixedly supported in the melting tank, the pouring operation of the molten metal into the cavity is stabilized and the injection failure can be eliminated.

[0040] Further, since the molten metal heated in the melting tank is directly injected into the cavity, there is a heating means such as a heater (or a panner) for heating the molten metal injected into the cavity from the outside as in the prior art. This eliminates the need for simplification of the configuration, reduces the occurrence of trouble, and makes it possible to stably maintain the heating temperature and cooling temperature of the forging mold, thereby obtaining good forging quality. Furthermore, surplus molten metal removal means removes the surplus molten metal after it has been poured into the cavity to remove the surface force of the mold, so that it is possible to suppress the occurrence of burrs and improve the mold releasability. The forged quality is also improved. And since a molten metal is not stirred, generation | occurrence | production of an acid soot is suppressed in the case of molten metal SCa alloy. In addition, since all forging processes can be performed in the melting tank, it is easy to take environmental measures that prevent lead components (molten metal) from being taken out.

[0041] In the forging method of the present invention according to claim 8, since the molten metal is poured into the cavity by raising the molten metal surface by the operation of immersing the float in the molten metal, the molten metal is pumped up by the pump and injected into the cavity. Therefore, the trouble that clogs the molten metal in the pump and the piping as in the conventional device does not occur. Since the forging die is fixedly supported in the dissolution tank, The operation of pouring the molten metal into the cavity becomes stable and the injection failure can be solved.

[0042] Further, since the molten metal heated in the melting tank is directly injected into the cavity, there is a heating means such as a heater (or a panner) for heating the molten metal injected into the cavity from the outside as in the prior art. This eliminates the need for simplification of the configuration, reduces the occurrence of trouble, and makes it possible to stably maintain the heating temperature and cooling temperature of the forging mold, thereby obtaining good forging quality. Since the molten metal is not agitated, when the molten metal is a Ca alloy, the generation of acid is suppressed. In addition, since all the forging processes can be performed in the melting tank, it is easy to take environmental measures that prevent the lead component (molten metal) from being taken out.

[0043] In the forging method of the present invention according to claim 9, after the forged product is forged, the forged product is released by releasing the insert fitted in the through hole. Since the inserted insert is in contact (contact) with the entire bottom of the manufactured product, the release operation of the manufactured product is stable when the insert is released and the release of the manufactured product is remarkably improved. To improve. Therefore, a conventional extrusion pin and an expensive release agent are not required, and a high-quality manufactured product can be manufactured at a low cost. In addition, since the through hole does not require a bottom, it is easy to form a bowl shape. For example, the through hole can be formed by wire cutting. In that case, the surface finishing accuracy is remarkably improved as compared with the case of the conventional electric discharge machining, and the vertical shape can be formed at low cost.

Brief Description of Drawings

FIG. 1 shows a strap according to an embodiment of the present invention, wherein (a) is a side view thereof, (b) is a front view, and (c) is a perspective view.

FIG. 2 shows the same insert, (a) is a side view thereof, and (b) is a perspective view.

FIG. 3 shows the strap, the insert and the forging mold, where (a) is a side view of the strap, (b) is a side view of the insert, and (c) is a cross-sectional view of the forging mold.

FIG. 4 is a plan view of the same forging mold.

FIG. 5 is a perspective view showing a state in which a strap is integrated with the electrode plate group.

FIG. 6 is a half sectional view of the battery.

FIG. 7 is a sectional view of the main part of the forging device.

FIG. 8 is a perspective view of the same. FIG. 9 shows the lifting mechanism of the float, in which (a) is a front view and (b) is a side view.

FIG. 10 shows the releasing means, where (a) is a front view, (b) is a side view, and (c) is a plan view.

FIG. 11 shows an example of a conventional strap formed by electric discharge machining, where (a) is a side view and (b) is a perspective view.

Explanation of symbols

[0045] 1 ... Fake product

2 · · · Connection between cells

3 ... Connection with electrode plate group

4 ... Nesting

5 ... Mold for mold

5a…; Through hole

6 ... Cabinetity

12. Cooling water supply means

22 ... Dissolution tank

23 ··· Mold support

24 ··· Melt injection method

25 .. Excess molten metal removal means

26 ··· Molten metal

27 ... Mold release means

BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, the strap, the insert, the forging die, the forging device, and the forging method according to the best embodiment of the present invention will be described in detail with reference to the drawings.

1 shows the strap 1, FIG. 1 (a) is a side view, FIG. 1 (b) is a front view, and FIG. 1 (c) is a perspective view. The strap 1 is formed in an L-shape in which the inter-cell connection portion 2 and the electrode connection portion (connection portion to the electrode plate group of the present invention) 3 correspond to substantially right angles, and the inter-cell connection portion 2 and the electrode It is formed so as to be connected to the force S straight on both sides of the connection part 3 and eliminates the step that becomes a demolding inhibiting factor.

[0047] Then, the back side 2a and the front side 2b of the inter-cell connecting portion 2 to be resistance-welded are the electrode connecting portion. For example, it has a draft angle with a taper angle of 1 ° (inclined taper angle) in the downward inward direction with respect to the perpendicular drawn to the connection surface 3a (or its back surface 3c), and is connected to the cell indirectly. Both side portions 2c and 2c of the portion 2 and the electrode connecting portion 3 also have a draft angle with a taper angle (tapered taper angle) of 1 ° downward in the figure. The front surface portion 3b of the electrode connection portion 3 has a draft angle that forms a taper angle of 2 ° inward in the figure. That is, all of the above-mentioned taper angles are formed so as to expand in the mold release direction (upward in the drawing) of the strap 1. In addition, the connection surface 3a and the back surface 3c of the electrode connection part 3 are set in parallel.

[0048] As described above, since both side portions of the inter-cell connecting portion 2 and the electrode connecting portion 3 are connected in a straight line, there is no step which hinders the releasing operation as in the prior art, and easy release of the cavity is possible. Become. In addition, the manufacturing of the cavity for forming the strap 1 is facilitated, and the protrusions are eliminated.Therefore, if the thickness of the inter-cell connection 2 and the electrode connection 3 is the same as before, lead (raw material) ) Can be reduced and light weight can be achieved.

[0049] Since the back side 2a of the inter-cell connecting portion 2 has a taper angle of 1 °, the inter-cell connecting portions 2 and 2 facing each other across the partition wall 8b (see Fig. 6) are connected to both sides. In addition, when resistance welding is performed by clamping at high pressure, the gap (2 °) between the cell connection parts 2 and 2 is reduced, so that the welding workability is improved and residual stress is generated in the welded part. , Welding quality is also improved. This point will be described later with reference to FIG.

FIG. 2 shows the insert 4, FIG. 2 (a) is a side view, and FIG. 2 (b) is a perspective view. This insert 4 is an upper surface 4a that contacts (contacts) the rear surface 3c of the electrode connection 3 of the strap 1, and the front side 2b of the intercell connection 2 of the strap 1 connected to the upper surface 4a. A side surface 4b that contacts (contacts) the side surface 4c, a side surface 4c that continues to the lower side, a side surface 4d that faces the side surface 4c, side surfaces 4f, 4f, and a bottom surface 4e formed between the side surfaces 4c, 4d.

[0051] The side surface 4c described above has, for example, a taper angle of 1 ° inward in the figure with respect to the perpendicular drawn on the upper surface 4a, and the side surface 4d has 2 inward in the figure with respect to the perpendicular. It has a draft angle with a taper angle of °. The side 4c and side 4d have different taper angles so that the insert 4 is inserted in the correct direction when inserted into the through hole 5a of the strap forging die 5 (see Fig. 3 (c)). be able to. Further, the side contact surface 4b that contacts (contacts) the front side 2b of the strap 1 is, for example, a pulling slope that forms a taper angle of 1 ° upward in the figure with respect to the perpendicular. Have a composition. On the other hand, both side surfaces 4f, 4f have a taper angle of 1 ° downward. As described above, each taper angle is formed so as to expand in the direction of removal of the insert 4 (upward in the figure).

[0052] Fig. 3 shows the strap 1, the insert 4 and the strap forging die (forging die of the present invention) 5. Fig. 3 (a) is a side view of the strap 1, and Fig. 3 (b). 3 is a side view of the insert 4 and FIG. 3 (c) is a side sectional view of the strap 1 and the insert 4 fitted into the through hole 5a of the strap forging die 5. FIG. The through-hole 5a formed in the strap forging mold 5 is composed of four side walls, and two opposing side walls 5b and 5c are tapered inwardly by 1 ° and 2 ° respectively in the downward direction in the figure (strap Two side walls (unsigned) formed so as to face each other between the side walls 5b and 5c have a taper of 1 ° downward. Make a corner (taper angle that expands in the release direction of strap 1).

[0053] Prior to the fabrication of the strap 1, first, when the insert 4 is inserted into the through hole 5a, it is prevented from being removed by the taper angles of the side walls 5b, 5c (1 °, 2 ° inward in the figure). At this time, the bottom (4e) of the insert 4 slightly protrudes from the through hole 5a. In this state, the cavity 6 for forming (molding) the strap 1 is formed in the space surrounded by the upper surface 4a and the side surface 4b of the insert 4 and the side walls 5b, 5c of the through hole 5a. The Fig. 3 (c) shows a state in which the strap 1 is fabricated in the cavity 6.

[0054] Since the bottom portion of the cavity 6 is formed by fitting the insert 4, the through hole 5a can be formed in a penetrating shape without a step portion having a draft, and a strap forging die For example, the through hole 5a can be formed by wire cutting. In that case, the surface finish accuracy is significantly improved compared to the case of conventional electric discharge machining, and as described above, the draft angle can be set small, and the strap forging die 5 is provided at a low cost. can do.

[0055] Since the insert 4 that forms the bottom of the cavity 6 can be detached in the direction of releasing the strap 1, after the strap 1 is manufactured, the insert 4 is detached upward from the through-hole 5a. The forged strap 1 can be released by pushing up the nest 4 about 2 mm upward. The nesting force 4 is in contact (contact) with the entire bottom of the strap 1 and the draft angle is set to be small. The mold operation is stabilized and the releasability of the strap is greatly improved. Therefore expensive No mold release agent is required and no extrusion pin is required, so that the forging apparatus can be simplified.

FIG. 4 shows a plan view of a strap forging die as the forging die 5. In the example shown in the figure, the mold body is provided with six through holes 5a in two rows (12 in total), and inserts 4 are fitted into the respective through holes 5a to form the cavity 6. Two cooling water passages (1 Kl la, l ib) are formed on both sides of the two rows of through-holes 5a, and one end of each is closed with plugs 14 and 14 after drilling, and each cooling water passage 11a, l Lower end force of ib Four cooling posts for supplying cooling water (cooling water supply means of the present invention) 12 are connected to the upper end opening of the cooling water passage 12a in the cooling water passage 12a.

[0057] Six guide pins 13 are erected on both side portions of the mold body, and the two guide pins 13 disposed in the central portion are used for positioning and formed in a stepped shape. As will be described later, the four guide bins 13 at both ends are hooked to a conveying means (not shown) so that each ear portion of the electrode plate group is uniformly immersed by a predetermined dimension (about 3 mm). A hooking piece 13a for projecting is provided. As described above, the through hole 5a of the strap forging mold 5 can be formed by wire cutting, but is not limited to this, and can be formed by other machining (milling, etc.). be able to.

FIG. 5 is a perspective view showing a state in which the strap 1 is integrated with the electrode plate group 7. In the electrode plate group 7, four positive electrode plates 71 and five negative electrode plates 72 are alternately overlapped with each other being insulated via separators 73. 71a are integrally formed in the connection surface 3a of the electrode connection 3 of one strap 1, and the ears 72a of the negative electrode plate 72 are integrated in the connection surface 3a of the electrode connection 3 of the other strap 1. I will be deceived. The ears 71a and 72a are integrated in a state where about 3 mm of the tip part enters the electrode connection part 3.

[0059] FIG. 6 shows the battery 8 as a final product. In the illustrated example, the casing 8a is partitioned by five partition walls 8b to form six cells 8c, and the inter-cell connection portions 2, 1 (back side of the straps 1, 1) facing each other across the partition walls 8b. 2a and 2a) are joined together by resistance welding. In the cell 8c on one end side (the right end in the figure), the ears 71a of the positive electrode plate 71 of the electrode plate group 7 are integrated with the pole column 9, and in the cell 8c (not shown) on the other end, the electrode plate group 7 The ears 7 2a of the negative electrode plate 72 are integrally connected to the pole columns 9, and the terminals 10 are connected to the respective pole columns 9, Terminal 10 is a positive electrode and the other terminal 10 is a negative electrode.

[0060] The taper angle of the back side 2a is set to 1 ° when resistance-welding the back side 2a and 2a of the straps 1 and 1 between the cells 1 and 2 facing each other across the partition wall 8b. Therefore, a total of 2 ° taper gaps are generated between the opposing back sides 2a and 2a, but the gap is much smaller than the conventional 6 ° angle. Therefore, when the back surfaces 2a and 2a are pressed together with the electrode tip, the deformation generated between the electrode connecting portion 3 of the strap 1 and the ear portions 71a and 72a of the electrode plate group 7 is extremely reduced. Accordingly, the generation of residual stress after welding is reduced, so that the welding quality is improved and the durability is improved.

[0061] If the above-mentioned inter-cell connection section 2 is formed so as to have a taper angle of 0.6 ° to 1.0 °, the adjacent inter-cell connection sections 2 and 2 that face each other are resisted. When welding, the gap between the connection parts 2 and 2 between the cells is reduced, so that the welding workability is improved, residual stress is generated in the welded part, and the welding quality is also improved. When the taper angle is smaller than 0.6 °, for example, when forming the strap 1 by forging, high processing accuracy is required for forming the cavity 6, and the processing conditions become too severe. If the taper angle is greater than 1.0 °, residual stress is likely to occur when resistance-welding the cell connection portions 2 and 2 together.

FIG. 7 is a cross-sectional view of a main part of a float type forging apparatus (forging apparatus of the present invention), and FIG. 8 is a perspective view thereof. As shown in these drawings, this float type forging apparatus is immersed in a melting tank 22 equipped with a heating device (not shown), a mold support 23 for fixing the forging mold 5, and a molten metal 26. Lifted float 24 and surplus molten metal for removing surplus molten metal 26 from the surface of forging mold 5 after pouring molten metal 26 into the mold 6 of the forging mold 5 (see FIG. 3 (c)) A removing means 25, a cooling post 12 (see FIGS. 4, 10 (a) and (b)) for supplying cooling water for cooling the molten metal 26 injected into the cavity 6, and formed in the cavity 6 are formed. Also, a vertical pulling device 27 as a mold release means for releasing the manufactured product (for example, strap) 1 is provided. In FIG. 7, L1 indicates the lower limit position of the molten metal surface 26, L2 indicates the upper limit position of the molten metal surface, and when the float 24 is in the solid line position, the molten metal surface of the molten metal 26 is at the lower limit position L1. Yes, when the float 24 is in the position of the two-dot chain line, the molten metal surface of the molten metal 26 is at the upper limit position L2.

[0063] The above-mentioned mold support part 23 is a vertical pull-in device 2 for detaching the insert 4 from the cavity 6. The mold 5 for casting is fixed and supported in a floating island shape between the lower surface level L1 and the upper surface level L2 of the molten metal 26. By removing the insert 4 (see Fig. 1 (c)) from the through hole 5a of the mold 5, the strap 1 is released from the cavity 6. In this way, by removing the insert 4 from the through hole 5a, the molded strap 1 can be stably released from the cavity 6. The configuration can be simplified. A floating island portion for fixing and supporting the forging die 5 in a floating island shape is denoted by reference numeral 22a in FIGS. 7 and 10 (a) and 10 (b).

[0064] The surplus molten metal removing means 25 for removing the surplus molten metal after pouring the molten metal 26 into the cavity 6 from the surface of the forging die 5 is provided along the support portion 45 horizontally mounted on the apparatus body. Alternatively, a removal plate 46, 46 that is driven back and forth in the horizontal direction by fluid pressure drive means such as hydraulic pressure (not shown) is provided, and the tip (lower end) of the removal plate 46 is in sliding contact with the surface of the forging die 5. It is configured to remove excess molten metal after the molten metal is injected. The surplus molten metal removing means 25 removes the surplus molten metal after the molten metal 26 has been injected, so that the occurrence of drought burrs can be suppressed, and the releasability is improved and the forging quality is also improved.

[0065] The float 24 is formed in a rectangular parallelepiped shape with, for example, SUS304 and is filled with a heat insulating material. For example, as shown in FIGS. 9 (a) and 9 (b), the float 24 is installed on the apparatus body. The lower end of the guide shafts 33 and 33 guided in the vertical direction by the slide bushes 32 and 32 provided in 31 and the jack 34 erected vertically between the two guide shafts 33 and 33 It is suspended at the lower end by bolt fastening or the like. The driven gear 35 attached to the input shaft of the jack 34 is connected to the drive gear 38 attached to the output shaft of the motor 37 mounted on the gantry 31 via the chain 36, and is connected to the float 24. Can be moved up and down at a predetermined speed.

[0066] For example, if the self-weight of the float 24 is approximately 71Kgf (about volume 0. 08m ^3), at a lifting speed of about 18 mm / sec, by setting the maximum stroke of about 140 mm, to ensure proper melt exclusion amount be able to. As the float 24 moves up and down, the degree of immersion (immersion) in the molten metal 26 is changed (increased) to change (increase) the amount of molten metal discharged to raise the molten metal surface. Forging die 5 fixedly supported on floating island 22a The molten metal 26 can be poured into the bitty 6 in a stable state. The initial amount of molten metal is set so that molten metal 26 does not overflow even when float 24 moves the maximum stroke.

[0067] In addition, a sensor bracket 39 is erected in the vicinity of one guide shaft 33, and proximity switches 40 and 41 are provided on the upper and lower portions, respectively, so that the collar fixed to one guide shaft 33 is fixed. The position of 42 can be detected, and when the collar 42 is shown in the figure (shown by a solid line), it is detected that the float 24 is at the upper limit position, and the collar 42 is at the lower position shown by the two-dot chain line. In some cases, float 24 is in the alarm position just before the lower limit position (upward), and when float 24 descends to this position, an alarm is issued, prompting the worker to prepare for ingot injection, and continuing operation The float 24 automatically stops at the lower limit position, preventing the production of forged products that could cause quality abnormalities.

[0068] Since the molten metal 26 is poured into the cavity 6 by raising the molten metal surface with such a float 24, the structure of the pouring mechanism is simple, and the conventional apparatus pumps the molten metal into the cavity by pumping it up. This prevents troubles such as clogging in the pump and piping. In addition, since the molten metal 26 heated in the melting tank 22 is directly injected into the cavity 6, there is a heating means such as a heater (or a panner) for heating the molten metal injected into the cavity as in the conventional case. This eliminates the need to simplify the configuration and reduce the occurrence of trouble in the heating system. In addition, the heating temperature and cooling temperature of the forging die 5 can be stably maintained, and good forging quality can be obtained.

[0069] The vertical pull-in device 27 is shown, for example, in FIGS. 10 (a) and 10 (b), and has four cooling posts (cooling water supply means of the present invention) 12 that are movable up and down and have cooling water passages 12a therein. The forging die 5 is fixed to the die support 23 provided on the upper side of the metal plate via a gasket, while the insert 4 (see FIG. 3 (c)) is fixed to the plate 45. The strap 1 is configured to be released from the cavity 6 when the insert 4 is moved slightly upward and released from the through hole 5a of the forging die 5 by the pushing-up operation.

More specifically, as shown in FIGS. 10 (a) and 10 (b), an under plate 47 is fixed to the lower part of the four cooling posts 12 and is erected at the center of the under plate 47. A shaft 49 is passed through the linear bush 48 so as to be movable up and down. A shaft for fixing and supporting the insert 4 via a connection plate 50 and a pipe 51 is provided above the shaft 49. A rate 45 is connected, and a latch member 52 is connected to the lower part of the shaft 49, and the latch member 52 is latched by a latch member 53 fixed to the output shaft of the air cylinder 46. Yes.

[0071] On the other hand, a pair of hook plates 54 and 54 hang down at positions on both sides of the linear bush 48 of the under plate 47, and the other ends of the hooked ends 54a and 54a are arranged directly below the air cylinder 46. It is latched by latching members 56, 56 fixed to the output shaft of the air cylinder 55. With such a configuration, in the forging process, as shown in the drawing, the forging die 5 and the insert 4 are pulled into the initial positions by both the air cylinders 46 and 55. Reference numeral 57 denotes a thermocouple for measuring the temperature of the forging die 5.

[0072] Next, a method of forging the strap 1 using the float-type forging device will be described. First, the insert 4 is fitted into the through hole 5a of the forging die 5 to form the cavity 6, and the conveying means is used. The forging die 5 is carried in and fixed to the die support 23 in a positioned state. At this time, the cooling water passages 12a of the cooling posts 12 are respectively connected to the cooling water passages 11a, rib of the forging die 5 (see FIG. 4 and FIG. 10 (c)). Next, the float 24 is immersed in the molten metal 26 heated to a predetermined temperature to a predetermined depth to raise the molten metal surface, and the molten metal 26 is poured into the cavity 6.

[0073] After the forging mold 5 reaches a predetermined temperature, the float 24 is pulled up to expose the surface of the forging mold 5, and the excess molten metal remaining on the surface is removed by the excess molten metal removing means 25. To do. Next, the ears (not shown) of the electrode plate group are immersed downward in the cavity 6 (about 3 mm) by the conveying means (not shown), and the cooling water is circulated in the cooling water passages 11a and ib. After cooling the mold 5 to a predetermined temperature, the air cylinder 46 of the mold retractor 27 is operated, and the insert 4 is pushed upward to release from the through hole 5a of the mold 5 The strap 1 with the ears of the electrode plate group integrated can be released from the cavity 6 with the strap 1 placed on the insert 4.

[0074] In the COS method using the forging die 5 using the insert 4 as described above, the strap 1 is removed by detaching the insert 4 from the through hole 5a of the forging die 5 by the saddle drawing device 27. Because the mold is released, the mold release operation is stable, the uncured strap 1 can be released without being deformed, and the mold release failure can be minimized without using a mold release agent. . Book In the embodiment, the force that moves the insert 4 upward by the vertical pull-in device 27 and separates it from the forging die 5 The moving die 5 moves downward to release the insert 4 Please do it.

[0075] Further, since the forging die 5 is fixed and supported in a floating island shape in the melting tank 22 by the float type forging device, the molten metal 26 that does not require the forging die 5 to be moved during the forging process is provided. Spilling is less likely to prevent filling errors (lead molten metal has a high specific gravity, so there is a risk of spilling if the mold 5 is slightly inclined or vibrated). When the electrode plate ears are immersed in the molten metal 26, a part of the molten metal 26 crawls along the surface of the ear and forms a meniscus, so the molten metal 26 is filled in the cavity 6 and the ears are filled. Even if the group is immersed, the molten metal 26 does not overflow, and the poor bonding of the electrode group ear due to the lack of molten metal is resolved

[0076] It should be noted that the present invention is not limited to the embodiments, and it is free to make design changes and improvements as appropriate according to the use conditions and the like without departing from the spirit of the invention. For example, the forged product 1 forged by the forging die 5 is not limited to the strap, and may be, for example, a pole column or other parts. Further, the cavity 6 formed in the forging die 5 may be formed in a concave shape with a bottom instead of a through hole.

Industrial applicability

[0077] The present invention is used in a technical field for manufacturing a lead storage battery (battery) strap and other parts mounted on various vehicles such as a single car, a passenger car, a truck, and a forklift.

Claims

The scope of the claims

[1] A strap (1) for a lead-acid battery,

The inter-cell connection part (2) and the connection part (3) with the electrode plate group are formed in an L shape corresponding to substantially a right angle, and the connection between the inter-cell connection part (2) and the electrode plate group Both side portions of the portion (3) are formed to be connected in a straight line, and the wall surfaces (2a, 2b, 2c) of the inter-cell connecting portion (2) are formed to have a tapered taper angle. Features a strap.

[2] The strap according to claim 1, wherein the taper angle is set to 0.6 ° to 1.0 °.

[3] A through hole (5a) is formed in the mold body with a draft angle upward without a stepped portion, and a nest (4) is formed at the bottom of the through hole (5a). The mold for forging is characterized in that the mold (6) is formed on the insert (4) so as to be detachably attached.

[4] A nesting (4) for forming a forging capability (6),

The cavity (5) is formed in the lower part of the through-hole (5a) so as to be detachable upward, and the cavity (6) is formed thereon, and the cavity (6) The nest is characterized in that the forged product (1) is released when it is removed from the through hole (5a) after the forged product (1) is formed.

[5] A mold support portion (23) for fixing and supporting the forging mold (5) according to claim 3, and a molten metal injection means (24) for injecting the molten metal (26) into the cavity (6). The excess molten metal removal means (25) for removing the excess molten metal (26) after pouring the molten metal (26) into the cavity (6) from the surface of the mold (5), and the cavity (6) A cooling water supply means (12) for supplying cooling water for cooling the injected molten metal (26), a mold release means (27) for releasing the insert (4) from the through hole (5a), and A forging device comprising:

[6] A melting tank (22) for storing the molten metal (26) in a heatable manner, and a mold support (23) for fixing and supporting the forging mold (5) in a floating island shape in the melting tank (22) And a lift type float (24) immersed in the molten metal (26) stored in the melting tank (22).

[7] A melting tank (22) for storing the molten metal (26) in a heatable manner, and a mold support (23) for fixing and supporting the forging mold (5) in a floating island shape in the melting tank (22) And stored in the dissolution tank (22). The float (24) that injects the molten metal (26) into the cavity (6) of the mold (5) by changing the degree of immersion in the molten metal (26), and the cavity (6 ) Removing the surplus molten metal after the molten metal (26) is poured from the surface of the mold (5), and the molten metal poured into the cavity (6) ( Cooling water supply means (12) for supplying cooling water for cooling 26), and mold release means (27) for releasing the fabricated product (1) formed in the cavity (6). A forging device characterized by comprising.

[8] Forging mold fixed and supported in a floating island shape in the melting tank (22) by immersing the float (24) in the molten metal (26) stored in the melting tank (22) so as to be heatable A forging method characterized by injecting the molten metal (26) into the cavity (6) of (5).

[9] An insert (4) is removably fitted to the bottom of the through hole (5a) formed in the mold body, and a cavity (6) is formed thereon, and the cavity (6 After the molten metal (26) is poured into the forged product (1), the insert (4) is also released from the through-hole (5a) force to remove the fabricated product (1) from the cavity (6). ) From the mold.