Note: Descriptions are shown in the official language in which they were submitted.
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Description
Technical Field
This invention relates to a metal sheet perforating
disk roll for making holes successively in a long belt-
like metal sheet or metal foil, a metal sheet perforating
device and a metal sheet perforating method which use the
same roll, and a perforated metal sheet produced by using
these metal sheet perforating device and metal sheet
perforating method.
Background Art
In recent years, the demand for a perforated metal
sheet in which a multiplicity of holes are made so that
the perforated metal sheet is used as a base for a
secondary battery electrode has increased. The perforated
metal sheet for a secondary battery electrode base is
wound with an active material deposited on a surface
thereof, and loaded into a battery case. The holes are
made in the metal sheet for the purpose of giving an
anchoring effect to the active material to promote the
adhesion thereof to the metal sheet, and also filling the
holes with the active material. In order to increase the
capacity of a battery, it is necessary to load the
largest possible quantity of active material into the
battery case, so that the thinnest possible metal sheet
is demanded as a metal sheet to be perforated and used
for an electrode base.
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A method of perforating a metal sheet by using a
dieing out press has heretofore been generally used as a
perforated metal sheet manufacturing method. However, in
a perforating method using a press, a metal sheet to be
perforated is necessarily fed intermittently, and
necessarily stopped when the metal sheet is pressed.
Moreover, it was very difficult to improve the
productivity of perforated metal sheets by increasing a
perforating speed while exerting a great force on the
press.
Japanese Patent Laid-Open No. 133936/1985 discloses
a method of continuously manufacturing perforated metal
sheets by rotating a perforating roller having a
multiplicity of projections as a method of improving the
productivity of perforated metal sheets by increasing a
perforating speed. The manufacturing of this metal sheet
is done in the following manner. Namely, first, a metal
sheet is passed continuously between a roller provided
with a multiplicity of saw-tooth-like projections on an
outer circumferential surface thereof and a receiving
roller, and holes are thereby perforated by the
projections with burrs raised at the same time. The
perforated metal sheet advances continuously, and the
burrs impinge upon an end of a scratch jig provided ahead
of the perforated metal sheet, the burrs being thereby
folded back. The metal sheet further advances
continuously, and is fed to a rolling roller provided
ahead thereof. The metal sheet is then rolled, and the
folded-back portions thereof eat into the metal sheet, so
that a burrless perforated metal sheet is formed. When
this perforated metal sheet manufacturing method is used,
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carrying out a continuous perforating operation becomes
possible, and a perforating speed increases to enable the
improvement of the productivity of perforated metal
sheets to be attained.
However, this method of continuously manufacturing a
perforated metal sheet by rotating the above-mentioned
projection-carrying perforating roller still had problems
to be solved.
Namely, the thickness of the burr-folded-back
portions becomes nearly two times that of the original
metal sheet. When this metal sheet is used as a
perforated metal sheet for a secondary battery electrode
base, the volume of the metal sheet itself increases when
the metal sheet with an active material deposited on a
surface thereof and wound is loaded into a battery case,
and the quantity of the active material loaded into the
battery jar therefore decreases correspondingly, so that
this method is not preferable to increase the capacity of
the battery.
When the thickness of the folded-back portions is
set equal to that of the other portion of the metal sheet
by increasing a rolling force, the folded-back portions
only are rolled extremely and elongated since the
thickness of these portions is nearly two times as large
as that of the other portion of the metal sheet.
Therefore, the distance between the holes made by a
perforating operation increases to cause the density of
the holes to decrease. When a metal sheet having such
holes is used as a perforated metal sheet for a secondary
battery base, the anchoring effect becomes insufficient,
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and the quantity of the active material packed in the
holes decreases, so that such a perforated metal sheet is
not preferable.
The present invention has been made in view of the
above-mentioned circumstances, and provides a metal sheet
perforating disk roll capable of perforating a
multiplicity of uniform holes successively in a long
belt-like metal sheet, especially, very thin metal foil
used as a secondary battery electrode base while keeping
the thickness of the metal sheet uniform; a metal sheet
perforating device and a metal sheet perforating method
which use the disk roll; and a perforated metal sheet
produced by using the metal sheet perforating device and
metal sheet perforating method.
Disclosure of the Invention
One aspect of the present invention is to provide a
metal sheet perforating disk roll formed with a plurality
of perforating blades provided on an outer
circumferential surface thereof in a circumferentially
spaced manner and in a radially projecting state,
the shape in plan of each perforating blade on the
outer circumferential surface of the disk roll is set to
a geometric shape surrounded by one closed line,
the shape in side elevation of side surfaces of the
perforating blade being set concave so that the height of
both of circumferential end portions of the blade becomes
larger than that of the other portion thereof with the
height of the blade becoming gradually smaller from the
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two circumferential end portions thereof toward a central
portion thereof, characterized in that:
the shape in side elevation of side surfaces of the
perforating blade is set so that the height of a
preceding circumferential end portion thereof with
respect to the rotational direction of the disk roll
becomes smaller than that of a posterior circumferential
end portion thereof with respect to the same direction.
Brief Description of the Drawings
Fig. 1 is a schematic diagram showing an example of
the condition of a metal sheet being perforated by using
a metal sheet driving disk roll according to the present
invention;
Fig. 2 is a perspective view showing an example of
the shape of perforating blades provided in a projecting
state on an outer circumferential surface of the metal
sheet driving disk roll according to the present
invention;
Fig. 3 is a schematic diagram showing another
example of the condition of a metal sheet being
perforated by using the metal sheet perforating disk roll
according to the present invention;
Fig. 4 is a schematic diagram showing a mode of
perforating a metal sheet in a metal sheet perforating
operation using the metal sheet perforating disk roll
according to the present invention;
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Fig. 5 is a schematic diagram showing an example of
a perforating unit of the metal sheet perforating device
according to the present invention;
Fig. 6 is a schematic diagram showing an example of
the metal sheet perforating device according to the
present invention;
Fig. 7 is a schematic diagram showing another
example of the perforating unit of the metal perforating
device according to the present invention;
Fig. 8 is a schematic diagram showing another
example of the metal sheet perforating device according
to the present invention; and
Fig. 9 is a schematic diagram showing still another
example of the metal sheet perforating device according
to the present invention.
Best Mode for Carrying Out the Invention
The present invention will now be described in
detail with reference to the drawings.
A metal sheet perforating disk roll according to the
present invention is provided so as to make a
multiplicity of holes in a metal sheet or metal foil of
around 0.02 to 0.2 mm in thickness.
As shown in Fig. 1, the disk roll 1 is provided on
an outer circumferential surface thereof with a plurality
of perforating blades 2 in a circumferentially spaced
manner and in a radially outwardly projecting state.
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The shape in plan of each perforating blade on the
outer circumferential surface of the disk roll, i.e. a
cross-sectional shape of a perforated hole is set to a
geometrical shape surrounded by one closed line. In this
embodiment, this shape is set rectangular.
As shown in Figs. 1 and 2, the shape in side
elevation of each perforating blade 2 is set concave so
that the height of front and rear edges 21, 22 thereof
constituting both circumferential end portions of the
perforating blade becomes larger than that of the other
portions thereof with the height of the perforating blade
becoming gradually smaller from the front and rear edges
21, 22 toward a central portion thereof.
As shown in Fig. 2, the perforating blade 2 is
formed so that both side edges 23 thereof, which
correspond to the portions of both-side closed lines
opposed to each other in the circumferential direction of
the disk roll 1, project lower than an imaginary straight
line 24 connecting together the front and rear edges 21,
22 which correspond to the portions of both-side closed
lines which are opposed to each other in the direction of
the thickness of the disk roll 1.
The shape in plan of the perforating blade 2, i.e.
the cross-sectional shape of the perforated hole can also
be set to a substantially rectangular shape with its four
corner portions rounded besides an accurate rectangular
shape having the front edge 21, rear edge 22 and side
edge 23 as shown in Fig. 2.
The front and rear edges 21 and 22 constituting the
two circumferential end portions on the outer
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circumferential surface of the disk roll 1 of the
perforating blade 2 can be formed so that the height of
the front edge 21 thereof, a circumferentially preceding
end portion which eats into the metal sheet or metal foil
(which will hereinafter be referred to generically as a
metal sheet) 10 first in accordance with the rotation of
the disk roll 1 as shown in Fig. 3 is smaller than that
of the rear edge 22 thereof, a circumferentially
posterior end portion which is thereafter eats into the
metal sheet 10. Since the shape in side elevation of the
driving blade 2 is set in this manner, the front edge 21
and rear edge 22 can be made so that these edges eat into
the metal sheet 10 at once as shown in Fig. 3.
The shape in plan of the perforating blade 2 can
also be formed to other shapes, for example, desired
geometric shapes, such as an elongated circular shape, an
elliptic shape, a right circular shape, a rhomboidal
shape, or a substantially rhomboidal shape with its four
corner portions rounded, etc. in accordance with the
property of the metal sheet instead of setting the shape
to the above-mentioned rectangular shape and a
substantially rectangular shape.
The construction of the metal sheet perforating
device according to the present invention will now be
described with reference to Fig. 6.
As shown in the drawing, the metal sheet perforating
device includes a perforating unit 20, upper and lower
pinch rolls 6a, 6b provided on the front side and rear
side of the perforating unit 20 as tensile force
application means, and tensile force application units 30
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having 17a, 17b. On the other hand, the perforating unit
20 is formed by providing on the outer circumferential
surfaces of the upper and lower rolls 11, 12 with
perforating blades 2 in a circumferentially spaced
manner.
As shown in Fig. 9, upper and lower bridle rolls
16a, 16b and 17a, 17b may also be used as the tensile
force application means.
In the metal sheet perforating device having the
above-described construction, the perforating portion 2
can have the construction shown, for example, in Fig. 5.
Namely, as shown in Fig. 5, a pair of disk rolls 3
the radius of each of which is set shorter than a
distance between the center of the metal sheet
perforating disk roll 1 and the lowest portion (lowest
portion of the side edge 23) of the edge of the
perforating blade 2 by at least a length corresponding to
the thickness of the metal sheet 10 are connected
coaxially as upper side guide rolls to both sides of the
metal sheet driving disk roll 1 to form an upper roll
unit 11.
A disk roll the thickness of which is slightly
larger than that of a disk of the metal sheet perforating
disk roll 1 is provided as a guide roll 4, and a pair of
disc rolls 5 the radius of each of which is set larger
than that of the guide roll 4 by at least a length
corresponding to the sum of the thickness of the metal
sheet 10 and a difference between an amount of projection
of the highest portion (front edge 21 or rear edge 22) of
the perforating blade 2 and that of projection of the
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lowest portion (side edge 23) thereof being connected to
both sides of the guide roll coaxially to form a lower
roll unit 12.
The above-mentioned upper roll unit 11 and lower
roll unit 12 are engaged with each other, the perforating
unit 20 being thereby formed.
Another example of the perforating unit 20 of the
metal sheet perforating device according to the present
invention will be shown in Fig. 7. As shown in the
drawing, the perforating unit 20 is formed by the metal
sheet perforating disk roll 1 and guide roll 4 arranged
in a vertically symmetric manner with respect to the
center of the metal sheet 10. The guide roll 4 having a
thickness slightly larger than that of the disk of the
metal sheet perforating disk roll 1 is provided on the
portions of the outer circumferential surface thereof
which are opposed to the plural perforating blades 2
formed so as to project in the radially outward direction
with a plurality of recesses 42 each of which has a
cross-sectional shape identical with the shape in plan
(i.e. the shape of a cross section of a perforated hole)
of the perforating blade 2.
The guide roll 4 of an elastic material, such as
rubber can also be formed of a disk having a flat outer
circumferential surface without forming a recessed
portion 42 having a cross section identical with that of
the perforated hole as mentioned above. In this case, the
perforating blade 2 provided on the metal sheet
perforating disk roll 1 eats into the outer
circumferential portion of the upper roll unit 12 during
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a perforating operation, and the outer circumferential
portion of the guide roll 4 is elastically deformed in
accordance with the shape of the perforating blade 2.
However, when the hole perforating operation finishes to
cause the perforating blade 2 to be disengaged from the
guide roll 4, the shape of the perforating blade 2 is
restored to that of a disk having the original flat outer
circumferential surface.
In order to make a plurality of rows of holes in the
metal sheet 10 so that the holes are parallel spaced in
the widthwise direction, a metal sheet perforating device
can also be formed by connecting a plurality of sets of
upper rolls 11 and lower rolls 12, which constitute the
above-mentioned perforating unit 20, to each other
coaxially in the axial direction of each roll shaft as
shown in Fig. 8.
The perforating blade 2 in the present invention is
formed on the outer circumferential surface of the disk
roll 1 in a radially outwardly projecting state so as to
be spaced at regular intervals in the circumferential
direction as shown in Fig. 1. When the disk roll 1 is
rotated, the metal sheet 10 provided with unperforated
hole portions at regular intervals is subjected to
p'erforating. It is also possible to provide some of
adjacent perforating blades 2 at intervals larger than
those of the other thereof instead of providing the
perforating blades on the outer circumferential surface
of the metal sheet at regular intervals in the
circumferential direction thereof. Namely, it is possible
to form a disk roll 1 having no perforating blades 2 on a
part of the outer circumferential surface thereof, and
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perforate the metal sheet 10 by rotating the resultant
disk roll so that the metal sheet has in the lengthwise
direction thereof unperforated hole portions spaced at
predetermined intervals larger than those of the other
perforated portions. Thus, it becomes possible to provide
unperforated portions at regular intervals larger than
those of the other unperforated portions, and cut the
metal sheet 10 at the greatly spaced unperforated portion
thereof. Especially, when the sheet perforating device
formed as mentioned above, by connecting a plurality of
sets of the upper roll 11 and lower roll 12, which
constitute the perforating unit 20, to each other
coaxially in the axial direction of each roll, is used to
perforate holes in the metal sheet 10 in a staggered
manner in the widthwise direction thereof, an object
portion of the metal sheet 10 can be cut irrespective of
the presence of the staggeringly arranged perforated
portions on the metal sheet. When the metal sheet 10 is
used as a core of a battery, it is possible to provide
unperforated portions, the intervals of which are larger
than those of other portions, at predetermined intervals
so that the distance between perforated portions agrees
with the length of the core needed for one battery. This
enables the metal sheet 10 to be cut without causing both
of lengthwise end portions thereof to fall on perforated
portions. Such intervals of the unperforated portions
that are larger than those of the other unperforated
portions can be changed arbitrarily by selecting the
diameter of the disk roll.
A method of making a multiplicity of holes
successively in a metal sheet 10 by using the metal sheet
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perforating disk roll 1 according to the present
invention and the metal sheet perforating device
according to the present invention will now be described
with a case where the shape in plan (cross-sectional
shape of a perforated hole) of a perforating blade 2 of
the metal sheet perforating disk roll 1 is rectangular
taken as an example will now be described with reference
to Fig. 4.
According to the present invention, a metal sheet of
around 0.02 to 0.2 mm in thickness, and, especially,
extremely thin metal foil of not larger than 0.1 mm in
thickness is perforated.
As described above, the metal sheet perforating
device according to the present invention includes as
shown in Fig. 6 a perforating unit 20, a pair of pinch
rolls 6a and 6b provided ahead of the perforating unit
20, and a tensile force application units 30 formed of a
pair of pinch rolls 7a and 7b provided at the back of the
perforating unit 20. As mentioned above, the pinch rolls
may be replaced with upper and lower bridle rolls as
shown in Fig. 9.
In order to perforate the metal sheet 10, first, a
tensile force is applied to the portion of the metal
sheet 10 which is between the pinch rolls 6a and 6b and
7a and 7b which constitute tensile force application
means. The metal sheet 10 is passed continuously between
the upper and lower rolls 6a, 6b and upper and lower
rolls 7a, 7b which constitute the perforating unit 20 and
tensile force application unit 30 with the tensile force
applied condition maintained.
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When the metal sheet 10 with a tensile force applied
thereto is brought into contact with the metal sheet
perforating disk roll 1, the upper roll 11 of the
perforating unit, first, a front edge 21 of a perforating
blade 2 and a part of a side edge 23 extending from the
f ront edge 21 eat into the metal sheet 10 as shown in
Fig. 4 i) to cause a break to occur.
When the metal sheet perforating disk roll 1 is
further rotated, the mentioned part of the side edge 23
extending from the front edge 21 of the perforating blade
2 further eats into the metal sheet as shown in Fig. 4
ii), and the break stretches with the rear edge 22 of the
perforating blade 2 and the part of the side edge 23
which extends from the rear edge 22 eating into the metal
sheet 10 to cause a break to occur.
When the metal sheet perforating disk roll 1 is
further rotated, the mentioned part of the side edge 23
extending from the front edge 21 of the perforating blade
2 further eats into the metal sheet as shown in Fig. 4
iii), and the break stretches with the mentioned part of
the side edge 23 which extends from the rear edge 22 of
the perforating blade 2 further eating into the metal
sheet to cause the break to stretch. The break in the
side edge 23 thus comes to stretch from both sides, i.e.,
from the front edge 21 and rear edge 22.
When the metal sheet disk roll 1 is further rotated,
the break in the side edge 23 extending from both the
front edge 21 and rear edge 22 are joined together as
shown in Fig. 4 iv), and a hole of a rectangular shape is
formed in the metal sheet 10.
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When the metal sheet disk roll 1 is further rotated,
a subsequent perforating blade 2 eats into the metal
sheet 10, and a rectangular hole is formed in the same
manner as mentioned above.
When the metal sheet perforating disk roll 1 is thus
rotated, rectangular holes can be formed successively in
the metal sheet 10 in a spaced manner.
When in this case the height of the front edge 21
forming a preceding circumferential end portion which
eats into the metal sheet 10 first in accordance with the
rotation of the disk roll 1 is set lower than that of the
rear edge 22 forming a posterior circumferential end
portion which thereafter eats into the metal sheet 10 as
shown in Fig. 3, it becomes possible to have the front
edge 21 and rear edge 22 eaten into the metal sheet 10 at
once, and make rectangular holes in the metal sheet 10
more accurately and reliably.
In the case where a metal sheet perforating
operation is carried out in practice with a tensile force
not applied to the metal sheet 10, which is made of,
especially, metal foil of an extremely small thickness of
not larger than 0.1 mm, the rigidity of the metal sheet
lowers even when the height of the portions constituting
intermediate portions between the front edge 21 and rear
edge 22 is set lower than those of the front and rear
edges 21, 22 as shown in Fig. 2, i.e., even when a metal
sheet perforating disk roll 1 in which the portion of the
blade corresponding to the side edge 23 projects lower
than an imaginary straight line connecting together the
apexes of the portions of the blade which correspond to
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the front edge 21 and rear edge 22 is used. As a result,
it becomes difficult to have the portions of the blade
which correspond to the front edge 21 and rear edge 22
eat into the metal sheet, and make accurately shaped
holes successively. Therefore, it is preferable to give a
tensile force to the metal sheet 10 when metal foil of
extremely small thickness of not larger than 0.1 mm is
perforated.
When a method of moving the metal sheet 10 so that
the metal sheet winds round a part of the outer
circumference of the guide roll 2 (lower roll 12) as
shown in Fig. 9, and perforating the metal sheet with the
metal sheet 10 brought into close contact with the lower
roll 12 is used, metal foil of an extremely small
thickness of not larger than 0.1 mm can be perforated
more reliably. In this case, the upper and lower bridle
rolls 16a and 16b and 17a and 17b, which serve as tensile
force application means, and upper roll 11 and lower roll
12 are provided in the positional relation which permits
the metal sheet to advance along a part of the outer
circumference of the guide roll 2 (lower roll 12), and
not in the positional relation shown in Fig. 9, i.e., not
in the positional relation in which the metal sheet 10 is
moved linearly between the perforating unit 20 and
tensile force application units 30 as shown in Fig. 6.
Fig. 5 and Fig. 7 show a case where holes are formed
in one row in a metal sheet 10. As shown in Fig. 8, it is
possible to form a metal sheet perforating device by
arranging a plurality of sets of lower rolls 12 and upper
rolls 11, which constitute a metal sheet perforating
unit, coaxially in the axial direction of the rolls, and
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make in a metal sheet 10 a plurality of widthwise
arranged rows of substantially rectangular holes
successively in a lengthwise spaced manner. When in this
case the intervals of perforating blades 2 of adjacent
metal sheet perforating disk rolls 1 are mutually
regulated, making holes in an arbitrary arrangement, such
as a staggered arrangement and a latticed arrangement and
the like can be done.
The perforated metal sheet having a multiplicity of
holes according to the present invention can be made by
using the above-mentioned metal sheet perforating device
having a metal sheet perforating disk roll 1, and the
above-mentioned metal sheet perforating method. The
perforated metal sheet having a multiplicity of holes
according to the present invention can be formed by
making uniform holes successively and accurately in,
especially, metal foil of an extremely small thickness of
not larger than 0.1 mm. Since such a perforated metal
sheet does not have projecting portions, such as folded-
back portions and the like, the metal sheet is suitable
for a base for a secondary battery electrode.
(Embodiment)
30 sets of metal sheet perforating disk rolls (upper
rolls) were prepared each of which was formed of a disk
of alloy tool steel (SKS1) of 1 mm in thickness and 80 mm
in diameter and provided on its outer circumferential
surface with 60 perforating blades so that the blades
were spaced at 1.59 mm intervals and projected in the
radially outward direction, each of which blades had a
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rectangular perforating section of 2.6 mm in
circumferential length and 1 mm in width.
Each of the perforating blades was formed in a
projecting manner so that the height (maximum height) of
rectangular front edge and rear edge projecting at front
and rear portions of the blade with respect to the
direction of the thickness of the disk roll became 1 mm
with the height (minimum height) of the centers of side
edges projecting at left and right portions of the blade
with respect to the circumferential direction 0.5 mm so
as to vary the height of the front edge - the centers of
the side edges - the rear edge continuously and
arcuately.
31 sets of disk rolls (upper side guide rolls) of 80
mm in diameter formed of alloy tool steel (SKS1) of 1 mm
in thickness were prepared. The metal sheet perforating
disk rolls and side guide rolls were arranged alternately
and coaxially so that the rolls at both ends became side
guide rolls with the distance between each side guide
roll and each metal sheet perforating disk roll becoming
0.05 mm, by inserting spaces therebetween and thereby
regulating the distance, to form upper rolls.
On the other hand, 30 sets of disk rolls (guide
rolls) of 80 mm in diameter were prepared from alloy tool
steel (SKS1) of 1.1 mm in thickness. Also, 31 sets of
disk rolls (lower side guide rolls) of 81 mm in diameter
were prepared from alloy tool steel (SKS1) of 1 mm in
thickness. The guide rolls and side guide rolls were
arranged alternately and coaxially so that the rolls at
both ends became side guide rolls, to form lower rolls.
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The upper rolls and lower rolls thus prepared were
engaged with each other to form a perforating unit. The
perforating blades of adjacent upper rolls were lined so
as to stagger the blades thereof by a half pitch in the
circumferential direction so that the holes formed after
a perforating operation were arranged in a staggered
manner.
Moreover, a pair of bridle rolls were provided at
each of the front and rear sides of this perforating unit
in such positional relation that permitted a metal sheet
to advance so as to wind round a part of the outer
circumference of the lower roll of the perforating unit
as shown in Fig. 9, to form tensile force application
units. The rotational speed of the front bridle roll was
set slightly higher than that of the rear bridle roll so
that a tensile force be applied at all times to the
portion of the metal sheet which is between the two
bridle rolls. Thus, the metal sheet perforating device
was formed.
A long belt-like nickel plated steel foil of 0.035
mm in thickness and 65 mm in width was then perforated by
using the above-mentioned metal sheet perforating device.
The rotational speeds of the bridle roll in front of the
tensile force application unit, bridle roll at the back
thereof and upper and lower rolls of the perforating unit
were set respectively so that the steel foil advances at
a speed of 1 m/sec. The rotational speeds of the bridle
rollers were set so that 2 kgf tensile force was exerted
on the portion of the metal sheet which was between the
front bridle roll and rear bridle roll. Thus, rectangular
holes of 2.6 mm in length and 1 mm in width were made
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successively at 1.59 mm intervals in the lengthwise
direction, and nickel plated steel foil having 30 rows of
holes made in a staggered manner at 1.1 mm intervals in
the widthwise direction thererof was obtained.
Industrial Applicability
The present invention relates to a metal sheet
perforating device and a metal sheet perforating method
which use a metal sheet driving disc roll provided on an
outer circumferential surface thereof with a plurality of
perforating blades arranged in a circumferentially spaced
manner and in a radially projecting state. Using the
metal sheet perforating device and metal sheet
perforating method according to the present invention has
enabled a multiplicity of uniform holes of a constant
depth to be made successively in a long belt-like metal
sheet, especially, long belt-like metal foil used for a
base for a secondary battery electrode.
