JP4453799B2

JP4453799B2 - Batteries for battery electrode plate and apparatus for manufacturing the same

Info

Publication number: JP4453799B2
Application number: JP2002057580A
Authority: JP
Inventors: 義臣藤原
Original assignee: GS Yuasa Corp
Current assignee: GS Yuasa Corp
Priority date: 2002-03-04
Filing date: 2002-03-04
Publication date: 2010-04-21
Anticipated expiration: 2022-03-04
Also published as: JP2003257435A

Description

【０００１】
【発明の属する技術分野】
本発明は、ロータリ式エキスパンダによって製造される電池極板用格子体及びその製造装置に関する。
【０００２】
【従来の技術】
鉛蓄電池の極板は、鉛又は鉛合金からなる格子体のマス目に活物質を充填したものである。この格子体は、鉛又は鉛合金の鋳造等によって直接格子状に作製する他に、鉛又は鉛合金からなる鉛シートにエキスパンダによってマス目を形成して作製する場合がある。そして、このエキスパンダには、ダイスカッタの上下動作によって鉛シートに両端部から順に各マス目を形成するレシプロ方式と、円板カッタの回転によって鉛シートに千鳥状のスリットを形成し、この鉛シートを両側から引き広げることによりスリットをマス目に展開するロータリ方式とがある。
【０００３】
上記ロータリ方式のエキスパンダ（ロータリ式エキスパンダ）で用いる円板カッタ１は、図８に示すように、金属製の円板の周縁部に、周方向の長さが比較的長い山部１ａと比較的短い谷部１ｂとをこの周方向に沿って交互に多数配置したものである。各山部１ａには、円板カッタ１の軸心を中心として所定半径の基準円周面からさらに外周方向に向けて山形に突出した周側面が形成されている。なお、図８の楕円形の拡大図の中では、この基準円周面を平面に展開して示している。各谷部１ｂは、この基準円周面からなる周側面が形成されている。また、これらの各谷部１ｂには、山部１ａを介して隣り合う両側の谷部１ｂとは表裏逆の円板面の周縁部に、当該谷部１ｂの周側面に開口する凹溝１ｃが形成されている。即ち、円板カッタ１の表裏双方の円板面には、それぞれ１つおきの谷部１ｂに凹溝１ｃが形成されていて、一方の円板面に凹溝１ｃが形成された谷部１ｂと他方の円板面に凹溝１ｃが形成された谷部１ｂとが円周上に交互に並んで配置されるようになっている。これらの凹溝１ｃは、谷部１ｂの周長とほぼ同じ幅を有すると共に、円板カッタ１の板厚のほぼ半分の深さを有する円板カッタ１の円板面に形成された溝であり、一端はこの谷部１ｂの周側面に開口すると共に、他端は円板カッタ１の軸心側に向けてある程度の長さにわたって形成されている。
【０００４】
上記円板カッタ１は、多数枚をそれぞれこの円板カッタ１の厚さとほぼ同じ間隔ずつ離して共通の回転軸上に並べて固定することにより円板カッタロール２を形成する。そして、図９に示すように、こような円板カッタロール２を２本上下に配置して、これらの間に鉛シート３を通すことにより千鳥状のスリット３ａを多数形成する。この際、図１０（ａ）（ｃ）に示すように、上下の円板カッタ１は、谷部１ｂ同士がわずかに重なり合うような高さ位置に配置されると共に、下方の各円板カッタ１の間に上方の各円板カッタ１が挟まるように、軸方向に半ピッチだけずらして配置される。また、図１０（ａ）に示すように、下方の円板カッタ１における一方の側（図では右側）の円板面に凹溝１ｃが形成された谷部１ｂが上端に達したときに、上方の円板カッタ１における他方の側（図では左側）の円板面に凹溝１ｃが形成された谷部１ｂが下端に達するように、回転方向の位相も調整される。従って、図１０（ｂ）に示すように、下方の円板カッタ１の山部１ａが上端に達したときには、上方の円板カッタ１も山部１ａが下端に達するようになり、図１０（ｃ）に示すように、下方の円板カッタ１における他方の側（図では左側）の円板面に凹溝１ｃが形成された谷部１ｂが下端に達したときに、上方の円板カッタ１における一方の側（図では右側）の円板面に凹溝１ｃが形成された谷部１ｂが下端に達するようになる。
【０００５】
上記下方の円板カッタロール２の軸方向の両端には、最端円板カッタ４がそれぞれ配置されている。この最端円板カッタ４は、図１１及び図１２に示すように、周縁部に山部４ａと谷部４ｂとが交互に配置されている。そして、谷部４ｂとこの谷部４ｂに形成される凹溝４ｃの構成は、通常の円板カッタ１の谷部１ｂや凹溝１ｃと全く同じであるが、山部４ａには、基準円周面からなる周側面が形成されている。即ち、この最端円板カッタ４は、山部４ａが外周方向に向けて山形に突出するようなことはなく、谷部４ｂも、この山部４ａに比べて相対的に窪んだ形状とはならない。このような最端円板カッタ４は、上方の円板カッタロール２の両端にある通常の円板カッタ１よりもさらに外側に隣接するように、下方の円板カッタロール２の両端に並べて配置される。
【０００６】
上記構成の円板カッタロール２の間に鉛シート３を通すと、図１０（ｂ）及び図９に示すように、上下の円板カッタ１の山部１ａが重なり合うことによって鉛シート３が切断されスリット３ａが形成されると共に、この鉛シート３の幅方向に隣接する別のスリット３ａとの間に形成される細長い桟３ｂが上下の山部１ａに押されて交互に鉛シート３のシート面から上下方向に山形に突出する。また、上下の円板カッタ１の谷部１ｂでは、図１０（ａ）（ｃ）及び図９に示すように、凹溝１ｃ同士が背中合わせになった隣接部分では、これらの谷部１ｂの周側面同士がわずかに重なり合うことにより鉛シート３が切断されてスリット３ａが連続的に形成されるが、凹溝１ｃ同士が向かい合わせになった隣接部分では、これらの凹溝１ｃによって谷部１ｂの周側面同士が重なり合わずに鉛シート３が切断されないので、スリット３ａが途切れて結節部３ｃが形成されることになる。従って、鉛シート３に形成されるスリット３ａは、山部１ａに押された山形の桟３ｂの２山分のものが、結節部３ｃで途中途切れながら移送方向に連続的に形成される。また、鉛シート３上で幅方向に隣接するスリット３ａは、この結節部３ｃが半ピッチずれた位置で形成されるので、これらのスリット３ａは、図９の円内に平面図で示すように千鳥状となる。
【０００７】
上記円板カッタロール２の両端では、図１０（ｂ）に示すように、下方の円板カッタロール２における最端円板カッタ４の山部４ａと、上方の円板カッタロール２における両端の円板カッタ１の山部１ａとが重なり合うことによって、これらの間の鉛シート３が切断されてスリット３ａが形成され、桟３ｂが下方に山形に突出する。また、図１０（ａ）（ｃ）に示すように、下方の両端の最端円板カッタ４の谷部４ｂと、上方の両端の円板カッタ１の谷部１ｂとにおける凹溝１ｃと凹溝４ｃとが背中合わせになった隣接部分（図１０（ａ）では右端、図１０（ｃ）では左端）でも、谷部１ｂ，４ｂがわずかに重なり合うことによって鉛シート３が切断されてスリット３ａが連続的に形成される。しかしながら、下方の両端の最端円板カッタ４の谷部４ｂと、上方の両端の円板カッタ１の谷部１ｂとにおける凹溝１ｃと凹溝４ｃとが対向面側に形成されて向かい合わせになった隣接部分（図１０（ａ）では左端、図１０（ｃ）では右端）では、これらの凹溝１ｃ，４ｃによって谷部１ｂ，４ｂの周側面同士が重なり合わずに鉛シート３が切断されないので、結節部３ｃと同様の最端結節部３ｄが形成される。ただし、この最端結節部３ｄは、外側の端にスリット３ａが形成されないので、鉛シート３の幅方向の両端部に形成される額縁部３ｅにそのまま繋がることになる。
【０００８】
上記のようにして多数のスリット３ａが形成された鉛シート３は、ロータリ式エキスパンダの後工程において幅方向の両側に引き広げられることにより、図１３に示すように、これらのスリット３ａをマス目状に展開されて、各結節部３ｃや最端結節部３ｄの間が斜め方向に引き出された４本の桟３ｂによって繋がった格子状の格子体が形成される。なお、実際には、展開時に桟３ｂに引っ張られて各結節部３ｃがねじれ方向に傾くことになるが、図１３では、このようなねじれを省略して模式的に示している。
【０００９】
【発明が解決しようとする課題】
ところが、上記鉛シート３の結節部３ｃや最端結節部３ｄは、図１０（ａ）（ｃ）に示すように、幅方向の両側を凹溝１ｃが向かい合わせになった上下の円板カッタ１や最端円板カッタ４の谷部１ｂ，４ｂによって上下逆方向に押圧されるので、この幅方向の両側で鉛シート３の厚さ分以上に上下方向に大きく変形すると共に、この最端結節部３ｄの鉛シート３が変形に伴って延ばされ薄くなる。そして、このような鉛シート３を幅方向の両側に引き広げると、上下方向に変形し薄くなった結節部３ｃや最端結節部３ｄから引き出された桟３ｂが横方向に引っ張られて斜めに折れ曲がることにより展開が行われるので、この結節部３ｃや最端結節部３ｄに応力が集中して腐食や発熱により桟３ｂとの間に断線を起こす可能性が高くなる。しかも、極板の集電を行う格子体の耳部が形成される鉛シート３の額縁部３ｅに繋がる最端結節部３ｄでこのような桟３ｂの断線が発生すると、それよりも幅方向に他方側の極板部分が他の迂回経路を介して耳部と繋がることになるので、電流が極めて流れ難くなり、その部分の活物質が有効に利用されなくなったり、迂回経路上の電流が増加して発熱を起こす等の不都合が極めて大きくなる。なお、最端結節部３ｄ以外の結節部３ｃでも、桟３ｂの断線が発生すると、同様にその結節部３ｃより他方側の極板部分の電流が流れ難くなるが、耳部が形成される額縁部３ｅから遠い結節部３ｃほどこの影響は極端に小さくなる。
【００１０】
このため、従来は、鉛シート３の額縁部３ｅに繋がる最端結節部３ｄが他の結節部３ｃと同様に桟３ｂの断線を生じ易かったために、この最端結節部３ｄでの断線によって容量が大幅に低下する電池が多くなるという問題が生じていた。
【００１１】
本発明は、かかる事情に対処するためになされたものであり、最端円板カッタの谷部の周側面を中心寄りに窪ませることにより、最端結節部の変形が小さくなり桟の断線が生じ難い電池極板用格子体及びその製造装置を提供することを目的としている。
【００１２】
【課題を解決するための手段】
請求項１の発明は、円板の周縁部に、この円板の回転軸を中心とする所定半径の基準円周面からさらに外周方向に向けて山形に突出した周側面が形成された山部と、この基準円周面にほぼ沿った面からなる周側面が形成された谷部とが円周方向に交互に全周にわたって形成されると共に、各谷部ごとに、山部を介して隣り合う両側の谷部で表裏逆となる片方の円板面の周縁部に、当該谷部の周側面に開口する凹溝が形成された円板カッタを、間隔を開けて同軸上に複数枚並べて円板カッタロールとし、この円板カッタロ−ルを２本以上対向させて配置した間に金属シートを通すことにより、この金属シートに千鳥状のスリットを多数形成するロータリ式エキスパンダを用いた電池極板用格子体の製造装置において、対向する円板カッタロールによる切断面が、搬送面上を搬送される金属シートのシート厚の中間部分に一致するように設定可能であり、これらの円板カッタロールにおける最も外側に円板カッタを配置したものに対向する円板カッタロールに、当該最も外側の円板カッタよりもさらに外側に円板状の最端円板カッタを配置し、この最端円板カッタにおける谷部（最端円板カッタの場合、同じ円板カッタロールに配置された円板カッタの各谷部に対応する周縁部を「谷部」という）のうちで、金属シートを介して対向する他の円板カッタロールの円板カッタの谷部がこの最端円板カッタ側を向く円板面に凹溝を形成したものとなる場合のもの（以下「最端結節部形成谷部」という）に、基準円周面よりも軸の中心寄りに金属シートのシート厚の３０％以上７０％以下窪んだ周側面が形成されたことを特徴とする。
【００１３】
通常の結節部は、金属シートを介して対向する円板カッタロールの双方の円板カッタの谷部の周側面が、これらの円板カッタロールの軸間の中央の切断面を超えるまで両側からそれぞれ押圧するので、この金属シートのシート厚以上の変形が発生することになる。しかしながら、請求項１の発明によれば、最端円板カッタの最端結節部形成谷部の周側面が基準円周面よりも窪んでいるので、金属シートを介して対向する円板カッタの谷部の周側面が最端結節部の端部側を切断面を超えて押圧しても、この最端円板カッタの最端結節部形成谷部の周側面は、最端結節部の基部側を切断面の手前までしか押圧しないようになる。このため、最端結節部の変形が小さくなるので、ここから引き出される桟が断線し易くなるのを確実に防止することができる。
【００１４】
上記最端結節部形成谷部の周側面は、金属シートのシート厚の３０％以上７０％以下だけ、所定半径の円周面よりも中心寄りに窪んだものである。例えば最端結節部形成谷部の周側面をシート厚の２０％だけ窪ませると、最端結節部の変形はシート厚の８０％を超えたものとなり、従来と大きな差を生じさせることができない。また、最端結節部形成谷部の周側面をシート厚の８０％まで窪ませると、最端結節部の変形はシート厚の２０％を超えた程度に納めることができるが、最端円板カッタの最端結節部形成谷部以外の谷部では、円板カッタロールの間の切断面を超えるまで金属シートを押圧してスリットを形成し、通常は山部（最端円板カッタの場合、同じ円板カッタロールに配置された円板カッタの各山部に対応する周縁部を「山部」という）でも同様となるので、これらの部分と最端結節部形成谷部との間にシート厚の８０％程度の段差が生じることになる。これに対して、最端結節部形成谷部の周側面の窪みをシート厚の５０％前後の大きさにすれば、最端結節部の変形もその周囲の金属シートとの段差も５０％前後の最適な大きさにすることができるので、シート厚の３０％以上７０％以下の窪みとしている。
【００１５】
なお、上記最端円板カッタの各谷部には、必ずしも凹溝を形成する必要はない。即ち、最端円板カッタの最端結節部形成谷部以外の各谷部の凹溝は、この最端円板カッタの外側を向く円板面に形成されるものであるため、反対側の外側端に配置する最端円板カッタと部品を共通化する場合を除けば、設ける必要は全くない。これに対して、最端円板カッタの各最端結節部形成谷部の凹溝は、この最端円板カッタの内側を向く円板面に形成されるものであり、金属シートを介して対向する円板カッタの谷部の凹溝との間で最端結節部を形成するスペースが必要となるので、通常は設けることが好ましい。しかし、請求項１の発明の場合、最端結節部形成谷部は周側面が窪んでいるので、この窪みを十分に大きくすれば、対向する円板カッタの谷部の凹溝との間に十分なスペースを確保することができ、最端結節部に無理な変形を加えることにはならないため、必ずしも凹溝を設けなくても済むようになる。
【００１６】
また、上記最端円板カッタにおける最端結節部形成谷部を除いた各谷部及び／又は各山部の周側面には、外側ほど中心寄りとなる傾斜面が形成されていることが好ましい。最端円板カッタの最端結節部形成谷部以外の谷部では、円板カッタロールの間の切断面を超えるまで金属シートを押圧してスリットが形成され、通常は山部でも同様となるので、周側面が窪んだ最端結節部形成谷部との間に段差が生じ、金属シートの額縁部に段状のうねりが生じることがある。しかしながら、最端結節部形成谷部以外の谷部や山部の周側面が傾斜面になっていれば、金属シートの額縁部を緩やかに撓ませることができる。
【００１７】
また、上記最端円板カッタの各山部には、基準円周面の周側面又はこの基準円周面よりも中心寄りの周側面が形成されることが好ましい。最端円板カッタの山部の周側面が円板カッタと同様に山形に突出していると、その外側にはスリットを形成しないので、金属シートの額縁部の縁を不必要に上下に押圧して変形させることになる。また、通常の円板カッタの山部の山形に突出した周側面は、円板カッタロールの間の切断面を大きく超えて金属シートを押圧するので、これに対向する最端円板カッタの山部の周側面は、切断面を超えていなくても、ほとんどの場合にこの金属シートを切断することができる。そこで、この最端円板カッタの山部の周側面は、基準円周面に形成すればよく、例えば最端結節部形成谷部の周側面と同じ程度に中心寄りとなる周側面を形成すれば、金属シートの額縁部の縁に大きなうねりが生じるのを防ぐこともできる。
【００１８】
請求項２の電池極板用格子体の製造装置は、前記最端結節部形成谷部の周側面に、内側ほど軸の中心寄りとなる傾斜面が形成されたことを特徴とする。
【００１９】
最端結節部形成谷部に凹溝が形成されていない場合、周側面が基準円周面よりもわずかに窪んだ程度であると、金属シートを介して対向する円板カッタの谷部の凹溝内のスペースだけで最端結節部が変形されることになるので、変形量が大きいときにこの変形が急激になりすぎるおそれがある。しかし、請求項２の発明によれば、最端結節部形成谷部の周側面に傾斜面が形成されるので、最端結節部をこの傾斜面に沿って緩やかに変形させることができるようになる。また、最端結節部形成谷部に凹溝が形成されている場合であっても、周側面に傾斜面があれば、最端結節部の変形をさらに緩やかにすることができる。
【００２０】
請求項３の電池極板用格子体は、請求項１又は２に記載の製造装置によって製造されたことを特徴とする。
【００２１】
請求項３の発明によれば、最端結節部から引き出される桟が断線し難い電池極板用格子体となる。
請求項４の電池極板用格子体の製造方法は、請求項１又は２に記載の製造装置によって電池極板用格子体を製造することを特徴とする。
請求項４の発明によれば、最端結節部から引き出される桟が断線し難い電池極板用格子体を製造することができる。
【００２２】
【発明の実施の形態】
以下、本発明の実施形態について図面を参照して説明する。
【００２３】
図１〜図７は本発明の一実施形態を示すものであって、図１は上下の円板カッタロールの円板カッタによって鉛シートにスリットが形成される過程を示す部分拡大縦断面正面図、図２は最端円板カッタの構成を示す側面図、図３は最端円板カッタの構成を示す部分拡大斜視図、図４は鉛シートに形成されたスリットを展開した格子体における最端結節部付近を示す部分拡大斜視図、図５は山部の周側面に傾斜面を形成した最端円板カッタを用いて鉛シートにスリットが形成される過程を示す部分拡大縦断面正面図、図６は谷部の周側面を円周面とした最端円板カッタを用いて鉛シートにスリットが形成される過程を示す部分拡大縦断面正面図、図７は山部の周側面を窪ませた最端円板カッタを用いて鉛シートにスリットが形成される過程を示す部分拡大縦断面正面図である。なお、図８〜図１３に示した従来例と同様の機能を有する構成部材には同じ番号を付記する。
【００２４】
本実施形態は、従来例と同様に、鉛蓄電池の極板に用いる格子体を製造するためのロータリ式エキスパンダについて説明する。このロータリ式エキスパンダは、図９に示したように、上下の円板カッタロール２の間に鉛シート３を通すことにより、この鉛シート３に千鳥状のスリット３ａを形成する。上方の円板カッタロール２は、従来例と同じ構成である。また、下方の円板カッタロール２も、多数の円板カッタ１の両端に最端円板カッタ４を並べた構成は従来例と同じであるが、これらの最端円板カッタ４の構成が従来例とは異なる。
【００２５】
本実施形態の最端円板カッタ４も、図２及び図３に示すように、周縁部に山部４ａと谷部４ｂとが交互に配置されていることは、従来例と同じである。ただし、最端円板カッタ４における山部４ａと谷部４ｂは、同じ円板カッタロール２に配置された円板カッタ１の各山部１ａや谷部１ｂに対応する周縁部を示し、必ずしも形状が山状とや谷状とはならない。即ち、山部４ａには、最端円板カッタ４の軸心を中心とした所定半径の基準円周面からなる周側面が形成されていて、谷部４ｂも、これら山部４ａの間の凹状の部分とはならない。また、この谷部４ｂには、従来例のような凹溝４ｃは形成されず、交互に配置された一方の谷部４ｂ（最端結節部形成谷部）には、基準円周面よりも中心寄りに窪んだ周側面であって内側に傾斜した内側傾斜面４ｄが形成されると共に、他方の谷部４ｂには、外側に傾斜した外側傾斜面４ｅが形成されている。即ち、この一方の谷部４ｂの周側面は、最端円板カッタ４の外側円板面（図２の背面、図３の右手前面）に接する部分が、この最端円板カッタ４の軸心を中心として基準円周面の所定半径よりも鉛シート３のシート厚の５０％分だけ半径の小さい円周面に一致し、これよりも最端円板カッタ４の内側円板面（図２の正面、図３の左背後面）に近付くほど半径が小さくなるテーパ面の一部からなる内側傾斜面４ｄを形成している。従って、この一方の谷部４ｂは、両側に隣接する基準円周面からなる周側面を形成した山部４ａよりも一段窪んだ中心寄りの周側面が形成されると共に、この周側面は、最端円板カッタ４の内側の円板面に向けてより中心寄りに傾斜した内側傾斜面４ｄからなることになる。ただし、この内側傾斜面４ｄは、必ずしもテーパ面の一部である必要はなく、山部４ａの周側面より窪み内側に傾斜した面であれば、加工の都合等によって平面やその他の曲面であってもよい。
【００２６】
上記最端円板カッタ４における他方の谷部４ｂ（最端結節部形成谷部以外の谷部）は、最端円板カッタ４の内側円板面に接する部分が所定半径の基準円周面に一致し、これよりも最端円板カッタ４の外側円板面に近付くほど所定半径よりも半径が小さくなるテーパ面の一部からなる外側傾斜面４ｅを形成している。従って、この他方の谷部４ｂは、両側に隣接する基準円周面からなる周側面を形成した山部４ａと最外径は同じであるが、外側円板面側に斜め方向の切り欠きを設けることにより外側傾斜面４ｅを形成した形状となる。ただし、この外側傾斜面４ｅも、必ずしもテーパ面の一部である必要はなく、外側円板面に近付くほど所定半径の周側面よりも中心寄りに傾斜した面であれば、加工の都合等によって平面やその他の曲面であってもよい。
【００２７】
上記構成の最端円板カッタ４は、上方の円板カッタロール２の両端にある通常の円板カッタ１よりもさらに外側に隣接するように、下方の円板カッタロール２の両端に並べて配置される。また、これらの最端円板カッタ４の最端結節部形成谷部となる谷部４ｂは、上端において鉛シート３を介して対向する上方の円板カッタロール２の円板カッタ１の谷部１ｂが対向面側に凹溝１ｃを形成したものとなるように回転方向の位相が調整される。鉛シート３は、これら上下の円板カッタロール２の間を搬送されて通過する。この際、従来は、上下の円板カッタロール２の間の切断面Ｓに一致する搬送面上に鉛シート３を乗せて搬送していたが、本実施形態では、この搬送面を切断面Ｓよりも鉛シート３のシート厚の５０％分だけ低くした。即ち、従来は、上下の円板カッタロール２の切断面Ｓが、鉛シート３の搬送面、つまりこの鉛シート３の下面に一致するように設定されていたが、本実施形態では、上下の円板カッタロール２の切断面Ｓが、搬送面上を搬送される鉛シート３のシート厚の中間部分に一致するように設定される。なお、切断面Ｓは、上下の円板カッタロール２の軸心からの距離が等しくなる平面をいい、上下の円板カッタ１の谷部１ｂの周側面を構成する基準円周面の所定半径は、この軸心から切断面Ｓまでの距離よりもわずかに大きい径となる。従って、上方の円板カッタ１の谷部１ｂの周側面は、下端部にあるときに、この切断面Ｓをわずかに超えて下方に達するようになり、下方の円板カッタ１の谷部１ｂの周側面と、最端円板カッタ４の山部４ａの周側面と、この最端円板カッタ４の最端結節部形成谷部以外の谷部４ｂの周側面の最外周端は、この切断面Ｓをわずかに超えて上方に達するようになる。
【００２８】
上記上下の円板カッタロール２の間に鉛シート３を通すと、上下の円板カッタ１の谷部１ｂ同士が切断面Ｓで重なり合う場合には、図１（ａ）（ｃ）に示すように、隣接する上下の円板カッタ１において凹溝１ｃが背中合わせになる部分で鉛シート３が切断されてスリット３ａが形成され、凹溝１ｃ同士が向かい合う部分では鉛シート３が切断されずに結節部３ｃが形成される。また、最端円板カッタ４の谷部４ｂが最端結節部形成谷部である場合、即ち、隣接する上方の円板カッタ１の凹溝１ｃと向かい合わせになる場合（図１（ａ）では左端、図１（ｃ）では右端）には、鉛シート３の額縁部３ｅに繋がった最端結節部３ｄが形成される。最端結節部３ｄは、鉛シート３の幅方向の一方（図１（ａ）では左方向、図１（ｃ）では右方向）が額縁部３ｅにそのまま繋がると共に、他方端は上方の円板カッタロール２における最も端の円板カッタ１の谷部１ｂと、下方の円板カッタロール２における最端円板カッタ４を除いた最も端の円板カッタ１の谷部１ｂとによって切断された部分であり、この他方端部が上方の円板カッタ１の谷部１ｂによってほぼ切断面Ｓまで押圧されるので、搬送面上を搬送される鉛シート３は、この最端結節部３ｄの他方端部がシート厚の５０％分だけ下方に押し下げられて変形する。これに対して通常の結節部３ｃは、従来と同様に一方端部と他方端部が上下方向からそれぞれ同じ切断面Ｓを超えるまで押圧されるので、シート厚の１００％分以上の上下方向の変形が生じる。しかも、この最端結節部３ｄは、最端円板カッタ４の谷部４ｂ上の部分が内側傾斜面４ｄに沿って搬送面から緩やかに折れ曲がるので、他方端部の変形はさらに緩やかなものになる。
【００２９】
さらに、最端円板カッタ４の谷部４ｂが最端結節部形成谷部ではない場合、即ち、隣接する上方の円板カッタ１の谷部１ｂが凹溝１ｃの背中側で対向する場合（図１（ａ）では右端、図１（ｃ）では左端）には、上方の円板カッタロール２における最も端の円板カッタ１の谷部１ｂとの間で鉛シート３の額縁部３ｅの端が切断されてスリット３ａが形成される。しかも、この額縁部３ｅの端部は、最端円板カッタ４の谷部４ｂ上の部分が外側傾斜面４ｅに沿って搬送面から緩やかに折れ曲がるようになっている。
【００３０】
上下の円板カッタ１の山部１ａ同士が重なり合う場合には、図１（ｂ）に示すように、隣接する上下の円板カッタ１の間で鉛シート３が切断されてスリット３ａが形成されると共に、これらの円板カッタ１の山部１ａによってスリット３ａ間の桟３ｂが上下方向に押圧される。即ち、桟３ｂは、従来と同様に、鉛シート３の搬送方向に沿って上下方向の山形に押圧されることになる。また、最端円板カッタ４の山部４ａ上の鉛シート３は、内側で隣接する上方の円板カッタ１との間で切断されて額縁部３ｅの端部になると共に、この山部４ａによって切断面Ｓまでシート厚の５０％分押し上げられる。
【００３１】
上記のようにして多数のスリット３ａが形成された鉛シート３は、ロータリ式エキスパンダの後工程において幅方向の両側に引き広げられることにより、図４に示すように、これらのスリット３ａをマス目状に展開されて、各結節部３ｃや最端結節部３ｄの間が斜め方向に引き出された４本の桟３ｂによって繋がった格子状の格子体が形成される。なお、図４でも、図１３と同様に、結節部３ｃや桟３ｂのねじれを省略して模式的に示している。
【００３２】
上記構成によれば、鉛シート３における最端結節部３ｄの上下方向の変形がシート厚の半分程度のものとなるため、この最端結節部３ｄへの応力の集中が緩和され、展開によって桟３ｂが斜め方向に引っ張られた後も、この最端結節部３ｄで腐食や発熱が発生し難くなり、通常の結節部３ｃに比べて桟３ｂが断線するようなことがほとんどなくなる。従って、鉛シート３の額縁部３ｅに最も近い桟３ｂが断線し難くなるので、鉛蓄電池の容量が大幅に低下するのを確実に防止できるようになる。
【００３３】
なお、上記実施形態では、最端結節部形成谷部となる谷部１ｂの最外径が、所定半径よりも鉛シート３のシート厚の５０％分だけ小さくなるような径に形成される場合を示したが、この最外径が所定半径よりも小さければ、必ずしもシート厚の５０％分である必要はない。ただし、この最外径が所定半径よりも小さくなる割合が減少するに従って、最端結節部３ｄの上下方向の変形量が増加する。また、逆にこの最外径が所定半径よりも小さくなる割合が増加すると、最端結節部形成谷部以外の谷部１ｂで鉛シート３を切断する位置との間の上下方向の高さ位置の差が大きくなりすぎる。しかも、この最外径が所定半径よりもシート厚の１００％分以上に小さくなると、最端結節部形成谷部となる谷部１ｂの周側面で鉛シート３の最端結節部３ｄを支持することができなくなる。従って、この最端結節部形成谷部となる谷部１ｂの最外径は、鉛シート３のシート厚の３０％以上７０％以下の範囲内で所定半径よりも小さくすることが好ましい。
【００３４】
また、上記実施形態では、最端円板カッタ４の山部４ａの周側面を基準円周面とした場合について示したが、図５に示すように、この山部４ａの周側面を最端結節部形成谷部以外の谷部４ｂの外側傾斜面４ｅと同様の傾斜面とすることもできる。そして、この場合は、最端円板カッタ４の山部４ａと最端結節部形成谷部以外の谷部４ｂの周側面が連続した同じ傾斜面となり、最端結節部形成谷部となる谷部４ｂの周側面にのみ逆方向に傾斜した内側傾斜面４ｄが形成されることになる。
【００３５】
また、上記実施形態では、最端円板カッタ４の谷部４ｂの周側面に内側傾斜面４ｄと外側傾斜面４ｅを形成する場合について示したが、図６に示すように、これらの谷部４ｂの周側面を共に円周面とすることもできる。図６では、最端結節部形成谷部となる谷部４ｂ（図６の左端）の周側面を所定半径よりもシート厚の１００％分だけ小さい半径の円周面とし、最端結節部形成谷部以外の谷部４ｂ（図６の右端）の周側面を所定半径の基準円周面としている。最端結節部形成谷部となる谷部４ｂの周側面は、例えば基準円周面の所定半径よりもシート厚の５０％分だけ小さい円周面としてもよいが、その場合には、本実施形態のような内側傾斜面４ｄを形成したときに比べ、最端結節部３ｄが狭い範囲で急に変形することになる。即ち、最端結節部３ｄの上下方向の変形量は同じであっても、円板カッタロール２の軸方向のより狭い範囲内で急激に変形が行われることになる。もっとも、本実施形態では、最端円板カッタ４には、凹溝４ｃを形成しないようにしているが、この最端円板カッタ４にも従来のような凹溝４ｃを形成した場合には、谷部４ｂの周側面の内側が階段状に落ち込むため、この周側面を基準円周面の所定半径よりもシート厚の５０％分だけ小さい円周面としても、最端結節部３ｄの変形が急峻になるようなことはなくなる。即ち、この凹溝４ｃによる段差が、本実施形態の谷部４ｂにおける内側傾斜面４ｄや外側傾斜面４ｅと同様に、鉛シート３を緩やかに変形させることができるようになる。
【００３６】
以上のように、最端円板カッタ４における最端結節部形成谷部となる谷部４ｂの周側面は、最外径が所定半径よりも小さければ足り、円周面である必要はなく、この円周面にほぼ沿った平面であったり、本実施形態のようなテーパ面やこのテーパ面にほぼ沿った平面の傾斜面であってもよい。また、凹溝４ｃを形成した場合のような階段状であってもよく、任意の曲面やその他の面であってもよい。これに対して、最端結節部形成谷部以外の谷部４ｂは、上方の円板カッタ１の谷部１ｂとの間で鉛シート３を切断するために、少なくとも内側端の外径が所定半径以上であり切断面Ｓを超えるような径である必要がある。しかし、この条件が満たされれば、この最端結節部形成谷部以外の谷部４ｂの周側面も、どのような面が形成されていてもよい。
【００３７】
また、上記実施形態では、最端円板カッタ４の山部４ａの周側面が所定半径の基準円周面である場合を示したが、図７に示すように、この山部４ａの周側面を所定半径よりもシート厚の５０％分だけ小さい径の円周面とすることもできる。この場合、山部４ａの周側面は、本実施形態の最端結節部形成谷部となる谷部４ｂの内側傾斜面４ｄにおける外側端の最外径と同じ径になる。この山部４ａも、上方の円板カッタ１の山部１ａとの間で鉛シート３を切断する必要があるが、この上方の円板カッタ１の山部１ａは山形に下方に突出するので、下方の最端円板カッタ４の山部４ａの周側面をこのように所定半径よりも小さい径の円周面とすることができる。ただし、上方の円板カッタ１の山部１ａの山形の両裾部分は下方への突出量が少なくなるので、この部分では鉛シート３を切断するために、山部４ａの周側面の径を大きくする必要が生じる可能性はある。
【００３８】
また、上記実施形態では、最端円板カッタ４を下方の円板カッタロール２の両端に配置する場合について説明したが、これらの最端円板カッタ４は、片方又は双方を上方の円板カッタロール２の片端や両端に配置することもできる。さらに、対となる円板カッタロール２は２本以上用いることもでき、例えば３本の円板カッタロール２を配置した間に鉛シート３を通すようにすることもできる。
【００３９】
また、上記実施形態では、鉛シート３における最端結節部３ｄに繋がる桟３ｂとその他の結節部３ｃに繋がる桟３ｂとが同じ太さに形成される場合について説明したが、最端結節部３ｄに繋がる桟３ｂの太さだけを特に太く形成するようにして、この桟３ｂがさらに断線し難くなるようにすることもできる。
【００４０】
また、上記実施形態では、鉛シート３を加工して鉛蓄電池の極板に用いる格子体を製造する場合について説明したが、極板の集電基材に同様の格子体を用いるものであれば、鉛蓄電池に限らず任意の電池にも実施可能であり、この電池の種類に応じた適宜な材質の金属シートを用いて格子体を製造することができる。
【００４１】
【実施例】
上記実施形態で説明した最端円板カッタ４と従来例で示した最端円板カッタ４とを下方の円板カッタロール２の両端に配置したロータリ式エキスパンダを用いて鉛シート３にスリット３ａを形成し比較した試験結果を表１に示す。
【表１】

ここで、鉛シート３は、シート厚が１．０ｍｍのものを用い、最端円板カッタ４は、谷部４ｂの周側面が所定半径の基準円周面に一致する従来例（即ち、この従来例は、谷部４ｂが鉛シート３のシート厚の０％分だけ窪む）と、谷部４ｂの周側面が所定半径の基準円周面よりも、鉛シート３のシート厚の１０％（０．１ｍｍ）、３０％（０．３ｍｍ）、５０％（０．５ｍｍ）、７０％（０．７ｍｍ）及び１００％（１．０ｍｍ）分だけ窪んだ円周面からなる実施例と、谷部４ｂの周側面の最外周端が鉛シート３のシート厚の５０％分だけ窪むと共に、この周側面に３０°の内側傾斜面４ｄを形成した実施例とを用いた。また、上下の円板カッタロール２は、間隔距離を固定した。
【００４２】
これらの従来例と実施例とによりスリット３ａを形成した鉛シート３は、それぞれ格子体に展開後に、最端結節部３ｄにおける最も薄い部分の厚さを測定し、鉛シート３の元のシート厚に対するシート厚比を算出した。また、これらの格子体に活物質を充填し、熟成及び乾燥を行って正極板として鉛蓄電池（ＪＩＳ形式５５Ｄ２３形）に組み込みＪＩＳ過充電試験を行うことにより、その寿命性能を試験すると共に、この試験後の最端結節部３ｄにおける桟３ｂの断線率を調査した。なお、この鉛蓄電池は、いずれの場合も、負極板として従来例のものを用い、これらの極板間に微孔性のポリエチレンを主体としたセパレータを介在させた。
【００４３】
上記比較試験の結果、実施例により作製された格子体は、いずれも最端結節部３ｄのシート厚比が従来例よりも大きくなり鉛シート３の延びが抑制されていることが確認されると共に、この格子体を用いた鉛蓄電池の寿命性能が向上し断線率が低下することが確認された。しかも、谷部４ｂの窪みを５０％とした場合を最高にして、この窪みが３０％以上７０％以下としたものが特に効果が高いことが分かった。また、谷部４ｂの周側面に内側傾斜面４ｄを形成すればさらに効果が高まることが分かった。
【００４４】
【発明の効果】
以上の説明から明らかなように、本発明の電池極板用格子体及びその製造装置によれば、最端円板カッタの最端結節部形成谷部の周側面を窪ませることにより、金属シートの最端結節部の変形を小さくすることができるので、この最端結節部から引き出される桟が断線し易くなるのを確実に防止することができ、電池不良の発生を抑制すると共に電池寿命を長くすることができるようになる。
【図面の簡単な説明】
【図１】本発明の一実施形態を示すものであって、上下の円板カッタロールの円板カッタによって鉛シートにスリットが形成される過程を示す部分拡大縦断面正面図である。
【図２】本発明の一実施形態を示すものであって、最端円板カッタの構成を示す側面図である。
【図３】本発明の一実施形態を示すものであって、最端円板カッタの構成を示す部分拡大斜視図である。
【図４】本発明の一実施形態を示すものであって、鉛シートに形成されたスリットを展開した格子体における最端結節部付近を示す部分拡大斜視図である。
【図５】本発明の一実施形態を示すものであって、山部の周側面に傾斜面を形成した最端円板カッタを用いて鉛シートにスリットが形成される過程を示す部分拡大縦断面正面図である。
【図６】本発明の一実施形態を示すものであって、谷部の周側面を円周面とした最端円板カッタを用いて鉛シートにスリットが形成される過程を示す部分拡大縦断面正面図である。
【図７】本発明の一実施形態を示すものであって、山部の周側面を窪ませた最端円板カッタを用いて鉛シートにスリットが形成される過程を示す部分拡大縦断面正面図である。
【図８】従来例を示すものであって、円板カッタとこの円板カッタの周縁部の構成を示す側面図である。
【図９】従来例を示すものであって、ロータリ方式のエキスパンダにおける円板カッタによる鉛シートへのスリットの形成工程を示す側面図である。
【図１０】従来例を示すものであって、上下の円板カッタロールの円板カッタによって鉛シートにスリットが形成される過程を示す部分拡大縦断面正面図である。
【図１１】従来例を示すものであって、最端円板カッタの構成を示す側面図である。
【図１２】従来例を示すものであって、最端円板カッタの構成を示す部分拡大斜視図である。
【図１３】従来例を示すものであって、鉛シートに形成されたスリットを展開した格子体における最端結節部付近を示す部分拡大斜視図である。
【符号の説明】
１円板カッタ
１ａ山部
１ｂ谷部
１ｃ凹溝
２円板カッタロール
３鉛シート
３ａスリット
３ｃ結節部
３ｄ最端結節部
４最端円板カッタ
４ａ山部
４ｂ谷部
４ｄ内側傾斜面[0001]
BACKGROUND OF THE INVENTION
  The present invention relates to a grid for a battery electrode plate manufactured by a rotary expander and a manufacturing apparatus therefor.
[0002]
[Prior art]
  The electrode plate of the lead-acid battery is obtained by filling an active material into the grid of a grid made of lead or a lead alloy. In addition to producing the lattice body directly in a lattice shape by casting lead or a lead alloy, the lattice body may be produced by forming a grid on a lead sheet made of lead or a lead alloy by an expander. In this expander, a reciprocating system in which each square is formed in order from both ends of the lead sheet by the vertical movement of the die cutter, and a staggered slit is formed in the lead sheet by rotating the disc cutter. There is a rotary system in which the slits are expanded into squares by spreading out from both sides.
[0003]
  As shown in FIG. 8, the disc cutter 1 used in the rotary type expander (rotary type expander) has a crest portion 1 a having a relatively long circumferential direction on a peripheral portion of a metal disc. A plurality of relatively short valleys 1b are alternately arranged along the circumferential direction. Each mountain portion 1a is formed with a circumferential side surface that protrudes in a mountain shape from the reference circumferential surface having a predetermined radius toward the outer circumferential direction with the axis of the disc cutter 1 as the center. In addition, in the oval enlarged view of FIG. 8, this reference | standard circumferential surface is expand | deployed and shown on the plane. Each trough portion 1b is formed with a peripheral side surface composed of this reference circumferential surface. Further, in each of these valleys 1b, a groove 1c opened on the peripheral surface of the disk surface opposite to the valleys 1b on both sides adjacent to each other via the peak 1a is opened on the peripheral side surface of the valley 1b. Is formed. That is, on both the disk surfaces of the disk cutter 1, the groove 1c is formed in every other valley 1b, and the valley 1b in which the groove 1c is formed in one disk. And trough portions 1b in which concave grooves 1c are formed on the other disk surface are arranged alternately on the circumference. These concave grooves 1c are grooves formed on the disk surface of the disk cutter 1 having substantially the same width as the circumferential length of the valley portion 1b and having a depth approximately half the plate thickness of the disk cutter 1. Yes, one end opens to the peripheral side surface of the valley 1b, and the other end is formed over a certain length toward the axial center side of the disc cutter 1.
[0004]
  The disk cutter 1 forms a disk cutter roll 2 by arranging a large number of sheets on the common rotating shaft at a distance substantially the same as the thickness of the disk cutter 1 and fixing them. Then, as shown in FIG. 9, two such disk cutter rolls 2 are arranged one above the other and a lead sheet 3 is passed between them to form a large number of staggered slits 3a. At this time, as shown in FIGS. 10 (a) and 10 (c), the upper and lower disk cutters 1 are arranged at a height position such that the valleys 1b slightly overlap each other, and the lower disk cutters 1 below. So that the upper disk cutters 1 are sandwiched between them by a half pitch in the axial direction. Further, as shown in FIG. 10 (a), when the trough portion 1b in which the concave groove 1c is formed on the disk surface on one side (right side in the figure) of the lower disk cutter 1 reaches the upper end, The phase in the rotational direction is also adjusted so that the valley 1b in which the concave groove 1c is formed on the disk surface on the other side (left side in the figure) of the upper disk cutter 1 reaches the lower end. Therefore, as shown in FIG. 10 (b), when the peak 1a of the lower disk cutter 1 reaches the upper end, the upper disk cutter 1 also reaches the lower end of the peak 1a. As shown in c), when the trough portion 1b in which the concave groove 1c is formed on the disk surface on the other side (the left side in the figure) of the lower disk cutter 1 reaches the lower end, the upper disk cutter 1, the trough portion 1 b in which the concave groove 1 c is formed on the disk surface on one side (right side in the drawing) reaches the lower end.
[0005]
  Endmost disc cutters 4 are respectively disposed at both axial ends of the lower disc cutter roll 2. As shown in FIGS. 11 and 12, the outermost disc cutter 4 has crests 4a and troughs 4b arranged alternately on the peripheral edge. The configuration of the valley 4b and the groove 4c formed in the valley 4b is exactly the same as the valley 1b and the groove 1c of the ordinary disc cutter 1, but the peak 4a has a reference circle. A peripheral side surface comprising a peripheral surface is formed. That is, in the outermost disc cutter 4, the peak portion 4a does not protrude in the shape of a mountain toward the outer peripheral direction, and the valley portion 4b also has a relatively depressed shape compared to the peak portion 4a. Don't be. Such an outermost disc cutter 4 is arranged side by side at both ends of the lower disc cutter roll 2 so as to be adjacent to the outside of the normal disc cutter 1 at both ends of the upper disc cutter roll 2. Is done.
[0006]
  When the lead sheet 3 is passed between the disk cutter rolls 2 having the above-described configuration, the lead sheet 3 is cut by overlapping the peak portions 1a of the upper and lower disk cutters 1 as shown in FIGS. The slits 3a are formed, and the strips 3b formed between the slits 3a adjacent in the width direction of the lead sheet 3 are pushed by the upper and lower ridges 1a and alternately the sheets of the lead sheet 3 Projects in a mountain shape vertically from the surface. Further, in the valley portions 1b of the upper and lower disk cutters 1, as shown in FIGS. 10 (a), 10 (c) and FIG. 9, in the adjacent portions where the concave grooves 1c are back to back, the circumference of these valley portions 1b When the side surfaces slightly overlap each other, the lead sheet 3 is cut and the slits 3a are continuously formed. However, in the adjacent portions where the concave grooves 1c face each other, these concave grooves 1c cause Since the peripheral side surfaces do not overlap each other and the lead sheet 3 is not cut, the slits 3a are interrupted and the knot portions 3c are formed. Therefore, the slits 3a formed in the lead sheet 3 are continuously formed in the transfer direction while two portions of the mountain-shaped crosspiece 3b pushed by the peak portion 1a are interrupted in the middle of the knot portion 3c. Further, the slits 3a adjacent to each other in the width direction on the lead sheet 3 are formed at positions where the knot portions 3c are shifted by a half pitch, so that these slits 3a are shown in a plan view in the circle of FIG. It becomes a staggered pattern.
[0007]
  At both ends of the disc cutter roll 2, as shown in FIG. 10 (b), the peaks 4 a of the outermost disc cutter 4 in the lower disc cutter roll 2 and the ends of the upper disc cutter roll 2. When the peak portion 1a of the disk cutter 1 overlaps, the lead sheet 3 between them is cut to form a slit 3a, and the crosspiece 3b protrudes downward in a mountain shape. Further, as shown in FIGS. 10 (a) and 10 (c), the concave groove 1c and the concave portion in the valley portion 4b of the lowermost disc cutter 4 at both lower ends and the valley portion 1b of the disc cutter 1 at both upper ends. Even in the adjacent portion where the groove 4c is back-to-back (the right end in FIG. 10 (a) and the left end in FIG. 10 (c)), the lead sheets 3 are cut and the slits 3a are formed by slightly overlapping the

valleys

1b and 4b. It is formed continuously. However, the concave groove 1c and the concave groove 4c in the valley portion 4b of the lowermost disc cutter 4 at the lower ends and the valley portion 1b of the upper disc cutter 1 at the upper ends are formed facing each other. In the adjacent portion (the left end in FIG. 10A and the right end in FIG. 10C), the lead sheet 3 is formed without the circumferential side surfaces of the

valley portions

1b and 4b being overlapped by these

concave grooves

1c and 4c. Since it is not cut | disconnected, the 3d end part 3d similar to the nodule part 3c is formed. However, since the slit 3a is not formed at the outer end, the outermost knot portion 3d is directly connected to the frame portions 3e formed at both ends in the width direction of the lead sheet 3.
[0008]
The lead sheet 3 on which a large number of slits 3a are formed as described above is spread on both sides in the width direction in the post-process of the rotary expander, so that these slits 3a are masked as shown in FIG. A grid-like lattice body is formed which is expanded in a grid and is connected to each other by the four crosspieces 3b drawn out in an oblique direction between the joint portions 3c and the endmost joint portion 3d. In actuality, each knot portion 3c is tilted in the twisting direction by being pulled by the crosspiece 3b at the time of deployment, but in FIG. 13, such twisting is schematically shown.
[0009]
[Problems to be solved by the invention]
However, the nodule portion 3c and the endmost nodule portion 3d of the lead sheet 3 are, as shown in FIGS. 10 (a) and 10 (c), upper and lower disc cutters having concave grooves 1c facing each other in the width direction. 1 and the

valleys

1b and 4b of the endmost disc cutter 4 are pressed in the upside down direction, so that they are greatly deformed in the up and down direction more than the thickness of the lead sheet 3 on both sides in the width direction. The lead sheet 3 of the knot 3d is extended and thinned with deformation. Then, when such a lead sheet 3 is stretched to both sides in the width direction, the nodal portion 3c deformed in the vertical direction and thinned, and the crosspiece 3b drawn from the endmost nodal portion 3d is pulled in the lateral direction and obliquely Since the unfolding is performed, the stress is concentrated on the joint portion 3c and the endmost joint portion 3d, and there is a high possibility that the wire 3b is broken by corrosion or heat generation. In addition, when such a breakage of the crosspiece 3b occurs at the outermost node portion 3d connected to the frame portion 3e of the lead sheet 3 on which the ears of the grid for collecting the electrode plates are formed, the width direction is further increased. Since the other electrode plate part is connected to the ear part through another detour path, the current becomes extremely difficult to flow, and the active material of that part is not used effectively, or the current on the detour path increases. As a result, inconveniences such as heat generation become extremely large. In addition, when the breakage of the crosspiece 3b occurs also in the joint portion 3c other than the endmost joint portion 3d, the current on the electrode plate portion on the other side from the joint portion 3c becomes difficult to flow in the same manner. This effect becomes extremely smaller as the nodule portion 3c is farther from the portion 3e.
[0010]
  For this reason, conventionally, since the endmost node 3d connected to the frame portion 3e of the lead sheet 3 was likely to be disconnected like the other nodes 3c, the breakage of the crosspiece 3b was easily caused. There has been a problem that the number of batteries in which the battery greatly decreases is increased.
[0011]
  The present invention has been made in order to cope with such a situation, and by deforming the peripheral side surface of the valley portion of the endmost disc cutter toward the center, the deformation of the endmost nodule portion is reduced and the breakage of the crosspiece is caused. An object of the present invention is to provide a grid for a battery electrode plate and a manufacturing apparatus therefor that are unlikely to occur.
[0012]
[Means for Solving the Problems]
  According to the first aspect of the present invention, the peripheral portion of the disc is formed with a peripheral side surface that protrudes in a chevron shape from the reference peripheral surface having a predetermined radius around the rotation axis of the disc toward the outer peripheral direction. And valleys formed with circumferential side surfaces that are substantially along the reference circumferential surface are alternately formed in the circumferential direction over the entire circumference, and each valley is adjacent to each other via the peak. Arrange a plurality of disk cutters coaxially with a gap formed on the peripheral edge of one disk surface that is opposite to the front and back in the valleys on both sides of the mating, with a groove formed on the peripheral side of the valley. A battery using a rotary expander that forms a disk cutter roll and passes a metal sheet between two or more disk cutter rolls facing each other to form a large number of staggered slits in the metal sheet. In the manufacturing apparatus of the grid for electrode plates,The cutting surface by the opposing disc cutter rolls can be set to coincide with the middle part of the sheet thickness of the metal sheet conveyed on the conveying surface,A disc-shaped outermost disc cutter is arranged on the outer side of the outermost disc cutter on the disc cutter roll facing the outermost disc cutter roll of these disc cutter rolls. In the valley part in this outermost disk cutter (in the case of the outermost disk cutter, the peripheral part corresponding to each valley part of the disk cutters arranged on the same disk cutter roll is referred to as “valley part”) In the case where the troughs of the disk cutters of the other disk cutter rolls facing each other through the metal sheet are formed with concave grooves on the disk surface facing the endmost disk cutter side (hereinafter “the most Than the reference circumferential surface).AxialCloser to the center30% to 70% of sheet thickness of metal sheetA recessed peripheral side surface is formed.
[0013]
  The normal knot portion is from both sides until the circumferential side surface of the valley portion of both disc cutter rolls of the disc cutter rolls facing each other through the metal sheet exceeds the central cut surface between the axes of these disc cutter rolls. Since each presses, the deformation | transformation more than the sheet | seat thickness of this metal sheet will generate | occur | produce. However, according to the invention of claim 1, since the peripheral side surface of the endmost nodule forming trough portion of the endmost disc cutter is recessed from the reference circumferential surface, the disc cutter facing the metal sheet is interposed. Even if the peripheral side surface of the trough presses the end side of the endmost knot beyond the cut surface, the peripheral side surface of the endmost knot forming valley of this endmost disc cutter is the base of the endmost knot The side is pressed only before the cut surface. For this reason, since the deformation | transformation of the endmost knot part becomes small, it can prevent reliably that the crosspiece pulled out here becomes easy to break.
[0014]
  The peripheral side surface of the valley portion where the endmost nodule portion is formed is recessed more toward the center than the circumferential surface of a predetermined radius by 30% or more and 70% or less of the sheet thickness of the metal sheet.TheFor example, if the peripheral side surface of the valley portion where the endmost nodule portion is formed is depressed by 20% of the sheet thickness, the deformation of the endmost nodule portion exceeds 80% of the sheet thickness and cannot make a big difference from the conventional one. . Moreover, if the peripheral side surface of the valley portion where the endmost nodule portion is formed is recessed to 80% of the sheet thickness, the deformation of the endmost nodule portion can be accommodated to the extent that it exceeds 20% of the sheet thickness. In troughs other than the cut end forming troughs of the cutter, a slit is formed by pressing the metal sheet until the cut surface between the disc cutter rolls is exceeded, and usually a crest (in the case of the extreme disc cutter) The peripheral edge corresponding to each peak portion of the disk cutters arranged on the same disk cutter roll is also called “peak portion”), and therefore, between these portions and the endmost nodule formation valley A step of about 80% of the sheet thickness is generated. On the other hand, if the depression on the peripheral side surface of the valley portion where the endmost nodule portion is formed is about 50% of the sheet thickness, the deformation of the endmost nodule portion and the step with the surrounding metal sheet will be around 50%. So that the size of the sheet is 30% or more and 70% or less of the sheet thickness.is doing.
[0015]
  It should be noted that it is not always necessary to form a concave groove in each trough of the outermost disk cutter. That is, the concave groove of each trough other than the most-end nodule-forming trough of the outermost disc cutter is formed on the disc surface facing the outer side of the outermost disc cutter. Except for the case where the outermost disk cutter arranged at the outer end and the parts are shared, there is no need to provide them. On the other hand, the concave groove of each endmost nodule portion forming trough of the endmost disc cutter is formed on the disc surface facing the inside of the endmost disc cutter, and a metal sheet is interposed therebetween. Since a space for forming the endmost nodule portion is required between the concave groove in the valley portion of the opposing disk cutter, it is usually preferable to provide it. However, in the case of the invention of claim 1, since the peripheral side surface is recessed in the endmost nodule formation valley, if this depression is made sufficiently large, it is between the groove in the valley of the opposing disc cutter. A sufficient space can be ensured, and an excessive deformation is not applied to the endmost knot portion, so that it is not always necessary to provide a concave groove.
[0016]
  Further, it is preferable that an inclined surface that is closer to the center toward the outer side is formed on each circumferential surface of each valley portion and / or each mountain portion excluding the most end nodule portion formation valley portion in the outermost disk cutter. . In the troughs other than the troughs forming the endmost node of the endmost disc cutter, a slit is formed by pressing the metal sheet until it exceeds the cut surface between the disc cutter rolls. Therefore, a level | step difference may arise between the outermost nodule part formation trough part with which the surrounding side surface was depressed, and a stepped wave | undulation may arise in the frame part of a metal sheet. However, if the peripheral side surfaces of the valleys and peaks other than the endmost nodule formation valley are inclined surfaces, the frame portion of the metal sheet can be gently bent.
[0017]
  In addition, it is preferable that a peripheral side surface of the reference circumferential surface or a peripheral side surface closer to the center than the reference circumferential surface is formed in each peak portion of the outermost disc cutter. If the peripheral side surface of the peak part of the outermost disk cutter protrudes in the shape of a mountain like the disk cutter, no slit is formed on the outer side, so the edge of the frame part of the metal sheet is unnecessarily pressed up and down. Will be transformed. In addition, the peripheral side surface of the normal disk cutter protruding in the shape of a mountain shape presses the metal sheet far beyond the cut surface between the disk cutter rolls, so the peak of the outermost disk cutter facing this Even if the peripheral side surface of the part does not exceed the cut surface, the metal sheet can be cut in most cases. Therefore, the peripheral side surface of the peak portion of the outermost disc cutter may be formed on the reference peripheral surface.For example, the peripheral side surface that is closer to the center is formed to the same extent as the peripheral side surface of the endmost nodule formation valley. For example, it is possible to prevent a large undulation from occurring at the edge of the frame portion of the metal sheet.
[0018]
  The apparatus for manufacturing a grid for a battery electrode plate according to claim 2, the inner side is closer to the peripheral side surface of the outermost knot forming valley.AxialAn inclined surface that is closer to the center is formed.
[0019]
  If no groove is formed in the endmost nodule formation trough, the recess in the trough of the disk cutter that faces the metal sheet as the peripheral side surface is slightly recessed from the reference circumferential surface. Since the endmost nodule portion is deformed only by the space in the groove, this deformation may be too rapid when the deformation amount is large. However, according to the second aspect of the present invention, since the inclined surface is formed on the peripheral side surface of the endmost nodule formation valley, the endmost nodule can be gently deformed along the inclined surface. Become. Further, even when a groove is formed in the endmost nodule formation valley, if the peripheral side surface has an inclined surface, the deformation of the endmost nodule portion can be further moderated.
[0020]
  The grid for battery electrode plates according to claim 3 is manufactured by the manufacturing apparatus according to

claim

1 or 2.
[0021]
  According to invention of Claim 3, the crosspiece | stretch | drawer pulled out from the endmost node part becomes a grid for battery electrode plates which is hard to be disconnected.
  According to a fourth aspect of the present invention, there is provided a method for manufacturing a battery electrode plate grid, wherein the battery electrode plate grid is manufactured by the manufacturing apparatus according to the first or second aspect.
  According to the invention of claim 4, it is possible to manufacture a battery electrode plate grid body in which a bar drawn out from the endmost node is hard to break.
[0022]
DETAILED DESCRIPTION OF THE INVENTION
  Embodiments of the present invention will be described below with reference to the drawings.
[0023]
  1 to 7 show an embodiment of the present invention, and FIG. 1 is a partially enlarged longitudinal sectional front view showing a process in which slits are formed in a lead sheet by disc cutters of upper and lower disc cutter rolls. 2 is a side view showing the structure of the outermost disk cutter, FIG. 3 is a partially enlarged perspective view showing the structure of the outermost disk cutter, and FIG. 4 is the outermost view of the lattice body in which slits formed in the lead sheet are developed. FIG. 5 is a partially enlarged perspective front view showing a process in which slits are formed in a lead sheet using an outermost disc cutter in which an inclined surface is formed on the peripheral side surface of the peak portion. FIG. 6 is a partially enlarged longitudinal sectional front view showing a process in which a slit is formed in a lead sheet using an outermost disc cutter having a circumferential surface of a valley as a circumferential surface, and FIG. 7 shows a circumferential surface of the mountain. Shows the process of forming slits in the lead sheet using the recessed endmost disk cutter. Is a partially enlarged longitudinal sectional front view. In addition, the same number is attached | subjected to the structural member which has the same function as the prior art example shown in FIGS.
[0024]
  This embodiment demonstrates the rotary type expander for manufacturing the grid | lattice body used for the electrode plate of a lead storage battery similarly to a prior art example. As shown in FIG. 9, this rotary expander forms staggered slits 3 a in the lead sheet 3 by passing the lead sheet 3 between the upper and lower disc cutter rolls 2. The upper disk cutter roll 2 has the same configuration as the conventional example. The lower disk cutter roll 2 has the same configuration as the conventional example in which the outermost disk cutters 4 are arranged on both ends of a large number of disk cutters 1, but the structure of these outermost disk cutters 4 is the same as that of the conventional example. Different from the conventional example.
[0025]
  As shown in FIGS. 2 and 3, the outermost disk cutter 4 of the present embodiment is also the same as the conventional example in that the ridges 4 a and the valleys 4 b are alternately arranged at the peripheral edge. However, the peak part 4a and the trough part 4b in the outermost disk cutter 4 show the peripheral part corresponding to each peak part 1a and trough part 1b of the disk cutter 1 arrange | positioned at the same disk cutter roll 2, The shape is neither mountain nor valley. That is, the crest 4a is formed with a peripheral side surface composed of a reference circumferential surface having a predetermined radius centered on the axis of the outermost disc cutter 4, and the trough 4b is also located between these crests 4a. It will not be a concave part. Further, in this trough portion 4b, the concave grooves 4c as in the conventional example are not formed, and one trough portion 4b (the endmost knot portion forming trough portion) arranged alternately is more than the reference circumferential surface. An inner inclined surface 4d that is a circumferential side surface that is recessed toward the center and is inclined inward is formed, and an outer inclined surface 4e that is inclined outward is formed in the other valley portion 4b. That is, the peripheral side surface of this one trough portion 4b is the portion of the outermost disk cutter 4 that is in contact with the outer disk surface (the rear surface in FIG. 2, the front surface on the right hand in FIG. 3). It coincides with the circumferential surface whose radius is smaller by 50% of the sheet thickness of the lead sheet 3 than the predetermined radius of the reference circumferential surface with the center as the center. The inner inclined surface 4d is formed of a part of a tapered surface whose radius decreases as it approaches the front surface of FIG. Accordingly, the one trough portion 4b is formed with a peripheral side surface closer to the center than the peak portion 4a forming the peripheral side surface composed of the reference circumferential surfaces adjacent to both sides, and this peripheral side surface is the outermost side surface. It consists of the inner inclined surface 4d inclined further toward the center toward the inner disk surface of the end disk cutter 4. However, the inner inclined surface 4d does not necessarily need to be a part of the tapered surface, and may be a flat surface or other curved surface depending on processing convenience or the like as long as it is a surface inclined inward from the peripheral side surface of the peak portion 4a. May be.
[0026]
  The other trough portion 4b (the trough portion other than the trough portion forming trough portion) in the outermost disc cutter 4 is a reference circumferential surface having a predetermined radius at a portion in contact with the inner disc surface of the outermost disc cutter 4 The outer inclined surface 4e is formed of a part of the tapered surface whose radius becomes smaller than the predetermined radius as it approaches the outer disk surface of the outermost disk cutter 4 more than this. Accordingly, the other trough 4b has the same outermost diameter as the crest 4a that forms the peripheral side surface composed of the reference circumferential surfaces adjacent to both sides, but has an oblique cutout on the outer disk surface side. By providing, it becomes the shape which formed the outer side inclined surface 4e. However, the outer inclined surface 4e is not necessarily a part of the tapered surface. If the surface is inclined closer to the center than the peripheral side surface having a predetermined radius as it approaches the outer disk surface, the outer inclined surface 4e may be used depending on the convenience of processing. It may be a flat surface or other curved surface.
[0027]
  The outermost disc cutter 4 having the above configuration is arranged side by side at both ends of the lower disc cutter roll 2 so as to be further adjacent to the outer side of the normal disc cutter 1 at both ends of the upper disc cutter roll 2. Is done. Further, the trough portion 4b serving as the trough portion forming trough portion of the endmost disc cutter 4 is a trough portion of the disc cutter 1 of the upper disc cutter roll 2 facing the lead sheet 3 at the upper end. The phase in the rotational direction is adjusted so that 1b is formed with a concave groove 1c on the opposite surface side. The lead sheet 3 is conveyed between the upper and lower disk cutter rolls 2 and passes therethrough. In this case, conventionally, the lead sheet 3 is transported on a transport surface that coincides with the cut surface S between the upper and lower disk cutter rolls 2. In this embodiment, this transport surface is used as the cut surface S. And 50% lower than the sheet thickness of the lead sheet 3. That is, conventionally, the cutting surfaces S of the upper and lower disk cutter rolls 2 are set so as to coincide with the conveying surface of the lead sheet 3, that is, the lower surface of the lead sheet 3. The cutting surface S of the disc cutter roll 2 is set so as to coincide with an intermediate portion of the sheet thickness of the lead sheet 3 conveyed on the conveying surface. The cut surface S is a plane having the same distance from the axis of the upper and lower disk cutter rolls 2 and has a predetermined radius of a reference circumferential surface constituting the peripheral side surface of the valley portion 1b of the upper and lower disk cutters 1. Is a diameter slightly larger than the distance from the axis to the cut surface S. Therefore, the circumferential side surface of the valley 1b of the upper disc cutter 1 reaches the lower side slightly beyond the cut surface S when it is at the lower end, and the valley 1b of the lower disc cutter 1 is reached. The outer peripheral end of the peripheral side surface of the valley portion 4b other than the peripheral end surface of the valley end 4b of the outermost disc cutter 4 and the peripheral side surface of the peak portion 4a of the outermost disc cutter 4 The cut surface S is slightly exceeded and reaches upward.
[0028]
  When the lead sheet 3 is passed between the upper and lower disk cutter rolls 2 and the valleys 1b of the upper and lower disk cutters 1 overlap with each other at the cut surface S, as shown in FIGS. Further, in the adjacent upper and lower disk cutters 1, the lead sheet 3 is cut at the portion where the concave grooves 1 c are back to back to form a slit 3 a, and the lead sheet 3 is not cut at the portion where the concave grooves 1 c face each other. Part 3c is formed. Further, when the valley 4b of the outermost disk cutter 4 is the outermost node forming valley, that is, when facing the concave groove 1c of the adjacent upper disk cutter 1 (FIG. 1A). In the left end and the right end in FIG. 1C, the outermost node portion 3d connected to the frame portion 3e of the lead sheet 3 is formed. The endmost nodule portion 3d is connected to the frame portion 3e as it is in the width direction of the lead sheet 3 (left direction in FIG. 1 (a) and right direction in FIG. 1 (c)), and the other end is an upper disk. Cut by the valley 1b of the endmost disc cutter 1 in the cutter roll 2 and the valley 1b of the endmost disc cutter 1 excluding the endmost disc cutter 4 in the lower disc cutter roll 2. Since the other end is pressed to the cutting surface S by the valley 1b of the upper disc cutter 1, the lead sheet 3 conveyed on the conveying surface is the other end of the outermost node 3d. The end portion is pushed down by 50% of the sheet thickness and deformed. On the other hand, the normal knot portion 3c is pressed until the one end portion and the other end portion thereof exceed the same cut surface S from the vertical direction as in the conventional case. Deformation occurs. In addition, the endmost nodule portion 3d is such that the portion on the valley 4b of the endmost disc cutter 4 is gently bent from the conveying surface along the inner inclined surface 4d, so that the deformation at the other end is further gradual. Become.
[0029]
  Further, when the valley 4b of the endmost disc cutter 4 is not the endmost nodule formation trough, that is, when the valley 1b of the adjacent upper disc cutter 1 faces on the back side of the groove 1c ( The right end in FIG. 1 (a) and the left end in FIG. 1 (c) show the frame portion 3e of the lead sheet 3 between the uppermost disc cutter roll 2 and the valley portion 1b of the outermost disc cutter 1. The end is cut to form the slit 3a. Moreover, the end of the frame portion 3e is configured such that a portion on the valley portion 4b of the outermost disc cutter 4 is gently bent from the conveying surface along the outer inclined surface 4e.
[0030]
  When the peaks 1a of the upper and lower disk cutters 1 overlap with each other, as shown in FIG. 1B, the lead sheet 3 is cut between the adjacent upper and lower disk cutters 1 to form slits 3a. At the same time, the crosspieces 3b between the slits 3a are pressed in the vertical direction by the crests 1a of the disc cutter 1. That is, the crosspiece 3b is pressed into a mountain shape in the vertical direction along the conveyance direction of the lead sheet 3 as in the prior art. Further, the lead sheet 3 on the peak portion 4a of the outermost disc cutter 4 is cut between the upper disc cutter 1 adjacent inside and becomes the end portion of the frame portion 3e, and the peak portion 4a. Is pushed up to the cut surface S by 50% of the sheet thickness.
[0031]
  The lead sheet 3 on which a large number of slits 3a are formed as described above is spread on both sides in the width direction in the post-process of the rotary expander, so that these slits 3a are masked as shown in FIG. A grid-like lattice body is formed which is expanded in a grid and is connected to each other by the four crosspieces 3b drawn out in an oblique direction between the joint portions 3c and the endmost joint portion 3d. In FIG. 4, similarly to FIG. 13, the knot portion 3 c and the crosspiece 3 b are not shown twisted and schematically shown.
[0032]
  According to the above configuration, the deformation in the vertical direction of the endmost nodule portion 3d in the lead sheet 3 is about half of the sheet thickness. Even after 3b is pulled in an oblique direction, corrosion or heat generation hardly occurs at the endmost node 3d, and the crosspiece 3b hardly breaks as compared with the normal node 3c. Accordingly, since the crosspiece 3b closest to the frame portion 3e of the lead sheet 3 is difficult to be disconnected, it is possible to reliably prevent the capacity of the lead storage battery from being significantly reduced.
[0033]
  In the above embodiment, when the outermost diameter of the valley portion 1b serving as the endmost nodule portion formation valley portion is formed to a diameter that is smaller than the predetermined radius by 50% of the sheet thickness of the lead sheet 3. However, if the outermost diameter is smaller than the predetermined radius, it is not necessarily 50% of the sheet thickness. However, as the rate at which the outermost diameter becomes smaller than the predetermined radius decreases, the amount of deformation in the vertical direction of the outermost node 3d increases. On the other hand, when the rate at which the outermost diameter is smaller than the predetermined radius increases, the height position in the vertical direction between the position where the lead sheet 3 is cut at the valley portion 1b other than the endmost nodule formation valley portion is increased. The difference is too large. In addition, when the outermost diameter becomes smaller than the predetermined radius by 100% or more of the sheet thickness, the outermost nodule portion 3d of the lead sheet 3 is supported by the peripheral side surface of the valley portion 1b that becomes the outermost nodule portion formation valley portion. I can't. Therefore, it is preferable that the outermost diameter of the trough portion 1b serving as the endmost knot portion forming trough is smaller than a predetermined radius within a range of 30% to 70% of the sheet thickness of the lead sheet 3.
[0034]
  Moreover, in the said embodiment, although shown about the case where the surrounding side surface of the peak part 4a of the outermost disc cutter 4 was made into the reference | standard circumferential surface, as shown in FIG. It can also be set as the inclined surface similar to the outer inclined surface 4e of the trough part 4b other than a nodule part trough part. In this case, the crest 4a of the endmost disc cutter 4 and the peripheral side surface of the trough 4b other than the endmost nodule formation trough are the same continuous inclined surface, and the trough becomes the endmost nodule formation trough. The inner inclined surface 4d inclined in the reverse direction is formed only on the peripheral side surface of the portion 4b.
[0035]
  Moreover, in the said embodiment, although shown about the case where the inner side inclined surface 4d and the outer side inclined surface 4e were formed in the surrounding side surface of the trough part 4b of the outermost disc cutter 4, as shown in FIG. Both of the peripheral side surfaces of 4b can also be a circumferential surface. In FIG. 6, the peripheral side surface of the valley 4b (the left end in FIG. 6), which is the endmost nodule formation trough, is a circumferential surface having a radius smaller than the predetermined radius by 100% of the sheet thickness to form the endmost nodule portion. A peripheral side surface of the valley portion 4b (the right end in FIG. 6) other than the valley portion is set as a reference circumferential surface having a predetermined radius. For example, the peripheral side surface of the valley portion 4b that becomes the endmost nodule formation valley portion may be a circumferential surface that is smaller than the predetermined radius of the reference circumferential surface by 50% of the sheet thickness. Compared to the case where the inner inclined surface 4d as in the form is formed, the endmost nodule portion 3d is suddenly deformed in a narrow range. That is, even if the amount of deformation in the vertical direction of the endmost node 3d is the same, the deformation is abruptly performed within a narrower range in the axial direction of the disc cutter roll 2. However, in this embodiment, the groove 4c is not formed in the outermost disk cutter 4, but when the conventional groove 4c is also formed in the outermost disk cutter 4 as well. Since the inside of the peripheral side surface of the valley portion 4b falls in a stepped manner, even if this peripheral side surface is a circumferential surface that is smaller than the predetermined radius of the reference circumferential surface by 50% of the sheet thickness, the deformation of the endmost node portion 3d Is no longer steep. That is, the step due to the concave groove 4c can gently deform the lead sheet 3 in the same manner as the inner inclined surface 4d and the outer inclined surface 4e in the valley 4b of the present embodiment.
[0036]
  As described above, it is sufficient that the peripheral side surface of the valley portion 4b that becomes the endmost nodule portion forming trough portion in the endmost disc cutter 4 only needs to have an outermost diameter smaller than a predetermined radius, and does not need to be a circumferential surface. It may be a flat surface substantially along the circumferential surface, a tapered surface as in the present embodiment, or a flat inclined surface substantially along the tapered surface. Further, it may have a stepped shape as in the case where the concave groove 4c is formed, or may be an arbitrary curved surface or other surface. On the other hand, in order to cut the lead sheet 3 between the valley portion 4b other than the valley portion where the outermost node is formed, the outer diameter of at least the inner end is predetermined. The diameter must be greater than the radius and beyond the cut surface S. However, as long as this condition is satisfied, any surface may be formed on the peripheral side surface of the valley portion 4b other than the endmost nodule portion formation valley portion.
[0037]
  Moreover, in the said embodiment, although the case where the peripheral side surface of the peak part 4a of the outermost disc cutter 4 was a reference | standard peripheral surface of predetermined radius was shown, as shown in FIG. 7, the peripheral side surface of this peak part 4a Can be a circumferential surface having a diameter smaller than the predetermined radius by 50% of the sheet thickness. In this case, the peripheral side surface of the peak portion 4a has the same diameter as the outermost diameter of the outer end of the inner inclined surface 4d of the valley portion 4b that becomes the valley portion where the outermost node is formed in the present embodiment. It is necessary to cut the lead sheet 3 between the peak portion 4a and the peak portion 1a of the upper disk cutter 1 because the peak portion 1a of the upper disk cutter 1 protrudes downward in a mountain shape. Thus, the circumferential side surface of the peak portion 4a of the lowermost disc cutter 4 can be a circumferential surface having a diameter smaller than a predetermined radius. However, since the two hem portions of the mountain shape of the crest portion 1a of the upper disc cutter 1 have a lower protruding amount, the diameter of the peripheral side surface of the crest portion 4a is reduced in order to cut the lead sheet 3 in this portion. It may be necessary to make it larger.
[0038]
  Moreover, although the said embodiment demonstrated the case where the endmost disc cutter 4 was arrange | positioned at the both ends of the lower disc cutter roll 2, these end disc cutters 4 are one side or both sides of an upper disc. It can also be arranged at one end or both ends of the cutter roll 2. Further, two or more disk cutter rolls 2 to be paired can be used. For example, the lead sheet 3 can be passed while three disk cutter rolls 2 are arranged.
[0039]
  Moreover, although the said embodiment demonstrated the case where the crosspiece 3b connected to the most end node part 3d in the lead sheet 3 and the crosspiece 3b connected to the other node part 3c were formed in the same thickness, 3d end part 3d It is also possible to make only the thickness of the crosspiece 3b connected to the line 3b particularly thick so that the crosspiece 3b is more difficult to be disconnected.
[0040]
  Moreover, although the said embodiment demonstrated the case where the lead sheet 3 was processed and the grid body used for the electrode plate of a lead storage battery was manufactured, if the same grid body is used for the current collecting base material of an electrode plate, The present invention can be applied not only to the lead storage battery but also to any battery, and the lattice body can be manufactured using a metal sheet made of an appropriate material according to the type of the battery.
[0041]
【Example】
  A slit is formed in the lead sheet 3 using a rotary expander in which the endmost disc cutter 4 described in the above embodiment and the endmost disc cutter 4 shown in the conventional example are arranged at both ends of the lower disc cutter roll 2. The test results of forming and comparing 3a are shown in Table 1.
[Table 1]

Here, the lead sheet 3 has a sheet thickness of 1.0 mm, and the outermost disk cutter 4 has a conventional example in which the peripheral side surface of the valley 4b coincides with the reference peripheral surface of a predetermined radius (that is, this In the conventional example, the valley portion 4b is depressed by 0% of the sheet thickness of the lead sheet 3), and the peripheral side surface of the valley portion 4b is 10% of the sheet thickness of the lead sheet 3 than the reference circumferential surface having a predetermined radius. (0.1 mm), 30% (0.3 mm), 50% (0.5 mm), 70% (0.7 mm) and an embodiment consisting of a circumferential surface that is recessed by 100% (1.0 mm); An example in which the outermost peripheral edge of the peripheral side surface of the valley portion 4b is recessed by 50% of the sheet thickness of the lead sheet 3 and an inner inclined surface 4d of 30 ° is formed on the peripheral side surface is used. Further, the distance between the upper and lower disk cutter rolls 2 was fixed.
[0042]
  The lead sheet 3 in which the slits 3a are formed according to these conventional examples and examples is measured on the thickness of the thinnest part in the endmost nodule portion 3d after being spread on the lattice, and the original sheet thickness of the lead sheet 3 is measured. The sheet thickness ratio was calculated. In addition, these grids are filled with an active material, aged and dried, incorporated into a lead-acid battery (JIS type 55D23 type) as a positive electrode plate, and a JIS overcharge test is performed, thereby testing the life performance. The disconnection rate of the crosspiece 3b at the endmost node 3d after the test was investigated. In each case, the lead storage battery used a conventional negative electrode plate, and a separator mainly composed of microporous polyethylene was interposed between the electrode plates.
[0043]
  As a result of the above comparative test, it is confirmed that all of the lattice bodies manufactured according to the examples have a sheet thickness ratio of the endmost knot portion 3d larger than that of the conventional example and the extension of the lead sheet 3 is suppressed. It was confirmed that the life performance of the lead storage battery using this lattice body was improved and the disconnection rate was lowered. In addition, it was found that the highest effect was obtained when the valley portion 4b had a depression of 50%, and the depression was 30% or more and 70% or less. Moreover, it turned out that an effect will increase further if the inner side inclined surface 4d is formed in the surrounding side surface of the trough part 4b.
[0044]
【The invention's effect】
  As is clear from the above description, according to the battery electrode plate grid body and the apparatus for manufacturing the same of the present invention, the metal sheet is formed by recessing the peripheral side surface of the endmost nodule forming trough of the endmost disc cutter. Therefore, it is possible to reliably prevent the rails drawn from the endmost knots from being easily disconnected, thereby suppressing the occurrence of battery failure and extending the battery life. You can be longer.
[Brief description of the drawings]
FIG. 1 is a partially enlarged longitudinal sectional front view showing a process in which a slit is formed in a lead sheet by disk cutters of upper and lower disk cutter rolls according to an embodiment of the present invention.
FIG. 2, showing an embodiment of the present invention, is a side view showing a configuration of an outermost disc cutter.
FIG. 3 is a partially enlarged perspective view showing an embodiment of the present invention and showing a configuration of an outermost disc cutter.
FIG. 4 is a partially enlarged perspective view showing an embodiment of the present invention and showing the vicinity of an endmost nodule portion in a lattice body in which slits formed in a lead sheet are developed.
FIG. 5 shows an embodiment of the present invention, and is a partially enlarged longitudinal section showing a process in which a slit is formed in a lead sheet using an outermost disc cutter having an inclined surface formed on a peripheral side surface of a peak portion; It is a surface front view.
FIG. 6 shows an embodiment of the present invention, and is a partially enlarged longitudinal section showing a process in which a slit is formed in a lead sheet using an outermost disc cutter with a circumferential surface of a valley portion as a circumferential surface. It is a surface front view.
FIG. 7 shows an embodiment of the present invention, and is a partially enlarged longitudinal sectional front view showing a process of forming a slit in a lead sheet using an outermost disk cutter having a recessed peripheral side surface FIG.
FIG. 8 is a side view showing a conventional example and a configuration of a disc cutter and a peripheral portion of the disc cutter.
FIG. 9 is a side view showing a conventional example and showing a process of forming a slit in a lead sheet by a disc cutter in a rotary type expander.
FIG. 10 is a partially enlarged longitudinal sectional front view showing a conventional example and showing a process in which a slit is formed in a lead sheet by the disc cutters of upper and lower disc cutter rolls.
FIG. 11 is a side view showing a configuration of an outermost disc cutter, showing a conventional example.
FIG. 12 is a partial enlarged perspective view showing a conventional example and showing a configuration of an outermost disc cutter.
FIG. 13 is a partial enlarged perspective view showing a conventional example and showing the vicinity of the endmost nodule portion in a lattice body in which slits formed in a lead sheet are developed.
[Explanation of symbols]
  1 Disc cutter
  1a Yamabe
  1b Tanibe
  1c groove
  2 Disc cutter roll
  3 Lead sheet
  3a slit
  3c Nodule
  3d endmost node
  4 End disc cutter
  4a Yamabe
  4b Tanibe
  4d inside inclined surface

Claims

The reference circumferential surface formed with a peripheral surface projecting in a chevron shape toward the outer circumferential direction from a reference circumferential surface having a predetermined radius centered on the rotation axis of the disk at the peripheral portion of the disk, and the reference circumferential surface And a trough formed with a circumferential side surface substantially consisting of a surface along the entire circumference is alternately formed over the entire circumference in the circumferential direction. A disk cutter roll is formed by arranging a plurality of disk cutters on the periphery of one disk surface opposite to each other on the peripheral side surface of the valley section, with a plurality of disks arranged coaxially at intervals. Manufacture of a grid for battery electrode plates using a rotary expander in which a large number of staggered slits are formed in the metal sheet by passing the metal sheet between two or more disk cutter rolls facing each other. In the device
It is possible to set the cutting surface of the opposing disk cutter rolls so as to coincide with the middle part of the sheet thickness of the metal sheet conveyed on the conveying surface, and the disk cutter is arranged on the outermost side of these disk cutter rolls. a disc cutter roll opposite to those disposed, the outermost disc outermost disc cutters further outward disc-shaped than the cutter disposed, among the valleys of the endmost disk cutter, even though the case where the one trough portion of the disc cutter of another disc cutter rolls face each other with a metal sheet to form a groove in a disk surface facing the endmost disk cutter side, the reference circle An apparatus for manufacturing a grid for a battery electrode plate, wherein a peripheral side surface that is recessed by 30% to 70% of the sheet thickness of the metal sheet is formed closer to the center of the shaft than the peripheral surface.

Of the troughs in the outermost disc cutter, the troughs of the disc cutters of the other disc cutter rolls facing each other through the metal sheet have concave grooves on the disc surface facing the outermost disc cutter side. The apparatus for manufacturing a grid for a battery electrode plate according to claim 1, wherein an inclined surface that is closer to the center of the shaft toward the inner side is formed on a peripheral side surface of the case where it is formed.

A grid for a battery electrode plate manufactured by the manufacturing apparatus according to claim 1.

A manufacturing method of a battery electrode plate grid, characterized in that a battery electrode plate grid is manufactured by the manufacturing apparatus according to claim 1.