[go: up one dir, main page]

US20030082455A1 - Grid for a battery plate, method of producing the same, and battery using the same - Google Patents

Grid for a battery plate, method of producing the same, and battery using the same Download PDF

Info

Publication number
US20030082455A1
US20030082455A1 US10/177,972 US17797202A US2003082455A1 US 20030082455 A1 US20030082455 A1 US 20030082455A1 US 17797202 A US17797202 A US 17797202A US 2003082455 A1 US2003082455 A1 US 2003082455A1
Authority
US
United States
Prior art keywords
disk
face
metal sheet
valley
disk cutter
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/177,972
Other languages
English (en)
Inventor
Yoshiomi Fujiwara
Ken Sawai
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
GS Yuasa Corp
Original Assignee
Japan Storage Battery Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2001190103A external-priority patent/JP2003007307A/ja
Priority claimed from JP2001215197A external-priority patent/JP4848597B2/ja
Priority claimed from JP2001215198A external-priority patent/JP4848598B2/ja
Priority claimed from JP2001372429A external-priority patent/JP4174649B2/ja
Priority claimed from JP2002057580A external-priority patent/JP4453799B2/ja
Priority claimed from JP2002065639A external-priority patent/JP2003263990A/ja
Application filed by Japan Storage Battery Co Ltd filed Critical Japan Storage Battery Co Ltd
Assigned to JAPAN STORAGE BATTERY CO., LTD. reassignment JAPAN STORAGE BATTERY CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FUJIWARA, YOSHIOMI, SAWAI, KEN
Publication of US20030082455A1 publication Critical patent/US20030082455A1/en
Assigned to GS YUASA CORPORATION reassignment GS YUASA CORPORATION CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: JAPAN STORAGE BATTERY CO., LTD.
Priority to US12/011,372 priority Critical patent/US7814628B2/en
Priority to US12/893,812 priority patent/US8256074B2/en
Priority to US12/893,836 priority patent/US8256075B2/en
Abandoned legal-status Critical Current

Links

Images

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/70—Carriers or collectors characterised by shape or form
    • H01M4/72—Grids
    • H01M4/74—Meshes or woven material; Expanded metal
    • H01M4/745—Expanded metal
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/70—Carriers or collectors characterised by shape or form
    • H01M4/72—Grids
    • H01M4/73—Grids for lead-acid accumulators, e.g. frame plates
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/82—Multi-step processes for manufacturing carriers for lead-acid accumulators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/06—Lead-acid accumulators
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/10—Battery-grid making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/18—Expanded metal making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49108—Electric battery cell making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T83/00—Cutting
    • Y10T83/04—Processes
    • Y10T83/0605—Cut advances across work surface

Definitions

  • the present invention relates to a grid for a battery plate which is produced by a rotary expander, a method of producing it, and a battery using it.
  • a battery plate of a lead storage battery is configured by filling an active material into meshes of a grid made of lead or a lead alloy.
  • a grid is often produced by directly forming a grid-like shape by means of, for example, casting of lead or a lead alloy, or alternatively by forming meshes in a metal sheet made of lead or a lead alloy (hereinafter, a sheet such as that containing lead, a lead alloy, or another alloy is referred to merely as a metal sheet) by an expander.
  • the expander is of the reciprocal type in which meshes are sequentially formed in a metal sheet with starting from both the ends of the sheet, by vertical motions of a die cutter, or of the rotary type in which slits are formed in a zigzag pattern by rotation of a disk cutter, and the metal sheet is stretched from both the sides to develop the slits into meshes.
  • a disk cutter 1 which is used in the rotary expander, large numbers of ridges 1 a and valleys 1 b are alternately formed at regular intervals along a circumferential direction on the peripheral side face of a metal disk.
  • the valleys 1 b are curved faces consisting of the circumferential face itself constituting the peripheral side face of the disk of the disk cutter 1 .
  • the oval enlarged view in FIG. 37 shows the circumferential face in a form developed to a plane.
  • Each of the ridges 1 a is formed by protruding the circumferential face of the disk cutter 1 in a ridge-like shape toward the outer periphery.
  • the apex of the ridge is rounded and formed with being shifted toward the front side in the rotational direction (indicated by the arrow in the figure).
  • grooves 1 c are formed in both the disk-like faces and in every other valley 1 b .
  • Each of the grooves 1 c is a groove which has a width that is equal to the length (the distance between adjacent ridges 1 a ) of the corresponding valley 1 b , and a depth that is about one half of the thickness of the valley 1 b (the thickness of the disk cutter 1 ), and which is radially formed in the disk face of the disk cutter 1 .
  • the groove 1 c is formed so as to open in the valley 1 b in the outer peripheral side and have a length of some degree toward the center.
  • the grooves 1 c which are formed in every other valley 1 b are arranged so as to be alternate on both the faces.
  • a large number of such disk cutters 1 are arranged on a common rotation shaft with being separated from each other by a distance which is approximately equal to the thickness of the disk cutters 1 , thereby forming a disk cutter roll.
  • two disk cutter rolls each configured by a large number of such disk cutters 1 are vertically arranged, and a lead sheet 2 is passed between the rolls, thereby forming slits 2 a .
  • the upper and lower disk cutter rolls are placed respectively at levels which allow the valleys 1 b of the upper and lower disk cutter 1 to slightly overlap with each other.
  • the upper and lower disk cutter rolls are placed with being shifted in the axial direction by a half pitch so that each of the disk cutters 1 of the lower disk cutter roll is positioned between the disk cutters 1 of the upper disk cutter roll.
  • the rotational phase is adjusted so that, when the valley 1 b in which the groove 1 c is formed in one disk face of the upper disk cutter 1 reaches the lower end, the valley 1 b in which the groove 1 c is formed in the other disk face of the lower disk cutter 1 reaches the upper end, and, when the ridge 1 a of the upper disk cutter 1 reaches the lower end, as shown in FIG. 39( b ), the ridge 1 a of the lower disk cutter 1 reaches the upper end.
  • the slits 2 a are formed in the metal sheet 2 by the ridges 1 a of the upper and lower disk cutters 1 , and thin wires 2 b between the slits 2 a which are formed adjacently in the width direction of the metal sheet 2 are pressed by the upper and lower ridges 1 a to alternately vertically protrude in a ridge-like shape.
  • FIG. 38 shows that the slits 2 a are formed in the metal sheet 2 by the ridges 1 a of the upper and lower disk cutters 1 , and thin wires 2 b between the slits 2 a which are formed adjacently in the width direction of the metal sheet 2 are pressed by the upper and lower ridges 1 a to alternately vertically protrude in a ridge-like shape.
  • the metal sheet 2 is cut so that the slits 2 a are continuously formed, and, in the valleys where the grooves 1 c face each other, the metal sheet 2 is not cut so that the slits 2 a are intermitted to form nodes 2 c .
  • the slits 2 a each having a length corresponding to two ride-like shapes which are formed by pressing of the ridges 1 a are continuously formed in the transportation direction while being intermitted in the nodes 2 c .
  • Adjacent ones of the slits 2 a are similarly continuously formed while their nodes 2 c are shifted from each other by a half pitch. Therefore, the slits 2 a are formed in a zigzag pattern as shown in a plan view which is in a circle of FIG. 38.
  • the metal sheet (lead sheet) 2 in which the many slits 2 a are formed as described above is stretched toward both the sides in the width direction in a subsequent step.
  • the slits 2 a are widened so as to form meshes, whereby a lattice-like grid is formed in which the nodes 2 c are connected to one another by four wires 2 b that are obliquely bent to be drawn out.
  • endmost disk cutters 4 are disposed on both the axial ends of the lower disk cutter roll, respectively.
  • ridges 4 a and valleys 4 b are alternately arranged in the peripheral edge.
  • the valleys 4 b , and grooves 4 c which are formed in the valleys 4 b are configured in the strictly identical manner as the valleys 1 b and the grooves 1 c of the usual disk cutters 1 .
  • a peripheral side face configured by a reference circumferential face is formed.
  • the ridges 4 a do not protrude in a ridge-like shape toward the outer periphery, and the valleys 4 b do not have a shape which is relatively recessed with respect to the ridges 4 a .
  • the endmost disk cutters 4 are placed at the ends of the lower disk cutter roll so as to be outward juxtaposed with the usual disk cutters 1 at the ends of the upper disk cutter roll, respectively.
  • the metal sheet 2 in which the many slits 2 a are formed as described above is stretched toward both the sides in the width direction in the subsequent step of the rotary expander.
  • the slits 2 a are widened so as to form meshes, whereby a lattice-like grid is formed in which the nodes 2 c and the endmost nodes 2 f are connected to one another by four wires 2 b that are obliquely drawn out.
  • the nodes 2 c are pulled by the wires 2 b during the developing step to be inclined in a twisting direction. In FIG. 50, however, such twist is omitted and the grid is diagrammatically shown.
  • a conventional grid which is produced by using a rotary expander has a problem in that a basal end where a wire is connected to a node is cracked by corrosion and the life of a battery is shortened.
  • each of the ridges 1 a is not formed as a ridge having an isosceles triangular shape, but formed into a scalene triangular shape in which the apex 1 i is formed with being shifted toward the front side in the rotational direction.
  • the rotating disk cutter 1 forms the slits 2 a in the metal sheet 2 , and presses the fence-like portion between the slits 2 a by the ridges 1 a to project the portion in a ridge-like shape, thereby forming the wires 2 b .
  • the front half of the fence-like portion between the slits 2 a protrudes in a ridge-like shape while being gradually stretched by the apexes 1 i of the ridges 1 a , and in contrast the latter half is pressed only by the rear slopes of the ridges 1 a which are in rear of the apexes of the ridges 1 a .
  • the front half is more elongated to be thinned.
  • a rotary expander uses the disk cutter 1 in which the apex 1 i of the ridge 1 a is formed with being shifted toward the front side in the rotational direction (see Japanese Patent Publication (Kokoku) No. SH059-35694).
  • the metal sheet 2 in which the many slits 2 a are formed as described above is stretched toward both the sides in the width direction in a subsequent step, whereby the slits 2 a are widened to form rhombic meshes, with the result that a grid for a battery plate is formed.
  • the front angle ⁇ 10 is steeper than the rear angle ⁇ 20 .
  • the front bending angle ⁇ 11 is steeper than the rear bending angle ⁇ 21 .
  • the wires 2 b are pressed by the ridges 1 a of the disk cutters 1 to be elastically deformed in a ridge-like shape in which the apex 2 e is bent at the steepest curvature.
  • the ridges are stretched in an oblique direction in the developing step to become linear, therefore, the apex 2 e of each ridge remains to be elastically deformed and hence cannot be stretched into a fully linear form.
  • the wires 2 b are stretched in the developing step, consequently, the tensile stress in this process is easily concentrated in both sides of the elastically deformed portion of the apex 2 e which is bent.
  • the wires 2 b are developed in the developing step not only by being obliquely stretched to become linear, also by being twisted at the ends in opposite directions as indicated by the arrows D and E in FIG. 45.
  • FIG. 39( a ) or FIGS. 47 ( a ) and 47 ( c ) in each of the nodes 2 c , the sides in the width direction of the metal sheet 2 are vertically pressed in opposite directions by the valleys 1 b of the upper and lower the disk cutters 1 . Therefore, a level difference which approximately corresponds to the thickness of the sheet is formed between one side in the width direction and the other side, and also positions where the wires 2 b are drawn out are different in level. As shown in FIG.
  • the invention has been conducted in order to cope with the above-discussed circumstances. It is an object of the invention to provide a grid for a battery plate in which an inclined face is formed on a peripheral side face of each ridge of a disk cutter, and wires are formed in a ridge-like shape in a state where the wires are pretwisted, thereby causing the wires to hardly rupture, and also a method of producing the grid.
  • FIGS. 37 to 40 The shape of the disk cutter 1 and production steps in the production of a grid for a battery plate in which disk cutters for a rotary expander are used are shown in FIGS. 37 to 40 .
  • the slits 2 a and the nodes 2 c are formed in the metal sheet 2 .
  • the cutting is conducted while pressing each of the nodes 2 c against a ridgeline 1 k of the portion of the disk cutter 1 where the groove 1 c of the peripheral side face of the valley 1 b is formed.
  • FIG. 46( a ) As shown in FIG.
  • the invention has been conducted in order to cope with the above-discussed circumstances. It is an object of the invention to provide a method of producing a grid for a battery in which stress concentration is relaxed and rupture hardly occurs in the node 2 c , and a battery using the grid for a battery.
  • the sides in the width direction are vertically pressed in opposite directions by the valleys 1 b and 4 b of the upper and lower disk cutters 1 and the endmost disk cutters 4 in which the grooves 1 c are opposed to each other. Therefore, the sides in the width direction are vertically deformed with respect to each other by a large degree corresponding to the thickness of the metal sheet 2 or more, and the metal sheet 2 of the endmost nodes 2 f is stretched to be thinned in accordance with the deformation.
  • the invention has been conducted in order to solve the above-discussed problems. It is an object of the invention to provide a grid for a battery plate in which various unique measures are taken mainly on the peripheral side faces of the valleys 1 b between the ridges 1 a of the disk cutters 1 , to prevent rupture from occurring during a process of producing the grid, and corrosion and a crack of corrosion from occurring in nodes and edges of meshes of the grid for a battery plate, thereby preventing the capacity of a lead storage battery from being reduced, and the life of the battery from being shortened, a method of producing the grid, and a battery using the grid.
  • the invention set forth in claim 1 provides a grid for a battery plate in which a large number of slits each configured by a out elongating in a longitudinal direction are formed in a metal sheet in a zigzag pattern, the metal sheet is stretched in a width direction to develop the slits, and nodes configured between slits that are adjacent in the longitudinal direction are connected to one another to form a lattice-like shape, by four wires which are configured between slits that are adjacent in the width direction, and which are obliquely bent to be drawn out, wherein
  • At least one of the four wires connected to each of the nodes is bent in a predetermined oblique direction via a drawn-out portion which is drawn out from the node in a substantially longitudinal direction.
  • the invention set forth in claim 2 provides a method of producing a grid for a battery plate in which a metal sheet is passed between two rotating disk cutter rolls in each of which a plurality of disk cutters are placed on a same shaft with forming a gap therebetween, each of the disk cutters being configured by: alternately forming ridges which protrude in a ridge-like shape toward an outer peripheral side, and valleys composed of a circumferential face or a flat face along a circumferential direction on a peripheral side face of a disk; and forming grooves which are opened in an outer peripheral end and in every other valley alternately formed in both faces of the disk, in peripheral edges of both the faces of the disk, the disk cutter rolls being opposed to each other in a manner that the ridges of the disk cutters of one of the disk cutter rolls are placed in the gaps of the disk cutters of another disk cutter roll, whereby slits each configured by a cut elongating in a longitudinal direction are formed in the metal sheet, wherein
  • the valleys of the disk cutters of one of the disk cutter rolls which are placed respectively on both sides of the metal sheet are arranged with being shifted in phase from the valleys of the disk cutters of another disk cutter roll.
  • the invention set forth in claim 3 provides a method of producing a grid for a battery plate in which a metal sheet is passed between two rotating disk cutter rolls in each of which a plurality of disk cutters are placed on a same shaft with forming a gap therebetween, each of the disk cutters being configured by: alternately forming ridges which protrude in a ridge-like shape toward an outer peripheral side, and valleys composed of a circumferential face or a flat face along a circumferential direction on a peripheral side face of a disk; and forming grooves which are opened in an outer peripheral end and in every other valley alternately formed in both faces of the disk, in peripheral edges of both the faces of the disk, the disk cutter rolls being opposed to each other in a manner that the ridges of the disk cutters of one of the disk cutter rolls are placed in the gaps of the disk cutters of another disk cutter roll, whereby slits each configured by a cut elongating in a longitudinal direction are formed in the metal sheet, wherein
  • a length in a circumferential direction of the valleys of the disk cutters of the disk cutter roll which is placed on one side of the metal sheet is larger than a length of the valleys of the disk cutters of the disk cutter roll which is placed on another side of the metal sheet.
  • the invention set forth in claim 4 provides a method of producing a grid for a battery plate in which a metal sheet is passed between two rotating disk cutter rolls in each of which a plurality of disk cutters are placed on a same shaft with forming a gap therebetween, each of the disk cutters being configured by: alternately forming ridges which protrude in a ridge-like shape toward an outer peripheral side, and valleys composed of a circumferential face or a flat face along a circumferential direction on a peripheral side face of a disk; and forming grooves which are opened in an outer peripheral end and in every other valley alternately formed in both faces of the disk, in peripheral edges of both the faces of the disk, the disk cutter rolls being opposed to each other in a manner that the ridges of the disk cutters of one of the disk cutter rolls are placed in the gaps of the disk cutters of another disk cutter roll, whereby slits each configured by a cut elongating in a longitudinal direction are formed in the metal sheet, wherein
  • the grooves of the disk cutters of the disk cutter roll(s) which is placed on one side or both sides of the metal sheet are opened only in a part of a whole circumferential length of the valleys.
  • the slits are formed also by the valleys other than the openings, and one or more wires are pressed by the ridges to be bent in a ridge-like shape at the tip end of a drawn-out portion which is drawn out in a substantially straight manner from a node.
  • the wires which are bent via the drawn-out portion therefore, tensile stress produced during a developing process is dispersed, and hence the wires can be prevented from being easily corroded.
  • the invention set forth in claim 5 provides a method of producing a grid for a battery plate in which a metal sheet is passed between two rotating disk cutter rolls in each of which a plurality of disk cutters are placed on a same shaft with forming a gap therebetween, each of the disk cutters being configured by: alternately forming ridges which protrude in a ridge-like shape toward an outer peripheral side, and valleys composed of a circumferential face or a flat face along a circumferential direction on a peripheral side face of a disk; and forming grooves which are opened in an outer peripheral end and in every other valley alternately formed in both faces of the disk, in peripheral edges of both the faces of the disk, the disk cutter rolls being opposed to each other in a manner that the ridges of the disk cutters of one of the disk cutter rolls are placed in the gaps of the disk cutters of another disk cutter roll, whereby slits each configured by a cut elongating in a longitudinal direction are formed in the metal sheet, wherein
  • the settings including: setting in which the valleys of the disk cutters of one of the disk cutter rolls which are placed on both sides of the metal sheet are arranged with being shifted in phase from the valleys of the disk cutters of another disk cutter roll; setting in which a length in a circumferential direction of the valleys of the disk cutters of the disk cutter roll which is placed on the one side of the metal sheet is larger than a length of the valleys of the disk cutters of the disk cutter roll which is placed on the other side of the metal sheet; and setting in which the grooves of the disk cutters of the disk cutter roll(s) which is placed on the one side or both the sides of the metal sheet are opened only in a part of a whole circumferential length of the valleys.
  • the invention set forth in claim 6 provides a method of producing a grid for a battery plate wherein slits in which a small bent portion is formed between a node and a fence-like portion are formed in a metal sheet by using disk cutters of a rotary expander in each of which a plurality of ridges an apex of which is shifted toward a front side in a rotational direction protrude with forming a gap therebetween toward an outer circumference from a disk-like circumferential face at equal angular intervals, a small slope is interposed between a valley constituting a peripheral side face between two of the ridges, and at least a front slope of a peripheral side face of a ridge which is rearward adjacent to the valley, thereby connecting peripheral side faces, the small slope having an inclination angle which is between angles of the two faces, and grooves which are formed at equal angular intervals in peripheral edges of both disk-like faces are formed in every other gap face and opened alternately in both the faces.
  • the rising part of the fence-like portion between slits which are pressed by ridges of the disk cutters 1 to protrude from a node in a ridge-like shape is not bent by a steep angle, and can be bent in two steps via the small slope, so that edges of meshes which are formed by developing the slits are prevented from being easily corroded by electrolyte.
  • at least the bending angle which is formed by the valley and the slope of the ridge that is rearward adjacent thereto, and which is to be originally steep can be made gentle. Therefore, corrosion and a crack of corrosion in a node can be effectively prevented from occurring.
  • the invention set forth in claim 7 provides a method of producing a grid for a battery plate wherein slits in which a portion between a node and a fence-like portion is curved are formed in a metal sheet by using disk cutters of a rotary expander in each of which a plurality of ridges an apex of which is shifted toward a front side in a rotational direction protrude with forming a gap therebetween toward an outer circumference from a disk-like circumferential face at equal angular intervals, a curved face is interposed between a valley constituting a peripheral side face between two of the ridges, and at least a front slope of a peripheral side face of a ridge which is rearward adjacent to the valley, thereby connecting peripheral side faces, the curved face having a contact face of an inclination angle which is between angles of the two faces, and grooves which are formed at equal angular intervals in peripheral edges of both disk-like faces are formed in every other gap face and opened alternately
  • At least the edge which is formed by the valley and the slope of the ridge that is rearward adjacent thereto, and which is to be originally steeply bent can be smoothed. Therefore, corrosion and a crack of corrosion in a node can be effectively prevented from occurring.
  • the invention set forth in claim 8 provides a method of producing a grid for a battery plate wherein slits in which a node is inclined are formed in a metal sheet by using disk cutters of a rotary expander in each of which a plurality of ridges an apex of which is shifted toward a front side in a rotational direction protrude with forming a gap therebetween toward an outer circumference from a disk-like circumferential face at equal angular intervals, a valley constituting a peripheral side face between two of the ridges is formed into a face which is more inclined toward a center as being more forward than a contact face contacting with a circumferential face in which all contacting faces contacting with the valley have a same angular position at a center of a rotation shaft, and grooves which are formed at equal angular intervals in peripheral edges of both disk-like faces are formed in every other gap face and opened alternately in both the faces.
  • the valley between the ridges of the disk cutter used in the rotary expander is inclined toward the center as being more forward in the rotational direction, the bending angle formed by the valley and the steep slope of the ridge that is rearward adjacent thereto is made gentle, and that formed by the valley and the gentle slope of the ridge that is forward adjacent thereto is made steep. Consequently, the difference between the angles formed by the valley between the ridges and the slopes of the ridges that are respectively adjacent thereto on both the sides can be reduced.
  • slits are formed in a metal sheet, therefore, a node is inclined, and a phenomenon that only the rear side of the fence-like portion between slits is bent by a steep angle does not occur.
  • the valley is configured by using a face which is formed by inclining a circumferential face, the angle formed by contact faces of the circumferential face can be always made constant.
  • the valley may be configured by an inclined flat face or another curved face.
  • the invention set forth in claim 9 provides a method of producing a grid for a battery plate in which a plate is produced by a rotary expander for forming slits in a metal sheet by using disk cutters in each of which a plurality of ridges an apex of which is shifted toward a front side in a rotational direction protrude with forming a gap therebetween toward an outer circumference from a disk-like circumferential face at equal angular intervals, and grooves which are formed at equal angular intervals in peripheral edges of both disk-like faces are formed in every other valley constituting a peripheral side face between the ridges, and opened alternately in both the faces, wherein
  • each of the valleys of the disk cutter is formed into a face which is more inclined toward a center as being more forward than a contact face contacting with a circumferential face in which all contacting faces contacting with the valley have a same angular position at a center of a rotation shaft of the disk cutter.
  • the valley between the ridges of the disk cutter is inclined toward the center as being more forward in the rotational direction, the bending angle formed by the valley and the steep slope of the ridge that is rearward adjacent thereto is made gentle, and that formed by the valley and the gentle slope of the ridge that is forward adjacent thereto is made steep. Consequently, the difference between the angles formed by the valley between the ridges and the slopes of the ridges that are respectively adjacent thereto on both the sides can be reduced. Therefore, a phenomenon that only the rear side of the fence-like portion between slits of the metal sheet is bent by a steep angle does not occur.
  • the valley is configured by using a face which is formed by inclining a circumferential face, the angle formed by contact faces of the circumferential face can be always made constant.
  • the valley may be configured by an inclined flat face or another curved face.
  • the invention set forth in claim 10 is characterized in that the valley is formed into a face which is more inclined by 1° or more toward the center as being more forward than the contact face contacting with the circumferential face in which all contacting faces contacting with the valley have a same angular position at the center of the rotation shaft of the disk cutter.
  • the valley between the ridges of the disk cutter has an inclination of 10 or more, the bending angle formed by the valley and the steep slope of the ridge that is rearward adjacent thereto can be surely made gentle.
  • the invention set forth in claim 11 is characterized in that only a face of the valley excluding a front end portion is formed into a face which is more inclined toward the center as being more forward than the contact face contacting with the circumferential face in which all contacting faces contacting with the valley have a same angular position at the center of the rotation shaft of the disk cutter.
  • the valley between the ridges of the disk cutter may be configured by, for example, an inclined flat face in place of a face which is formed by inclining a circumferential face.
  • a flat face has a small inclination angle
  • the contact face of the circumferential face is more inclined toward the center as being more forward.
  • the portion where the valley is adjacent to the front ridge may be rounded, or a small slope having an intermediate inclination angle may be interposed between the valley and the front ridge.
  • a contact face of the rounded face or the small slope may be inclined more outward than a contact face of a circumferential face at the same angular position.
  • the contact face of the valley between the ridges of the disk cutter excluding such a front end portion is more inclined toward the center as being more forward. Therefore, at least the bending angle formed by the valley and the steep slope of the ridge that is rearward adjacent thereto can be surely made gentle.
  • the portion where the valley is adjacent to the rear ridge may be rounded, or a small slope having an intermediate inclination angle may be interposed between the valley and the rear ridge.
  • a contact face of the rounded face or the small slope is always more inclined toward the center than a contact face of a circumferential face at the same angular position.
  • the invention set forth in claim 12 is characterized in that the circumferential face serving as a reference of inclination of the valley is a flat face connecting together cross lines between the circumferential face and the slopes of the ridges on both the sides.
  • a conventional valley is sometimes configured by a flat face in place of a face extending along a circumferential face.
  • the rear half is a face which is slightly inclined toward the center in a larger degree as being more forward than a contact face contacting with a circumferential face at the same angular position
  • the front half is a face which is slightly inclined toward the center in a larger degree as being more rearward than a contact face contacting with a circumferential face at the same angular position.
  • the valley between the ridges is more inclined than the flat face, and hence at least the bending angle formed by the valley and the steep slope of the ridge that is rearward adjacent thereto can be surely made gentle.
  • the invention set forth in claim 13 provides a method of producing a grid for a battery plate in which a rotary expander is used for forming a large number of zigzag slits in a metal sheet by passing the metal sheet between two or more opposed disk cutter rolls, each of the disk cutter rolls being configured by placing a plurality of disk cutters on a same shaft with forming a gap therebetween, each of the disk cutters being configured by: alternately forming ridges in which a peripheral side face protrudes in a ridge-like shape toward an outer periphery from a reference circumferential face of a predetermined radius, and valleys in which a peripheral side face composed of a face substantially extending along the reference circumferential face is formed, in a whole periphery of a peripheral edge of a disk, the reference circumferential face being centered at an axis of the disk; and, for each of the valleys, forming a groove which is opened in a peripheral side face of the valley, in a peripheral edge
  • the inclined face is formed in the peripheral side face of the ridge of the disk cutters, thin wires which are configured between adjacent slits are formed in a ridge-like shape in a state where the wires are pretwisted along the inclined face when slits are formed in a metal sheet by pressing of the ridge. Furthermore, the wires are inclined toward the groove. During the developing process, therefore, the node is pulled by the wires to be set to a direction which is opposite to the twisting direction. As a result, concentration of torsion stress in the vicinity of the apexes of the wires during the developing process can be reduced.
  • the inclined face which more approaches the axis as being nearer to the disk face means that a contact face of the inclined face is inclined so as to more approach the axis of the disk cutter as being nearer to the disk face, or means that the inclined face may have a part where a contact face is parallel to the axis but is not allowed to have a part where a contact face is inclined toward the outer peripheral side.
  • the inclined face is formed from a position of a peripheral side face of a ridge, to a valley, the position being higher than the valley by one third or more of a height in a radial direction of the disk cutter extending from the valley to an apex of the ridge.
  • torsion stress is concentrated on the vicinity of an apex of a wire. Therefore, it is preferable to form the inclined face of a ridge of a disk cutter so as to extend as far as possible to the vicinity of the apex.
  • the inclined face is formed so as to extend from a level which is higher by one third or more of the ridge to the valley, therefore, the twisting which is previously formed in the wire can surely exert an effect.
  • the inclination angle of the inclined face is equal to or smaller than 40° with respect to the reference circumferential face.
  • the angle of an edge between the inclined face and the disk face can be set to 60° or more, and hence the metal sheet can be surely cut.
  • the grid for a battery plate of the invention set forth in claim 14 is characterized in that the grid is produced by the production method of claim 13.
  • the invention set forth in claim 15 provides a method of producing a grid for a battery plate in which a plurality of parallel slits are cut in a metal sheet into a zigzag pattern along an advancing direction of the metal sheet, wires which are formed by slits that are adjacent in a width direction of the metal sheet are elastically deformed in a ridge-like shape in both front and ewe directions from a face of the metal sheet, flat regions which are formed by non-slit portions are formed to become nodes of the wires, and the metal sheet is developed in the width direction, thereby forming meshes, wherein the slits which are cut into a zigzag pattern are formed by passing the metal sheet through a roll pair in which rolls are opposed to each other, each of the rolls is configured by stacking disk cutters each having ridges and valleys, the ridges protruding at regular intervals from a circumference of the disk cutter, and, in the disk cutter, grooves are disposed in a thickness direction in
  • the invention set forth in claim 16 is characterized in that the chamfered portions between the peripheral side face of the disk cutter and the disk faces of the disk cutter in which the grooves are formed are planer or curved chamfered portions.
  • the invention set forth in claim 17 provides a battery comprising a grid for a battery plate which is produced by the method of claim 15 or 16.
  • the invention set forth in claim 18 provides a method of producing a grid for a battery plate in which a rotary expander is used for forming a large number of zigzag slits in a metal sheet by passing the metal sheet between two or more opposed disk cutter rolls, each of the disk cutter rolls being configured by placing a plurality of disk cutters on a same shaft with forming a gap therebetween, each of the disk cutters being configured by: alternately forming ridges in which a peripheral side face protrudes in a ridge-like shape toward an outer periphery from a reference circumferential face of a predetermined radius, and valleys in which a peripheral side face composed of a face substantially extending along the reference circumferential face is formed, in a whole periphery of a peripheral edge of a disk, the reference circumferential face being centered at a rotation axis of the disk; and, for each of the valleys, forming a groove which is opened in a peripheral side face of the valley, in a
  • the peripheral side face of the endmost node forming valley is recessed toward the center with respect to a circumferential face of a predetermined radius by a degree which is not smaller than 30% and not larger than 70% of a thickness of the metal sheet.
  • a degree which is not smaller than 30% and not larger than 70% of a thickness of the metal sheet is not smaller than 30% and not larger than 70% of a thickness of the metal sheet.
  • the peripheral side face of the endmost node forming valley is recessed by 20% of the sheet thickness, for example, deformation of the endmost node exceeds 80% of the sheet thickness, and is not largely different from that of the prior art.
  • the peripheral side face of the endmost node forming valley is recessed by 80% of the sheet thickness, deformation of the endmost node can be restricted to a degree which slightly exceeds about 20% of the sheet thickness.
  • valleys of the endmost disk cutter other than the endmost node forming valleys slits are formed by pressing a metal sheet while exceeding the cutting plane between the disk cutter rolls, and, with respect to also the ridges (in the case of the endmost disk cutter, peripheral edge portions respectively corresponding to ridges of another disk cutter of the same disk cutter roll are referred to as “ridges”), pressing is usually conducted in a similar manner. Therefore, a step corresponding to about 80% of the sheet thickness is produced between these portions and the endmost node forming valleys.
  • the valleys of the endmost disk cutter it is not always necessary to form a groove.
  • the valleys of the endmost disk cutter other than the endmost node forming valleys the grooves are formed in the disk face of the endmost disk cutter which is outward directed. Therefore, it is entirely unnecessary to form such valleys, except the case where parts are shared by the endmost disk cutter and that which is placed in the opposite outer end.
  • the grooves of the endmost node forming valleys of the endmost disk cutter are formed in the disk face of the endmost disk cutter which is inward directed, and a space for forming endmost nodes is required between the grooves, and those of valleys of a disk cutter which is opposed to the endmost disk cutter via the metal sheet.
  • an inclined face which more approaches a center as being nearer to an outer side is formed in each of peripheral side faces of the valleys and/or the ridges of the endmost disk cutter other than the endmost node forming valleys.
  • slits are formed by pressing the metal sheet while exceeding the cutting plane between the disk cutter rolls.
  • pressing is conducted in a similar manner. Therefore, a step is produced between these portions and the endmost node forming valleys in which the peripheral side face is recessed, so that step-like undulation may be formed in the frame portion of the metal sheet.
  • each of the ridges of the endmost disk cutter preferably, a peripheral side face of the reference circumferential face or a peripheral side face which is nearer to the center than the reference circumferential face is formed.
  • the peripheral side faces of the ridges of the endmost disk cutter protrude in a ridge-like shape in the same manner as those of a usual disk cutter, the edge of the frame portion of the metal sheet is unnecessarily vertically pressed to cause deformation, because no slits are formed outside the ridges.
  • the metal sheet can be cut in many cases, even when the peripheral side face of each of the valleys of the endmost disk cutter which is opposed to the usual disk cutter does not exceed the cutting plane. Therefore, the peripheral side face of each of the valleys of the endmost disk cutter can be formed in the reference circumferential face.
  • the frame portion of the metal sheet can be prevented from largely undulating.
  • the method of producing a grid for a battery plate set forth in claim 19 is characterized in that an inclined face is formed in the peripheral side face of the endmost node forming valley, the inclined face being nearer to the center as being more inward.
  • the grid for a battery plate of the invention set forth in claim 20 is characterized in that the grid is produced by the production method of claim 18 or 19.
  • FIG. 1 is a partial enlarged perspective view showing a first example of a first embodiment of the invention, and showing the vicinity of a node of a grid in an enlarged manner;
  • FIG. 2 is a partial enlarged schematic view showing the first example of the first embodiment of the invention, and schematically showing in an enlarged manner a portion where disk cutters which are vertically placed overlap with each other;
  • FIG. 3 is a partial enlarged schematic view showing a second example of the first embodiment of the invention, and schematically showing in an enlarged manner a portion where disk cutters which are vertically placed overlap with each other;
  • FIG. 4 is a partial enlarged perspective view showing the second example of the first embodiment of the invention, and showing in an enlarged manner the vicinity of a node of a grid;
  • FIG. 5 is a partial enlarged schematic view showing a third example of the first embodiment of the invention, and schematically showing in an enlarged manner a portion where upper and lower phase-shifted disk cutters overlap with each other;
  • FIG. 6 is a partial enlarged perspective view showing the third example of the first embodiment of the invention, and showing in an enlarged manner the vicinity of a node of a grid which is produced by the phase-shifted disk cutters;
  • FIG. 7 is a partial enlarged schematic view showing a fourth example of the first embodiment of the invention, and schematically showing in an enlarged manner a portion where disk cutters which are vertically placed overlap with each other;
  • FIG. 8 is a partial enlarged perspective view showing the fourth example of the first embodiment of the invention, and showing in an enlarged manner the vicinity of a node of a grid;
  • FIG. 9 is a partial enlarged schematic view showing a fifth example of the first embodiment of the invention, and schematically showing in an enlarged manner a portion where disk cutters which are vertically placed with shifting grooves to one side overlap with each other;
  • FIG. 10 is a partial enlarged perspective view showing the fifth example of the first embodiment of the invention, and showing in an enlarged manner the vicinity of a node of a grid which is produced by the disk cutters having grooves shifted to one side;
  • FIG. 11 is a partial enlarged schematic view showing a sixth example of the first embodiment of the invention, and schematically showing in an enlarged manner a portion where disk cutters which are vertically placed with shifting grooves in opposite directions overlap with each other;
  • FIG. 12 is a partial enlarged perspective view showing the sixth example of the first embodiment of the invention, and showing in an enlarged manner the vicinity of a node of a grid which is produced by the disk cutters having grooves shifted in opposite directions;
  • FIG. 13 is a partial enlarged schematic view showing a seventh example of the first embodiment of the invention, and schematically showing in an enlarged manner a portion where upper and lower phase-shifted disk cutters overlap with each other;
  • FIG. 14 is a partial enlarged perspective view showing the seventh example of the first embodiment of the inventions, and showing in an enlarged manner the vicinity of a node of a grid which is produced by the phase-shifted disk cutters;
  • FIG. 15 is a partial enlarged front view showing a second embodiment of the invention, and showing a valley of a disk cutter;
  • FIG. 16 is a partial enlarged front longitudinal section view showing the second embodiment of the invention, and showing a fence-like portion between slits protruding in a ridge-like shape in a metal sheet;
  • FIG. 17 is a partial enlarged front view showing an embodiment of the invention, and showing a case where, in place of a small slope, a curved faces is interposed in both sides of a gap face of a disk cutter;
  • FIG. 18 is a partial enlarged front view showing a third embodiment of the invention, and showing an inclined valley of a disk cutter;
  • FIG. 19 is a partial enlarged front longitudinal section view showing the third embodiment of the invention, and showing a fence-like portion between slits protruding in a ridge-like shape in a metal sheet;
  • FIG. 20 is a front view showing a fourth embodiment of the invention, and showing the whole of a disk cutter, and a peripheral edge of the disk cutter in an enlarged manner;
  • FIG. 21 is a partial enlarged perspective view showing the fourth embodiment of the invention, and showing inclined faces formed in peripheral side faces of ridges which are opposed across a valley of the disk cutter;
  • FIG. 22 is a partial enlarged side longitudinal section view showing the fourth embodiment of the invention, and showing a slit forming step of a rotary expander and illustrating a manner in which wires of a metal sheet are twisted with being pressed by the inclined faces formed in ridges of disk cutters of upper and lower disk cutter rolls;
  • FIG. 23 is a partial enlarged perspective view showing the fourth embodiment of the invention, and showing a lead sheet and illustrating a node formed in the slit forming step, and four wires connected thereto;
  • FIG. 24 is a partial enlarged perspective view showing the fourth embodiment of the invention, and showing another first configuration example of the inclined faces formed in peripheral side faces of ridges which are opposed across a valley of the disk cutter;
  • FIG. 25 is a partial enlarged perspective view showing the fourth embodiment of the invention, and showing another second configuration example of the inclined faces formed in peripheral side faces of ridges which are opposed across a valley of the disk cutter;
  • FIG. 26 is a partial enlarged perspective view showing the fourth embodiment of the invention, and showing another third configuration example of the inclined faces formed in peripheral side faces of ridges which are opposed across a valley of the disk cutter;
  • FIG. 27( a ) is a schematic view showing a first example of a fifth embodiment of the invention, and showing a section shape taken along a plane passing through the disk center of a disk cutter and perpendicular to a disk face in the case where a node is formed in a metal sheet by a cutting tool
  • FIG. 27( b ) is a partial perspective view showing the vicinity of a valley of the disk cutter of the fifth embodiment
  • FIG. 28( a ) is a schematic view showing a second example of the fifth embodiment of the invention, and showing a section shape taken along a plane passing through the disk center of a disk cutter and perpendicular to a disk face in the case where a node is formed in a metal sheet by a cutting tool
  • FIG. 28( b ) is a partial perspective view showing the vicinity of a valley of the disk cutter of the fifth embodiment
  • FIG. 29( a ) is a schematic view showing a third example of the fifth embodiment of the invention, and showing a section shape taken along a plane passing through the disk center of a disk cutter and perpendicular to a disk face in the case where a node is formed in a metal sheet by a cutting tool
  • FIG. 29( b ) is a partial perspective view showing the vicinity of a valley of the disk cutter of the fifth embodiment
  • FIG. 30 is a partial enlarged front longitudinal section view showing a sixth embodiment of the invention, and showing a process of forming slits in a metal sheet by disk cutters of upper and lower disk cutter rolls;
  • FIG. 31 is a side view showing the sixth embodiment of the invention, and showing the configuration of an endmost disk cutter
  • FIG. 32 is a partial enlarged perspective view showing the sixth embodiment of the invention, and showing the configuration of the endmost disk cutter;
  • FIG. 33 is a partial enlarged perspective view showing the sixth embodiment of the invention, and showing the vicinity of an endmost node in a grid which is obtained by developing slits formed in a metal sheet;
  • FIG. 34 is a partial enlarged front longitudinal section view showing the sixth embodiment of the invention, and showing a process of forming slits in a metal sheet by using an endmost disk cutter in which inclined faces are formed in peripheral side faces of ridges;
  • FIG. 35 is a partial enlarged front longitudinal section view showing the sixth embodiment of the invention, and showing a process of forming slits in a metal sheet by using an endmost disk cutter in which peripheral side faces of valleys are configured as a circumferential face;
  • FIG. 36 is a partial enlarged front longitudinal section view showing the sixth embodiment of the invention, and showing a process of forming slits in a metal sheet by using an endmost disk cutter in which peripheral side faces of valleys are recessed;
  • FIG. 37 is a front view showing a prior art example, and showing the configuration of a disk cutter and a peripheral edge of the disk cutter;
  • FIG. 38 is a front view showing a prior art example, and showing a step of forming slits in a metal sheet by a disk cutter in a rotary expander;
  • FIG. 39 is a partial enlarged side longitudinal section view showing a prior art example, and showing an arrangement of disk cutters in a rotary expander;
  • FIG. 40 is a partial enlarged perspective view showing a prior art example, and showing a grid which is obtained by forming slits in a metal sheet and developing the slits;
  • FIG. 41 is a partial enlarged view showing a prior art example, and showing ridges and valleys of a disk cutter
  • FIG. 42 is a partial enlarged side longitudinal section view showing a prior art example, and showing a fence-like portion between slits protruding in a ridge-like shape in a metal sheet;
  • FIG. 43 is a partial enlarged plan view showing a prior art example, and showing a grid which is formed by developing slits of a metal sheet into meshes;
  • FIG. 44 is a partial enlarged perspective view showing a prior art example, and showing a metal sheet illustrating a node formed in the slit forming step, and wires connected thereto;
  • FIG. 45 is a partial enlarged perspective view showing a prior art example, and showing a grid which is obtained by, in a developing step, developing a metal sheet in which slits are formed in a slit forming step;
  • FIG. 46( a ) is a schematic view showing a prior art example, and showing a section shape taken along a plane passing through the disk center of a disk cutter and perpendicular to a disk face in the case where a node is formed in a metal sheet by a cutting tool
  • FIG. 46( b ) is a partial section view showing the node formed by the cutter
  • FIG. 47 is a partial enlarged front longitudinal section view showing a prior art example, and showing a process of forming slits in a metal sheet by disk cutters of upper and lower disk cutter rolls;
  • FIG. 48 is a side view showing a prior art example, and showing the configuration of an endmost disk cutter
  • FIG. 49 is a partial enlarged perspective view showing a prior art example, and showing the configuration of the endmost disk cutter.
  • FIG. 50 is a partial enlarged perspective view showing a prior art example, and showing the vicinity of an endmost node in a grid which is obtained by developing slits formed in a metal sheet.
  • FIGS. 1 and 2 show a first example of a first embodiment of the invention.
  • FIG. 1 is a partial enlarged perspective view showing the vicinity of a node of a grid in an enlarged manner
  • FIG. 2 is a partial enlarged schematic view schematically showing in an enlarged manner a portion where disk cutters which are vertically placed overlap with each other.
  • the components having the same functions as those of the prior art example shown in FIGS. 37 to 50 are denoted by the identical reference numerals.
  • the embodiment is a case where, as shown in FIG. 2, the disk cutters 1 , 1 which are vertically opposed to each other are changed in phase.
  • a plurality of the upper and lower disk cutters 1 , 1 are combined so as to be used as disk cutter rolls, respectively.
  • the disk cutters 1 , 1 lengths in the circumferential direction of the valleys 1 b and the ridges 1 a are equal to each other.
  • such disk cutters 1 , 1 are placed and rotated while their phases coincide with each other so that the valleys 1 b , 1 b vertically overlap with each other without being mutually shifted.
  • the phase of the disk cutter 1 which is placed in the upper side leads by a phase angle ⁇ .
  • the upper disk cutter 1 is placed with being slightly shifted toward the front side in the rotational direction (indicated by the arrow in FIG. 2).
  • the upper and lower disk cutters 1 , 1 in FIG. 2 are shown with being vertically separated from each other.
  • the disk cutters are placed so closely that the valleys 1 b slightly overlap with each other.
  • the circumferential faces of the disk cutters 1 , 1 are shown with being developed to a horizontal plane.
  • the slits 2 a are formed by the overlapping portions between the upper and lower ridges 1 a , 1 a , and those between the upper and lower valleys 1 b , 1 b where the grooves 1 c , 1 c are opened with facing in opposite directions, and the nodes 2 c are formed by the overlapping portions between the upper and lower valleys 1 b where the grooves 1 c are opened with facing each other.
  • the length of each node 2 c in the longitudinal direction is equal to the length in the circumferential direction of each valley 1 b , i.e., the width of each groove 1 c.
  • the nodes 2 c are formed only by the portions where the upper and lower grooves 1 c , 1 c overlap with each other, because the openings of the grooves are shifted from each other, with the result that the length of the nodes 2 in the longitudinal direction is shorter than the length of the valleys 1 b and the width of the grooves 1 c . As shown in FIG.
  • the wire 2 b (the right rear one in the figure) which is upward pressed by the ridge 1 a of the lower disk cutter 1 that lags in phase is upward bent with starting immediately from the basal end of the node 2 c
  • the wire 2 b (the right front one in the figure) which is downward pressed by the ridge 1 a of the upper disk cutter 1 that leads in phase is downward bent at the tip end of a drawn-out portion 2 d which is forward drawn out from the node 2 c in the longitudinal direction of the metal sheet 2 .
  • the drawn-out portions 2 d are portions which fail to be completely formed as the node 2 c , because they are caused to remain flat by the valley 1 b of one of the disk cutters 1 in the same manner as the node 2 c , but the metal sheet 2 is pressed to be cut by the ridge 1 a of the other disk cutter 1 where no groove 1 c exists.
  • the two diagonal wires 2 b (the left front and right rear ones in the figure) are bent with starting immediately from the basal end of the node 2 c and diagonally elongate in the same manner as in the prior art example, but the remaining two wires 2 b (the left rear and right front ones in the figure) are bent at the tip ends of the drawn-out portions 2 d which are once drawn out from the basal end of the node 2 c in the longitudinal direction of the metal sheet 2 , and then diagonally elongate.
  • FIG. 1 shows the grid after development.
  • the drawing out angles of the wires are made gentle, and there is no difference in the drawn-out portions 2 d before and after development.
  • the embodiment can be implemented simply by using as they are the disk cutters 1 which are shown in the prior art example, and shifting the phases of the upper and lower disk cutters when the disk cutter rolls are to be disposed.
  • FIG. 3 is a partial enlarged schematic view schematically showing a portion where disk cutters which are vertically placed overlap with each other
  • FIG. 4 is a partial enlarged perspective view showing the vicinity of a node of a grid in an enlarged manner.
  • FIGS. 5 and 6 show a third example of the first embodiment of the invention.
  • FIG. 5 is a partial enlarged schematic view schematically showing in an enlarged manner a portion where upper and lower phase-shifted disk cutters overlap with each other
  • FIG. 6 is a partial enlarged perspective view showing in an enlarged manner the vicinity of a node of a grid which is produced by the phase-shifted disk cutters.
  • the components having the same functions as those of the first embodiment shown in FIGS. 1 and 2 are denoted by the identical reference numerals.
  • FIGS. 3 and 5 show the upper and lower disk cutters with being vertically separated from each other, and the circumferential faces are shown with being developed to a horizontal plane.
  • FIGS. 4 and 6 show a grid which has been developed.
  • a grid for a plate of a storage battery will be described, and also a method of producing the grid from the metal sheet 2 by the upper and lower disk cutters 1 , 1 of the rotary expander will be described.
  • the lengths of the valleys 1 b of the disk cutters 1 , 1 which are vertically opposed to each other are different.
  • the length Ld in the circumferential direction of the valley 1 b of the disk cutter 1 which is placed in the lower side is longer than the length Lu of the valley 1 b of the disk cutter 1 which is placed in the upper side.
  • the width of the groove 1 c by which the groove is opened in each of the valleys 1 b of the lower disk cutter 1 is longer.
  • the pitch of the valleys 1 b along the circumference is made equal to that of the upper disk cutter 1 , by reducing the length of the ridges 1 a in the circumferential direction.
  • the phases of the upper and lower disk cutters 1 coincide with each other, so that each of the valleys 1 b of the upper disk cutter 1 overlaps just with the center of the whole length of the corresponding valley 1 b of the lower disk cutter 1 .
  • the phases of the upper and lower disk cutters 1 , 1 coincide with each other.
  • the phases may be shifted from each other.
  • the lower disk cutter 1 may lead in phase so that the rear ends of the grooves 1 c , 1 c vertically coincide with each other.
  • the wire 2 b (the right rear front one in the figure) which is upward pressed by the ridge 1 a of the lower disk cutter 1 having the longer valleys 1 b is upward bent at the tip end of the drawn-out portion 2 d which is forward drawn out from the node 2 c in the longitudinal direction.
  • the tensile stress applied to the wire 2 b during the developing process is dispersed to the whole drawn-out portion 2 d , whereby, although for one bar for each of the nodes 2 c , the possibility that a crack of corrosion due to electrolyte occurs in the wire 2 b during use of the storage battery can be reduced.
  • FIGS. 7 and 8 show a fourth example of the first embodiment of the invention.
  • FIG. 7 is a partial enlarged schematic view schematically showing in an enlarged manner a portion where disk cutters which are vertically placed overlap with each other
  • FIG. 8 is a partial enlarged perspective view showing in an enlarged manner the vicinity of a node of a grid.
  • FIGS. 9 and 10 show a fifth example of the first embodiment of the invention.
  • FIG. 9 is a partial enlarged schematic view schematically showing in an enlarged manner a portion where disk cutters which are vertically placed with shifting grooves to one side overlap with each other
  • FIG. 10 is a partial enlarged perspective view showing in an enlarged manner the vicinity of a node of a grid which is produced by the disk cutters having grooves shifted to one side.
  • FIGS. 11 and 12 show a sixth example of the first embodiment of the invention.
  • FIG. 11 is a partial enlarged schematic view schematically showing in an enlarged manner a portion where disk cutters which are vertically placed with shifting grooves in opposite directions overlap with each other
  • FIG. 12 is a partial enlarged perspective view showing in an enlarged manner the vicinity of a node of a grid which is produced by the disk cutters having grooves shifted in opposite directions.
  • FIGS. 13 and 14 show a seventh example of the first embodiment of the invention.
  • FIG. 13 is a partial enlarged schematic view schematically showing in an enlarged manner a portion where upper and lower phase-shifted disk cutters overlap with each other
  • FIG. 14 is a partial enlarged perspective view showing in an enlarged manner the vicinity of a node of a grid which is produced by the phase-shifted disk cutters.
  • FIGS. 7, 9, 11 , and 13 show the upper and lower disk cutters with being vertically separated from each other, and the circumferential faces are shown with being developed to a horizontal plane.
  • FIGS. 8, 10, 12 , and 14 show a grid which has been developed.
  • the length Lw of the valleys 1 b is longer than the width Ln of the grooves 1 c .
  • the disk cutter 1 is used in which each of the grooves 1 c is opened at the width Ln and only in the center area of the whole length Lw of a flat face 1 b (Ln ⁇ Lw).
  • the phases of the upper and lower disk cutters 1 , 1 coincide with each other.
  • the node 2 c the length of which is equal to the width Ln of the grooves 1 c is formed, because the upper and lower grooves 1 c , 1 c coincide and overlap with each other.
  • the wires 2 b connected to the node 2 c their ends are pressed by the valley 1 b where the groove 1 c is not opened. As shown in FIG. 8, therefore, the wires are upward or downward bent at the tip ends of the drawn-out portions 2 d which are frontward and backward drawn out from the node 2 c in the longitudinal direction of the lead sheet 2 .
  • the groove 1 c is opened in the center of the valley 1 b has been described.
  • the groove 1 c is opened with being shifted to one end of the valley 1 b as shown in FIG. 9.
  • the upper and lower grooves 1 c , 1 c coincide and overlap with each other, and hence the node 2 c the length of which is equal to the width Ln of the grooves 1 c is formed. As shown in FIG.
  • the tensile stress applied to the two wires 2 b during the developing process is dispersed to the whole drawn-out portions 2 d , whereby the possibility that a crack of corrosion due to electrolyte occurs in the wires 2 b during use of the storage battery can be reduced.
  • the grooves 1 c which are opened with being shifted to ends of the valleys 1 b may be formed respectively in the ends which are on the opposite sides along the frontward and backward directions in the upper and lower disk cutters 1 .
  • the upper and lower disk cutters 1 are oppositely rotated.
  • disk cutters having different shapes are used as the upper and lower disk cutters.
  • disk cutters having the same shape can be used as the upper and lower disk cutters, and hence sharing of the parts can be attained.
  • the upper and lower grooves 1 c , 1 c are shifted from each other, and hence the node 2 c is formed only by the portion where the grooves overlap with each other.
  • all of the four wires 2 b connected to the node 2 c are vertically pressed by the valleys 1 b where the groove 1 c is opened, and the valleys 1 b where the groove 1 c is not opened, and hence vertically bent at the tip ends of the drawn-out portions 2 d which are frontward and backward drawn out from the node 2 c in the longitudinal direction of the metal sheet 2 .
  • the tensile stress applied to the four wires 2 b during the developing process is dispersed to the whole drawn-out portions 2 d , whereby the possibility that a crack of corrosion due to electrolyte occurs in the wires 2 b during use of the storage battery can be remarkably reduced.
  • the grooves 1 c which are opened with being shifted to ends of the valleys 1 b may be formed respectively in the ends which are on the opposite sides along the frontward and backward directions in the upper and lower disk cutters 1 , and may be shifted in phase so that the upper and lower grooves 1 c , 1 c coincide and overlap with each other.
  • the upper and lower valleys 1 b , 1 b are shifted from each other, but the upper and lower grooves 1 c , 1 c coincide and overlap with each other, so that the node 2 c the length of which is equal to the width Ln of the grooves 1 c is formed.
  • FIG. 13 the grooves 1 c which are opened with being shifted to ends of the valleys 1 b may be formed respectively in the ends which are on the opposite sides along the frontward and backward directions in the upper and lower disk cutters 1 , and may be shifted in phase so that the upper and lower grooves 1 c , 1 c coincide and overlap with each other.
  • the two diagonal wires 2 b (the left rear and right front ones in the figure) are pressed by the upper and lower protrusions 1 a to be vertically bent with starting immediately from the basal end of the node 2 c , but the remaining two wires 2 b (the left front and right rear ones in the figure) which are vertically pressed by the ends of the valleys 1 b where the groove 2 c is not opened are vertically bent at the tip ends of the drawn-out portions 2 d which are drawn out from the basal end of the node 2 c in the longitudinal direction of the metal sheet 2 .
  • the tensile stress applied to the two wires 2 b during the developing process is dispersed to the whole drawn-out portions 2 d , whereby the possibility that a crack of corrosion due to electrolyte occurs in the wires 2 b during use of the storage battery can be reduced.
  • the various combinations in which the phases of the upper and lower disk cutters 1 , 1 are shifted from each other, the upper and lower flat faces 1 b , 1 b have different lengths, or the length of the valleys 1 b of the disk cutters 1 is longer than the width of the grooves 1 c have been described. Any other combinations of the disk cutters 1 , 1 can be used as far as at least one of the wires 2 b connected to the node 2 c has a shape in which it is bent via the drawn-out portion 2 d .
  • the upper and lower valleys 1 b , 1 b may have different lengths, and the width of both or one of the upper and lower grooves 1 c may be shorter than the lengths of the valleys 1 b .
  • the phases of the upper and lower disk cutters 1 , 1 may be shifted from each other.
  • the grid is produced by passing the metal sheet 2 of lead or a lead alloy between the upper and lower disk cutters 1 , 1 has been described.
  • the manner of arranging disk cutter rolls in which such disk cutters 1 are combinedly used can be arbitrarily selected, and is not restricted to the case where the metal sheet 2 is passed through two opposed disk cutter rolls.
  • the grid may be produced with arranging three or more disk cutter rolls in the transportation path of the metal sheet 2 .
  • a wire is bent at the tip end of a drawn-out portion which is drawn out in a substantially straight manner from a node, and hence the wire can be prevented from being easily corroded to cause a crack of corrosion.
  • a wire is bent at the tip end of a drawn-out portion which is drawn out in a substantially straight manner from a node, whereby wires of a produced grid can be prevented from being easily corroded.
  • FIGS. 15 to 17 show the second embodiment of the invention.
  • FIG. 15 is a partial enlarged front view showing a gap face of a disk cutter
  • FIG. 16 is a partial enlarged front longitudinal section view showing a fence-like portion between slits protruding in a ridge-like shape in a metal sheet
  • FIG. 17 is a partial enlarged front view showing a case where, in place of a small slope, a curved faces is interposed in both sides of a valley of a disk cutter.
  • the embodiment of the invention relates to the disk cutter 1 of a rotary expander.
  • the disk cutter 1 is a cutting tool in which a large number of ridges 1 a protrude from the peripheral side face of a thin disk-like steel plate.
  • the ridges 1 a protrude at equal angular intervals from the peripheral side face of the disk cutter 1 , and are arranged with forming a constant gap between adjacent ridges.
  • each of the ridges 1 a is formed so as to protrude in a ridge-like shape from the circumferential face A, and the apex 1 i (see FIG. 41) of the ridge 1 a is rounded so as to smoothly connect the peripheral side faces between the slopes across the apex.
  • the apex is formed with being shifted toward the front side in the rotational direction.
  • the front angle ⁇ 10 is closer to a right angle or steeper than the rear angle ⁇ 20 .
  • the valley 1 b which elongates along the circumferential face A of the disk cutter 1 is formed between the ridges 1 a .
  • the angle formed by the valley 1 b and the front slope of the ridge 1 a that is rearward adjacent thereto is ⁇ 10
  • the angle formed by the valley and the rear slope of the ridge 1 a that is forward adjacent thereto is ⁇ 20 .
  • the valley 1 b is shown in the same plane as the circumferential face A.
  • Small slopes 1 e are interposed respectively between the valley 1 b and the slopes of the ridges 1 a that are adjacent thereto on both the sides.
  • Each of the small slopes 1 e is a plane which connects the peripheral side face between the valley 1 b and the slope of the ridge 1 a , and has an inclination angle at which the small slope is raised from the valley 1 b , and which is a half of the protruding angle ( ⁇ 10 or ⁇ 20 ) of the slope of the ridge 1 a from the circumferential face A.
  • the small slopes 1 e are connected also to the slopes of the ridges 1 a at the same angle as the rising angle from the valley 1 b , and the slopes of the ridges 1 a protrude from the valley 1 b via the small slopes 1 e at the two-step bending angles.
  • the grooves 1 c which are similar to those of the prior art example are formed in both the disk-like faces and in every other valley 1 b .
  • a large number of thus configured disk cutters 1 are arranged on a rotation shaft with being separated from each other to form a roll, and two rolls of the disk cutters 1 are vertically arranged.
  • the metal sheet 2 is passed between the upper and lower roll-like disk cutters 1 , thereby forming the slits 2 a in the metal sheet 2 .
  • the fence-like portion between the slits 2 a is pressed by the ridges 1 a of the upper and lower disk cutters 1 to protrude in a ridge-like shape.
  • FIG. 2 shows that the fence-like portion between the slits 2 a is pressed by the ridges 1 a of the upper and lower disk cutters 1 to protrude in a ridge-like shape.
  • small bent portions 2 h which are bent in two steps by the small slopes 1 e are formed between the node 2 c where the slits 2 a are disconnected, and the fence-like portion (the wires 2 b ) which protrudes in a ridge-like shape.
  • the small bent portions 2 h are bent at both ends by an angle which is a half of a bending angle ( ⁇ 11 or ⁇ 21 ) in the prior art.
  • the fence-like portion (the wires 2 b ) between the slits 2 a of the metal sheet 2 can be bent in two steps via the small bent portion 2 h by an angle which is a half of the conventional bending angle.
  • the metal sheet 2 is stretched to widen the slits 2 a to form meshes, therefore, a phenomenon that the degree of cut of the slits 2 a in an end of the fence-like portion is increased to shorten the length of the nodes 2 c shown in FIG. 43 or reduce the strength of the nodes to cause rupture does not occur.
  • edges of the meshes can be prevented from being easily corroded by electrolyte.
  • each of the valleys 1 b is configured by a face which extends along the circumferential face A.
  • the valley 1 b may be configured by a face other than that extending along the circumferential face A, such as a flat face.
  • the inclination angle of the face is the inclination angle of a contacting face of a portion which is immediately in front of the portion connected to the small slope 1 e.
  • the small slope 1 e may be formed only between each of the valleys 1 b and at least the front slope of the ridge 1 a which is rearward adjacent to the valley in the rotational direction, because the slope of the rear ridge 1 a protrudes at the steeper angle ⁇ 10 with respect to the circumferential face A and hence a crack of corrosion in the node 2 c can be effectively prevented from occurring, even in a configuration in which the bending angle of the slope is simply divided into two steps.
  • the small slope 1 e has an intermediate inclination angle between the slopes of the valley 1 b and the ridge 1 a
  • the bending angle can be made gentle.
  • the bending angles in both the ends of the small slope 1 e are gentlest in the case where the intermediate inclination angle is employed as in the embodiment.
  • the curved face 1 f is rounded so that the inclination angle is closer to the inclination angle of the valley 1 b as more approaching the valley 1 b , and closer to that of the slope of the ridge 1 a as more approaching the slope of the ridge 1 a .
  • the fence-like portion between the slits 2 a of the metal sheet 2 can smoothly protrude in a ridge-like shape from the node 2 c . Therefore, cracks due to reduced strength caused by formation of angled bends can be prevented from occurring, and edges of meshes can be prevented from being easily corroded by electrolyte.
  • the slits 2 a were formed in the lead sheet 2 by using a rotary expander having the disk cutters 1 of each kind, and the amount of development which was conducted until crack occurred in the nodes 2 c was measured.
  • the slits 2 a were formed in the lead sheet 2 by using a rotary expander having the disk cutters 1 of each kind, and developed by a predetermined amount to form a grid, an active material was filled into the grid, and the grid was then cured and dried to form a positive plate.
  • the positive plate was combined with a negative plate which was produced by a conventional method, and a separator which is configured mainly by microporous polyethylene, to produce a lead storage battery for an automobile.
  • the lead storage battery was subjected to a light-load life test according to JIS standard (D 5301) in a gaseous phase of 75° C. After the life test was ended, the battery was disassembled, and the rates of crack portions in the higher- and lower-angle sides of the node 2 c in the grid were investigated.
  • a small slope or a curved face is interposed between each of the valleys and the slope of each of the ridges in the disk cutter, the angled bend between the valley and the slope of the ridge can be set to two steps so as to be gentle, or to be smoothly conducted. Therefore, the rising angle by which the fence-like portion between the slits of the metal sheet protrudes in a ridge-like shape can be made gentle, and the portion can be smoothly raised. Consequently, the portion can be prevented from being easily corroded by electrolyte, thereby preventing the capacity of a battery from being reduced, and the life of the battery from being shortened.
  • the third embodiment corresponds to a modification of the above-described second embodiment, and is also a preferable example of means for solving above discussed Problem (2) to be solved.
  • FIG. 18 is a partial enlarged front view showing an inclined valley of a disk cutter
  • FIG. 19 is a partial enlarged front longitudinal section view showing a fence-like portion between slits protruding in a ridge-like shape in a metal sheet.
  • the third embodiment of the invention relates to the disk cutter 1 of a rotary expander.
  • the disk cutter 1 is a cutting tool in which a large number of ridges 1 a protrude from the peripheral side face of a thin disk-like steel plate.
  • the ridges 1 a protrude at equal angular intervals from the peripheral side face of the disk cutter 1 , and are arranged with forming a constant gap between adjacent ridges. As shown in FIG.
  • each of the ridges 1 a is formed so as to protrude in a ridge-like shape from the circumferential face A, and rounded.
  • the apex of the ridge-like shape is formed with being shifted toward the front side in the rotational direction.
  • the front angle ⁇ 10 is closer to a right angle or steeper than the rear angle ⁇ 20 (hereinafter, for each of the ridges 1 a , the side of the front angle ⁇ 10 is referred to as “the higher-angle side”, and the side of the rear angle ⁇ 20 is referred to as “the lower-angle side”).
  • the valley 1 b in which the front side is inclined toward the center with respect to the circumferential face A of the disk cutter 1 is formed between the ridges 1 a .
  • the valley 1 b is configured by a face which is obtained by rotationally displacing the curved face extending along the circumferential face A so as to incline the front side toward the center, about the crossing line between the curved face and the slope of the rear ridge 1 a on the higher-angle side. Therefore, the valleys 1 b is a face in which all contact faces contacting with the valley 1 b are inclined toward the center by a constant angle as being more forward than the contact face which is centered at the rotation axis of the disk cutter 1 and has the same angular position.
  • the valley 1 b is set to 1° or more. Since FIG. 18 shows the circumferential face A with developing the face to a plane, also the valley 1 b is shown as a plane which is inclined by a constant angle with respect to the circumferential face A.
  • the valley 1 b is inclined in this way, the bending angle ⁇ 30 between the valley and the higher-angle side slope of the ridge 1 a which is rearward adjacent thereto is larger than the angle ⁇ 10 with respect to the circumferential face A or becomes gentle.
  • the bending angle ⁇ 40 between the valley and the lower-angle side slope of the ridge 1 a which is forward adjacent thereto is smaller than the angle ⁇ 20 with respect to the circumferential face A or becomes steep.
  • the angle ⁇ 10 with respect to the circumferential face A is originally sufficiently closer to a right angle or steeper than the angle ⁇ 20 , and hence the angle ⁇ 40 with respect to the valley 1 b is closer to the angle ⁇ 30 so as to reduce the difference.
  • the grooves 1 c which are similar to those of the prior art example are formed in both the disk-like faces and in every other valley 1 b .
  • a large number of thus configured disk cutters 1 are arranged on a rotation shaft with being separated from each other to form a roll, and two rolls of the disk cutters 1 are vertically arranged.
  • the upper and lower rollers of the disk cutters 1 are placed in the same manner as the prior art example shown in FIG. 39.
  • the valley 1 b is inclined, and hence the rolls are placed respectively at levels which allow at least the portions of the faces of the valleys 1 b which are closest to the center to slightly overlap with each other without forming a gap therebetween.
  • the metal sheet 2 is passed between the upper and lower roll-like disk cutters 1 , thereby forming the slits 2 a in the metal sheet 2 .
  • the fence-like portion between the slits 2 a is pressed by the ridges 1 a of the upper and lower roll-like disk cutters 1 to protrude in a ridge-like shape to be formed as the wires 2 b .
  • the node 2 c in which the slits 2 a are disconnected is obliquely formed by the valleys 1 b of the disk cutters 1 .
  • the bending angle ⁇ 31 with respect to the higher-angle side slope of the rear ridge is made gentle, and the bending angle ⁇ 41 with respect to the lower-angle side slope of the front ridge is made steep, so that the difference between the angles is reduced.
  • the fence-like portions (the wires 2 b ) between the slits 2 a which are adjacent to each other protrude respectively in opposite directions or upward and downward directions. Therefore, the fence-like portions on both sides of the node 2 c are inclined respectively in opposite directions or upward and downward directions, and hence the node 2 c itself is in a twisted state.
  • the fence-like portion between the slits 2 a of the metal sheet 2 is prevented from being bent only in the higher-angle side by a steep angle, and the bending angles ⁇ 31 and ⁇ 41 of the higher- and lower-angle sides can be averaged.
  • the metal sheet 2 is stretched to widen the slits 2 a to form meshes, therefore, the phenomenon in the prior art that the degree of cut in only the higher-angle side in the fence-like portion between the slits 2 a is large and the length and strength of the node 2 c shown in FIG. 43 are reduced to cause rupture in edge portions does not occur. Consequently, edges of meshes can be prevented from being easily corroded by electrolyte.
  • the valley 1 b is configured by a face which is obtained by rotationally displacing the curved face extending along the circumferential face A
  • the valley may be configured by any kind of face as far as all contact faces contacting with the valley 1 b are inclined toward the center as being more forward than the contact face which is in contact with the circumferential face A at the same angular position.
  • the face may be a curved or flat face other than a face extending along the circumferential face A.
  • the valley 1 b is a flat face which is inclined by a small angle
  • the valley 1 b is a flat face which is inclined by a small angle
  • the bending angle with respect to the higher-angle side slope of the rear ridge 1 a is made gentle.
  • the portion between the valley 1 b and the lower-angle side slope of the ridge 1 a which is forward adjacent is rounded, or a small slope having an intermediate inclination angle is interposed in the portion.
  • the face contacting with the valley 1 b may be a face which is inclined toward the center as being more forward than the contact face that is in contact with the circumferential face A at the same angular position, excluding at least a front end portion of the valley 1 b.
  • the valley 1 b is configured so that a face contacting with the valley 1 b is inclined toward the center as being more forward than the contact face which is in contact with the circumferential face A at the same angular position.
  • the face contacting with the valley 1 b may be configured by a face which is more inclined toward the center as being more forward than a plane connecting together cross lines between the circumferential face A and the slopes of the ridges 1 a on both the sides.
  • the valley 1 b is a flat face which is inclined by a small angle, a face which is surely inclined over a range to a front end portion is obtained.
  • the positive plate was combined with a negative plate which was produced by a conventional method, and a separator which is configured mainly by microporous polyethylene, to produce a lead storage battery for an automobile.
  • the lead storage battery was subjected to a light-load life test according to JIS standard (D 5301) in a gaseous phase of 75° C. After the life test was ended, the battery was disassembled, and the rates of crack portions in the higher- and lower-angle sides of the node 2 c in the grid were investigated.
  • the valley between the ridges of the disk cutter is more inclined toward the center as being more forward. Consequently, the bending angle between the valley and the steep slope of the ridge that is rearward adjacent thereto can be made large so as to be gentle.
  • the node is inclined, and the steep rising angle by which the fence-like portion between the slits protrudes in a ridge-like shape can be made gentle, so that the portion can be prevented from being easily corroded by electrolyte, thereby preventing the capacity of a battery from being reduced, and the life of the battery from being shortened.
  • FIGS. 20 to 26 show the fourth embodiment of the invention.
  • FIG. 20 is a front view showing the whole of a disk cutter, and a peripheral edge of the disk cutter in an enlarged manner
  • FIG. 21 is a partial enlarged perspective view showing inclined faces formed in peripheral side faces of ridges which are opposed across a valley of the disk cutter
  • FIG. 22 is a partial enlarged side longitudinal section view showing a slit forming step of a rotary expander and illustrating a manner in which wires of a metal sheet are twisted with being pressed by the inclined faces formed in ridges of disk cutters of upper and lower disk cutter rolls
  • FIG. 20 is a front view showing the whole of a disk cutter, and a peripheral edge of the disk cutter in an enlarged manner
  • FIG. 21 is a partial enlarged perspective view showing inclined faces formed in peripheral side faces of ridges which are opposed across a valley of the disk cutter
  • FIG. 22 is a partial enlarged side longitudinal section view showing a slit forming step of a rotary
  • FIG. 23 is a partial enlarged perspective view showing a metal sheet and illustrating a node formed in the slit forming step, and four wires connected thereto
  • FIG. 24 is a partial enlarged perspective view showing another first configuration example of the inclined faces formed in peripheral side faces of ridges which are opposed across a valley of the disk cutter
  • FIG. 25 is a partial enlarged perspective view showing another second configuration example of the inclined faces formed in peripheral side faces of ridges which are opposed across a valley of the disk cutter
  • FIG. 26 is a partial enlarged perspective view showing another third configuration example of the inclined faces formed in peripheral side faces of ridges which are opposed across a valley of the disk cutter.
  • the fourth embodiment of the invention relates to a rotary expander for producing a grid for a battery (lead storage battery) plate.
  • the metal sheet 2 is passed between the upper and lower disk cutter rolls to form a large number of zigzag slits 2 a in the metal sheet 2 .
  • the portion between the slits 2 a in the width direction of the lead sheet 2 is configured as the wire 2 b , and that between the slits in the advancing direction is configured as the node 2 c.
  • the disk cutter 1 In each of the disk cutter rolls, in the same manner as the prior art example, a large number of the disk cutters 1 are arranged with forming a gap therebetween. However, the disk cutter 1 is configured in a manner different from the prior art example.
  • the ridges 1 a having a relatively long circumferential length, and the valleys 1 b having a relatively short circumferential length are alternately formed in a large number in the peripheral edge of a metal disk over the whole circumference.
  • a peripheral side face configured by a reference circumferential face of a predetermined radius and centered at the axis of the disk cutter 1 is formed in the same manner as the prior art example.
  • the groove 1 c which is opened in a peripheral side face of the valley 1 b is formed in a peripheral edge portion of one of disk faces in which valleys 1 b that are adjacent to each other via the ridge 1 a are formed in an oppositely reverse manner.
  • the oval enlarged view shows the reference circumferential face in a form developed to a plane.
  • a peripheral side face which protrudes in a ridge-like shape from the reference circumferential face toward the outer periphery.
  • the peripheral side face of the ridge 1 a is formed in a ridge-like shape in which the peripheral side face obliquely rises in a substantially linear manner from the reference circumferential face that is a peripheral side face of the valley 1 b toward the outer peripheral side, is curved in the apex of the ridge 1 a , and obliquely falls in a substantially linear manner toward the inner peripheral side to return to the reference circumferential face.
  • the rising and falling portions of the peripheral side face of the ridge 1 a are not evenly formed in the rotational direction with respect to the apex of the ridge 1 a .
  • the apex is shifted toward the front side in the rotational direction, so that the rising portion which is in the front side in the rotational direction is a peripheral side face which is steeper than the falling portion in the rear side.
  • the configuration in which the apex of the ridge 1 a is shifted toward the front side in the rotational direction is identical with that of the prior art.
  • Inclined faces 1 g , 1 g are formed in the rising and falling portions of the peripheral side face of the ridge 1 a , respectively.
  • the inclined faces 1 g are formed respectively in ranges from middles of the rising and falling portions of the peripheral side faces of the ridges 1 a , to the valley 1 b , and, in the same manner as the grooves 1 c , formed as faces which are alternately inclined in opposite directions for each of the valleys 1 b .
  • the inclined faces are more inclined toward the center of the rotation shaft of the disk cutter 1 as being nearer to the disk face (directed to the right lower side in FIG.
  • the groove 1 c opened in the valley 1 b is formed, respectively in the falling portion of the peripheral side face of the ridge 1 a which is in the front side in the rotational direction, and the rising portion of the peripheral side face of the ridge 1 a which is in the rear side in the rotational direction (or in the falling and rising portions which are opposed to each other across the valley 1 b ), the ridge portions being adjacent to both the sides of the valley 1 b .
  • the inclined face 1 g formed in the rising portion, and that formed in the falling portion are inclined in opposite directions, respectively.
  • the inclined face 1 g is configured by a plane enclosed by a triangle in which the vertexes are points A, B, and C shown in FIG. 21.
  • the point A is a point where, when the distance (height) from the intermediate part of the edge of the falling portion of the peripheral side face of the ridge 1 a shown in the right upper side of FIG. 21 on the side of the disk face directed to the right lower side in FIG.
  • the reference circumferential face that is a peripheral side face of the valley 1 b , to the apex of the ridge 1 a is indicated by H, a tangential line with a circumferential face of a radius which is larger by H/2 than the predetermined radius of the reference circumferential face, and the peripheral side face of the ridge 1 a intersects the disk face.
  • the point B is a point where the edge of the falling portion of the peripheral side face of the ridge 1 a on the side of the disk face directed to the left upper side in FIG. 21 is in contact with the peripheral side face of the valley 1 b .
  • the point C is a point which is on the peripheral edge the disk face directed to the right lower side in FIG.
  • the inclined face 1 g is inclined with respect to the falling portion of the peripheral side face of the ridge 1 a.
  • the inclined face 1 g formed in the right upper side of the valley 1 b shown in FIG. 21 has been described. Also the inclined face 1 g formed in the left lower side of the valley 1 b shown in FIG. 21 is configured by a plane enclosed by a similar triangle, and is a face which is inclined in the same direction with respect to the peripheral side face of the ridge 1 a .
  • inclined faces 1 g , 1 g which are inclined in opposite directions are formed.
  • the metal sheet 2 is passed between disk cutter rolls using the disk cutters 1 in which the inclined faces 1 g are formed, the metal sheet is vertically pressed by the inclined faces 1 g of the ridges 1 a of the disk cutters 1 as shown in FIG. 22, at the timing when the slits 2 a are formed by the ridges 1 a , whereby the wires 2 b are deformed in a ridge-like shape while being twisted.
  • the section shape is not a rectangular shape but a parallelogram shape. In each of the wires 2 b , as shown in FIG.
  • the portion which is pressed by the inclined face 1 g of the ridge 1 a i.e., the end portion connected to the node 2 c (the dotted portion in FIG. 23) is formed with being twisted from the beginning.
  • the twisting direction of the end portion of the wire 2 b indicated by the arrow R of FIG. 23 is opposite to the direction in which the node 2 c connected to the end portion is twisted during the developing process, i.e., the direction of the arrow F which has been described in conjunction with FIG. 45.
  • the relationship in which the twisting directions of the arrows R and F are opposite to each other is applied also to the two upper wires 2 b shown in FIG. 23.
  • the wires 2 b connected to the node are formed with being twisted in the direction opposite to that of the arrow G.
  • the rotary expander of the embodiment deforms the wires 2 b into a ridge-like shape in a state where the end portions of each of the wires 2 b are pretwisted by the inclined faces 1 g formed in the peripheral side faces of the ridges 1 a of the disk cutter 1 . Moreover, the end portions of the wire 2 b are twisted in the direction opposite to the direction in which the node 2 c is twisted during the process of developing the metal sheet 2 .
  • the wires 2 b connected to the node receive torsion stress in which the previously applied twisting is canceled.
  • influence of torsion stress applied to the end portions can be reduced, and the torsion stress can be prevented from being concentrated into the vicinity of the apex 2 e of the wire 2 b.
  • the point C of the inclined face 1 g is made closer to the ridge 1 a along the reference circumferential face than the point O as shown in FIG. 21 .
  • the point C may be made close toward the axis along the edge of the groove 1 c , i.e., a radial direction of the disk cutter 1 .
  • the peripheral side face of the valley 1 b is widened by the area of the triangle BOC.
  • the inclined faces 1 g are naturally connected to the peripheral side face of the valley 1 b and the groove 1 c , so that twisting applied to the end portions of the wire 2 b can be smoothed.
  • the peripheral side face of the valley 1 b is caused to extend along the side BC of the inclined face 1 g by forming a tapered face in which the edge on the side of the disk face where the groove 1 c is not formed coincides with the reference circumferential face and the radius is made smaller as being nearer toward the disk face where the groove 1 c is formed.
  • the point B of the inclined face 1 g in FIG. 24 may be moved to the edge of the opening of the groove 1 c along the reference circumferential face.
  • the maximum width of the inclined face 1 g is only about one half of the width of the peripheral side face of the ridge 1 a , the torsion stress can be reduced even in the case where about a half portion of the width of the wire 2 b is pretwisted instead of the whole width.
  • the groove 1 c for forming the node 2 c in the metal sheet 2 is used for preventing the slits 2 a from being formed in the metal sheet 2 , by means of the gap between the groove and the groove 1 c of the opposed disk cutter 1 , the groove 1 c is not always required to be rectangular. As shown in FIG. 26, for example, the groove 1 c may be formed by chamfering the peripheral side face of the valley 1 b , so as to be configured by a face through which edge sides of the inclined faces 1 g on both sides are connected to each other.
  • the peripheral side faces of the ridges 1 a of the disk cutters 1 which are alternately opposed are pressed to each other through the metal sheet 2 , thereby forming the slits 2 a in the metal sheet 2 . Therefore, it is preferable to set the angle of the edge formed by the peripheral side face of the ridge 1 a and the corresponding one of the disk faces of the disk cutters 1 , to be as acute as possible, and usually to 90°.
  • the inclined face 1 g is formed in the peripheral side face of the ridge 1 a , however, the edge between the inclined face 1 g and the disk face inevitably has an obtuse angle.
  • the inclination angle of the inclined face 1 g must be set so as not to be excessively large.
  • the inclination angle with respect to the reference circumferential face is set to be equal to or smaller than 40°, so that the angle of an edge between the inclined face and the disk face can be set to 60° or more, thereby enabling the slits 2 a to be surely formed in the metal sheet 2 .
  • the inclined face 1 g is formed with starting from a position which is as near as possible to the apex of the ridge 1 a . Therefore, it is preferable to set the point A of the inclined face 1 g which is nearest to the apex to a level that is at least one third of the height H of the apex. In the embodiment, the point A is located at a level that is about a half of the height H of the apex. It is a matter of course that the inclined face 1 g may be formed with starting from a position which is nearer to the apex.
  • the inclined face 1 g When the inclined face 1 g is formed so as to extend to a position which is very near to the apex of the ridge 1 a , however, the inclined face 1 g abuts against the metal sheet 2 at the timing when cutting for the slits 2 a is initially formed in the metal sheet, and hence the edge with respect to the disk face has an obtuse angle, thereby causing the possibility that the cutting operation cannot be smoothly started.
  • the inclined face 1 g is formed as a flat face.
  • the inclined face is not always necessary to be flat, as far as the face more approaches the axis of the disk cutter 1 as being nearer to the disk face on the side where the groove 1 c of the adjacent valley 1 b is formed, and may be formed by a curved face or a plurality of flat faces.
  • the inclined face 1 g is not required to be a triangle surrounded by three vertexes.
  • the rotary expander in which the metal sheet 2 is passed between upper and lower or two disk cutter rolls has been described.
  • the disk cutter rolls can be arranged in an arbitrary manner.
  • the invention can be similarly applied also to a rotary expander in which the metal sheet 2 is passed between three or more disk cutter rolls that are opposedly arranged.
  • the metal sheet 2 is processed to produce a grid which is to be used in a battery plate of a lead storage battery.
  • the invention is not restricted to a lead storage battery, and can be applied also to a battery of any kind as far as a similar grid is used as a current collecting member of a battery plate.
  • a grid can be produced by using a metal sheet of an appropriate material which corresponds to the kind of the battery.
  • the grids of the embodiment and the prior art example were produced from the metal sheets (lead sheet) 2 by using the disk cutter 1 which has been described in the embodiment, and the disk cutter 1 which has been described in the prior art example.
  • the rate of rupture was investigated by observing in detail the vicinities of apexes 2 e of the wires 2 b after development.
  • An active material was filled into the grids of the embodiment and the prior art example, and the grids were then cured and dried to form positive plates.
  • the plates were incorporated into lead storage batteries (Type 55D23 of JIS) for an automobile, and a given amount of diluted sulfuric acid of a predetermined specific gravity was poured and formation was performed to complete the batteries.
  • the inclined face 1 g was configured as a triangular flat face such as shown in FIG. 21. Grids in which the height from reference circumferential face that is a peripheral side face of the valley 1 b to the inclination starting position (point A) of the inclined face 1 g which is nearest to the apex is 20%, 50% (H/2), or 70% of the height H of the apex of the ridge 1 a were produced. In principle, the inclination angle of the inclined face 1 g with respect to the reference circumferential face was set to 30°. In grids in which the inclination starting position of the inclined face 1 g is set to 70%, however, a plurality of grids were produced in a range of 10°to 50°.
  • the difference with respect to the prior art example is relatively small, and hence it has been seen that it is preferable to set the inclination starting position to a position which is at least one third (about 33%) or higher of the height H of the apex of the ridge 1 a.
  • the wires of the metal sheet are pressed into a ridge-like shape in a twisted state by the inclined faces formed in the peripheral side faces of the ridges of the disk cutter. Therefore, concentration of torsion stress of the opposite direction in the vicinity of the apexes of the wires and generated during the developing process can be suppressed. As a result, corrosion and a crack of corrosion can be prevented from occurring in the wires of the grid, so that a failure of a battery can be suppressed from occurring and the life of a battery can be prolonged.
  • FIGS. 27 to 29 show a fifth embodiment of the invention.
  • FIG. 27 is a longitudinal section view showing a first example of formation of a node in the metal sheet 2 by a disk cutter
  • FIG. 28 is a longitudinal section view showing a second example of formation of a node in the metal sheet 2 by a disk cutter
  • FIG. 29 is a longitudinal section view showing a third example of formation of a node in the metal sheet 2 by a disk cutter.
  • FIG. 27( a ) As shown in FIG. 27( a ), two disk cutter rolls each configured by a large number of such disk cutters 1 are vertically arranged, and a lead sheet 2 is passed between the rolls, thereby forming slits 2 a and the nodes 2 a .
  • the upper and lower disk cutter rolls are placed respectively at levels which allow the valleys 1 b of the upper and lower disk cutters 1 to slightly overlap with each other.
  • a chamfered portion 1 m is formed so as to be lowered toward each of the grooves 1 c which are alternately disposed in the width direction.
  • the ridges 1 a , and the valley 1 b between the ridges 1 a are formed, and the chamfered portion 1 m is disposed over a range from the peripheral side face of the valley 1 b to the groove 1 c .
  • the chamfered portion 1 m is lowered as moving from the peripheral side face of the valley 1 b toward the groove 1 c .
  • a new ridgeline 1 j which is formed on the side of the groove 1 c does not damage the node 2 c of the metal sheet 2 .
  • the chamfered portion 1 m which is formed from the peripheral side face of the valley 1 b of the disk cutter 1 to the groove 1 c may be further chamfered to form a chamfered portion 1 n in the ridgeline 1 j between the chamfered portion 1 m to the groove 1 c .
  • a curved face 1 p may be disposed in the peripheral side face of the valley 1 b .
  • the chamfered portions 1 m and 1 n , or the curved face 1 p is effective in improvement of the strength and suppression of local corrosion which are due to suppression of rupture of the node 2 c formed in the metal sheet 2 .
  • a plurality of slits which are parallel to one another were formed intermittently and in a zigzag pattern along the longitudinal direction of a lead sheet 2 that is the metal sheet 2 . Thereafter, the sheet was developed in the width direction to attain a predetermined dimension to form meshes, thereby producing a grid for a battery plate (see, for example, FIG. 38).
  • An active material was filled into grids which were produced by this method, and the grids were then cured and dried to form positive plates.
  • the positive plates, negative plates which were formed by a usual method, and separators which are configured mainly by microporous polyethylene were combined to one another to produce lead storage batteries (Type 55D23) for an automobile. Then, a given amount of diluted sulfuric acid of a predetermined specific gravity was poured into the batteries, and formation was performed to complete the batteries.
  • Batteries having grids that were produced by using the disk cutters 1 in which the angle ⁇ (FIG. 4) formed by the peripheral side face not constituting the ridge 1 a and the disk face 3 is changed in a range of 90 to 60°, and those having grids that were produced by using the disk cutters 1 in which the portion between the peripheral side face and the disk face 3 where the groove 4 is formed is chamfered and various kinds of flat or curved faces are formed were subjected to a light-load life test according to JIS standard (D 5301) in a gaseous phase of 75° C. After the life test was ended, the batteries were disassembled, and the rate of crack of corrosion due to rupture in the node 2 c was investigated (Table 4).
  • FIGS. 30 to 36 show the sixth embodiment of the invention.
  • FIG. 30 is a partial enlarged front longitudinal section view showing a process of forming slits in a metal sheet (including a lead sheet) by disk cutters of upper and lower disk cutter rolls
  • FIG. 31 is a side view showing the configuration of an endmost disk cutter
  • FIG. 32 is a partial enlarged perspective view showing the configuration of the endmost disk cutter
  • FIG. 33 is a partial enlarged perspective view showing the vicinity of an endmost node in a grid which is obtained by developing slits formed in a metal sheet
  • FIG. 30 is a partial enlarged front longitudinal section view showing a process of forming slits in a metal sheet (including a lead sheet) by disk cutters of upper and lower disk cutter rolls
  • FIG. 31 is a side view showing the configuration of an endmost disk cutter
  • FIG. 32 is a partial enlarged perspective view showing the configuration of the endmost disk cutter
  • FIG. 33 is a partial enlarged perspective view showing the vicinity of an end
  • FIG. 34 is a partial enlarged front longitudinal section view showing a process of forming slits in a metal sheet by using an endmost disk cutter in which inclined faces are formed in peripheral side faces of ridges
  • FIG. 35 is a partial enlarged front longitudinal section view showing a process of forming slits in a metal sheet by using an endmost disk cutter in which peripheral side faces of valleys are configured as a circumferential face
  • FIG. 36 is a partial enlarged front longitudinal section view showing a process of forming slits in a metal sheet by using an endmost disk cutter in which peripheral side faces of valleys are recessed.
  • the embodiment in a manner similar to the prior art example, also the embodiment relates to a rotary expander for producing a grid for a battery plate of a lead storage battery.
  • the metal sheet 2 is passed between the upper and lower disk cutter rolls to form zigzag slits 2 a in the metal sheet 2 .
  • the upper disk cutter roll is configured in the same manner as the prior art example.
  • the lower disk cutter roll has the same configuration as the prior art in which the endmost disk cutters 4 are disposed at both the ends of a large number of the disk cutters 1 , but the configuration of the endmost disk cutters 4 is different from that of the prior art example.
  • the ridges 4 a and the valleys 4 b are alternately arranged in the peripheral edge.
  • the ridges 4 a and the valleys 4 b in the endmost disk cutter 4 show the peripheral edge corresponding to the ridges 1 a and the valleys 1 b in the disk cutter 1 placed in the same disk cutter roll, and do not always have a ridge-like shape or a valley-like shape.
  • a peripheral side face configured by a reference circumferential face of a predetermined radius and centered at the axis of the endmost disk cutter 4 is formed in the ridge 4 a , and the valley 4 b is not formed as a concave portion between the ridges 4 a .
  • the groove 4 c is not formed in each of the valleys 4 b , an inward inclined face 4 d which is a peripheral side face recessed toward the center from the reference circumferential face, and which is inward inclined is formed in each of the valleys 4 b (endmost node forming valleys) on one side which are alternately arranged, and an outward inclined face 4 e which is outward inclined is formed in each of the valleys 4 b on the other side.
  • the peripheral side face of the valley 4 b on the one side forms the inward inclined face 4 d configured by a part of a tapered face wherein the portion contacting with the outer disk face (the rear face in FIG. 31, and the right front face in FIG.
  • the endmost disk cutter 4 coincides with a circumferential face which is centered at the axis of the endmost disk cutter 4 , and in which the radius is smaller than the predetermined radius of the reference circumferential face by 50% of the thickness of the metal sheet 2 .
  • the radius of the tapered face is smaller as further moving from the portion toward the inner disk face (the front face in FIG. 31, and the left rear face in FIG. 32).
  • a peripheral side face that is recessed by one step from the ridges 4 a which are adjacent on both the sides, and in which a peripheral side face is configured by the reference circumferential face is formed, and the peripheral side face is configured by the inward inclined face 4 d which is more inclined toward the center as being nearer the inner disk face of the endmost disk cutter 4 .
  • the inward inclined face 4 d is not always required to be a part of a tapered face, and may be a flat face or a curved face of another kind depending on the circumstances of the process or the like, as far as the face is recessed from the peripheral side face of the ridge 4 a and inward inclined.
  • Each of the valleys 4 b (the valleys other than the endmost node forming valleys) on the other side of the endmost disk cutter 4 forms the outward inclined face 4 e configured by a part of a tapered face wherein the portion contacting with the inner disk face of the endmost disk cutter 4 coincides with the reference circumferential face of the predetermined radius, and in which the radius is smaller than the predetermined radius as further moving from the portion toward the outer disk face of the endmost disk cutter 4 .
  • the valley 4 b on the other side has a shape where the outermost diameter is equal to that of the ridges 4 a which are adjacent on both the sides, and in which a peripheral side face configured by the reference circumferential face is formed, and the outward inclined face 4 e is formed by obliquely cutting away in the outer disk face.
  • the outward inclined face 4 e is not always required to be a part of a tapered face, and may be a flat face or a curved face of another kind depending on the circumstances of the process or the like, as far as the face is more inclined toward the center than the peripheral side face of the predetermined radius as being nearer to the outer disk face.
  • the thus configured endmost disk cutters 4 are placed at the ends of the lower disk cutter roll so as to be outward juxtaposed with the usual disk cutters 1 at the ends of the upper disk cutter roll, respectively.
  • the phase in the rotational direction is adjusted so that the valley 4 b which is an endmost node forming valley of the endmost disk cutter 4 is opposed at the upper end via the metal sheet 2 to the valley 1 b of the disk cutter 1 of the upper disk cutter roll in which the groove 1 c is formed in the opposed face.
  • the metal sheet 2 is transported so as to be passed between the upper and lower disk cutter rolls. At this time, conventionally, the metal sheet 2 is transported with being placed on the transportation face which coincides with the cutting plane S between the upper and lower disk cutter rolls.
  • the transportation face is set to be lower than the cutting plane S by 50% of the thickness of the metal sheet 2 .
  • the cutting plane S of the upper and lower disk cutter rolls is set so as to coincide with the transportation face for the metal sheet 2 , i.e., the lower face of the metal sheet 2 .
  • the cutting plane S of the upper and lower disk cutter rolls is set so as to coincide with the middle portion of the thickness of the metal sheet 2 transported on the transportation face.
  • the cutting plane S is a plane in which the distances from the axes of the upper and lower disk cutter rolls are equal to each other.
  • the predetermined radius of the reference circumferential face constituting the peripheral side face of the valley 1 b of each of the upper and lower disk cutters 1 is slightly larger than the distance from the axis to the cutting plane S.
  • the peripheral side face of the valley 1 b of the upper disk cutter 1 is at the lower end, the peripheral side face slightly downward exceeds the cutting plane S, and the peripheral side face of the valley 1 b of the lower disk cutter 1 , that of the ridge 4 a of the endmost disk cutter 4 , and the outermost peripheral end of the peripheral side face of the valleys 4 b of the endmost disk cutter 4 other than the endmost node forming valleys slightly upward exceed the cutting plane S.
  • the valley 4 b of the endmost disk cutter 4 is an endmost node forming valley, i.e., the valley faces the groove 1 c of the adjacent upper disk cutter 1 (the left end in FIG. 30( a ), and the right end in FIG. 30( c ))
  • the endmost node 2 f connected to the frame portion 2 g of the metal sheet 2 is formed.
  • one end in the width direction of the metal sheet 2 the left one in FIG. 30( a ), and the right one in FIG.
  • the valley 4 b of the endmost disk cutter 4 is not an endmost node forming valley, i.e., the valley faces the groove 1 c of the valley 1 b of the adjacent upper disk cutter 1 (the right end in FIG. 30( a ), and the left end in FIG. 30( c ))
  • the end of the frame portion 2 g of the metal sheet 2 is cut by means of the valley 1 b of the extreme end disk cutter 1 in the upper disk cutter roll.
  • the portion which is above the valley 4 b of the endmost disk cutter 4 is gently bent from the transportation face along the outward inclined face 4 e.
  • the metal sheet 2 above the ridge 4 a of the endmost disk cutter 4 is cut by the upper disk cutter 1 which is inward adjacent, to be formed as an end of the frame portion 2 g , and upward pressed by the ridge 4 a to the cutting plane S by 50% of the sheet thickness.
  • the metal sheet 2 in which the many slits 2 a are formed as described above is stretched toward both the sides in the width direction in the subsequent step of the rotary expander.
  • the slits 2 a are widened so as to form meshes, whereby a lattice-like grid is formed in which the nodes 2 c and the endmost nodes 2 f are connected to one another by four wires 2 b that are obliquely drawn out.
  • twist of the node 2 c and the wire 2 b is omitted and the grid is diagrammatically shown.
  • the vertical deformation of the endmost nodes 2 f in the metal sheet 2 is about a half of the sheet thickness. Therefore, concentration of stress in the endmost nodes 2 f is reduced. Even after the wire 2 b is obliquely pulled as a result of development, corrosion or heat generation hardly occurs in the endmost nodes 2 f , and there is little chance of breakage of the wire 2 b as compared with the usual node 2 c . Since the wire 2 b which is closest to the frame portions 2 g of the metal sheet 2 is hardly broken, it is possible to surely prevent the capacity of a lead storage battery from being largely reduced.
  • the outermost radius of the valley 1 b that is the endmost node forming valley is smaller than the predetermined radius by 50% of the thickness of the metal sheet 2 .
  • this difference is not restricted to 50% of the sheet thickness as far as the outermost radius is smaller than the predetermined radius.
  • the degree by which the outermost radius is reduced from the predetermined radius is smaller, the amount of the vertical deformation of the endmost nodes 2 f is larger.
  • the degree by which the outermost radius is smaller than the predetermined radius is large, the vertical level difference with respect to the position where the metal sheet 2 is cut in the valleys 1 b other than the endmost node forming valleys becomes excessively large.
  • the outermost radius is smaller than the predetermined radius by 100% or more of the sheet thickness
  • the peripheral side face of the valley 1 b that is the endmost node forming valley cannot support the endmost node 2 f of the metal sheet 2 . Therefore, it is preferable to set the outermost radius of the valley 1 b that is the endmost node forming valley, to be smaller than the predetermined radius by a degree in a range from 30% or more to 70% or less of the thickness of the metal sheet 2 .
  • the peripheral side face of the ridge 4 a of the endmost disk cutter 4 is used as the reference circumferential face.
  • the peripheral side face of the ridge 4 a may be formed as an inclined face similar to the outward inclined face 4 e of the valley 4 b other than the endmost node forming valleys.
  • the peripheral side faces of the ridge 4 a of the endmost disk cutter 4 and the valley 4 b other than the endmost node forming valleys constitute the same inclined face, and the inward inclined face 4 d which is inclined in the opposite direction is formed only in the peripheral side face of the valley 4 b that is the endmost node forming valley.
  • each of the peripheral side faces of the valleys 4 b may be configured by a circumferential face.
  • the peripheral side face of the valley 4 b (the left end in FIG. 35) that is the endmost node forming valley is configured by a circumferential face of a radius which is smaller than the predetermined radius by 100% of the sheet thickness, and the peripheral side face of the valley 4 b (the right end in FIG.
  • the reference circumferential face of the predetermined radius is the reference circumferential face of the predetermined radius.
  • the peripheral side face of the valley 4 b that is the endmost node forming valley may be configured by a circumferential face of a radius which is smaller than the predetermined radius of the reference circumferential face by 50% of the sheet thickness.
  • the endmost node 2 f is abruptly changed in a small range as compared with the case where the inward inclined face 4 d is formed as in the embodiment.
  • the amount of vertical deformation of the endmost node 2 f is identical, the node is abruptly changed in a smaller range in the axial direction of the disk cutter roll.
  • the groove 4 c is not formed in the endmost disk cutter 4 .
  • the inner side of the peripheral side face of the valley 4 b stepwise sinks.
  • the peripheral side face is configured by a circumferential face of a radius which is smaller than the predetermined radius of the reference circumferential face by 50% of the sheet thickness, therefore, the endmost node 2 f is not abruptly deformed.
  • the step due to the groove 4 c allows the metal sheet 2 to be gently deformed, in the same manner as the inward inclined face 4 d and the outward inclined face 4 e in the valleys 4 b in the embodiment.
  • the peripheral side face of the valley 4 b that is the endmost node forming valley in the endmost disk cutter 4 is requested only to have the outermost radius which is smaller than the predetermined radius, and not required to be a circumferential face.
  • the peripheral side face may be a flat face which extends substantially along the circumferential face, a tapered face as in the embodiment, or a flat inclined face which extends substantially along the tapered face.
  • the peripheral side face may have a step-like shape as in the case where the groove 4 c is formed, or may be an arbitrary curved face or a face of another kind.
  • the valley 4 b other than the endmost node forming valleys in order to cut the metal sheet 2 in combination with the valley 1 b of the upper disk cutter 1 , at least the outer radius of the inner end must be larger than the predetermined radius and exceed the cutting plane S.
  • the valley 4 b other than the endmost node forming valleys may be configured by any kind of face.
  • the peripheral side face of the ridge 4 a of the endmost disk cutter 4 is the reference circumferential face of the predetermined radius.
  • the peripheral side face of the ridge 4 a may be configured by a circumferential face of a radius which is smaller than the predetermined radius by 50% of the sheet thickness.
  • the peripheral side face of the ridge 4 a has a radius which is equal to the outermost radius of the outer end of the inward inclined face 4 d of the valley 4 b that is the endmost node forming valley in the embodiment.
  • the ridge 4 a must cut the metal sheet 2 in combination with the ridge 1 a of the upper disk cutter 1 .
  • the peripheral side face of the ridge 4 a of the lower disk cutter 1 can be formed as such a circumferential face of a radius which is smaller than the predetermined radius.
  • the amount of the downward protrusion in both the basal areas of the ridge 1 a of the upper disk cutter 1 is small, and hence there arises the possibility that, in the areas, the radius of the peripheral side face of the ridge 4 a must be increased in order to cut the metal sheet 2 .
  • the case where the endmost disk cutters 4 are placed respectively at both the ends of the lower disk cutter roll has been described.
  • one or both of the endmost disk cutters 4 may be placed in one or both ends of the upper disk cutter roll.
  • Two or more paired disk cutter rolls may be used.
  • the metal sheet 2 can be passed through an arrangement of three disk cutter rolls.
  • the wires 2 b connected to the endmost nodes 2 f in the metal sheet 2 , and those connected to the other nodes 2 c are formed so as to have the same thickness.
  • the wires 2 b connected to the endmost nodes 2 f may be formed so as to be particularly thicker, so that the wires 2 b are more hardly broken.
  • the metal sheet 2 is processed to produce a grid which is to be used in a battery plate of a lead storage battery.
  • the invention is not restricted to a lead storage battery, and can be applied also to a battery of any kind as far as a similar grid is used as a current collecting member of a battery plate.
  • a grid can be produced by using a metal sheet of an appropriate material which corresponds to the kind of the battery.
  • the metal sheet 2 a lead sheet of a thickness of 1.0 mm was used.
  • the endmost disk cutters 4 configured in the following manner were used.
  • the peripheral side face of the valley 4 b coincides with the reference circumferential face of the predetermined radius (namely, in the prior art example, the valley 4 b is recessed by 0% of the thickness of the lead sheet 2 ).
  • the peripheral side face of the valley 4 b is configured by a circumferential face which is recessed from the reference circumferential face of the predetermined radius by 10% (0.1 mm), 30% (0.3 mm), 50% (0.5 mm), 70% (0.7 mm), or 100% (1.0 mm) of the thickness of the lead sheet 2 .
  • the outermost end of the peripheral side face of the valley 4 b is recessed by 50% of the thickness of the lead sheet 2 , and the inward inclined face 4 d of 30° is formed in the peripheral side face.
  • the interval distance between the upper and lower disk cutter rolls was fixed.
  • the sheet thickness ratio of the endmost node 2 f is larger than that of the prior art example, and elongation of the lead sheet 2 is suppressed. It has been confirmed also that life performance of lead storage batteries using the grids is improved and the breakage rate is reduced. Furthermore, it has been confirmed that the configuration in which the recess of the valley 4 b is in a range from 30% or more to 70% or less is particularly effective, with attaining the highest effect in the case where the recess is 50%. Moreover, it has been confirmed that the effect is further enhanced by forming the inward inclined face 4 d in the peripheral side face of the valley 4 b.
  • the invention can be implemented by combining any one of claims 2 to 5 with claim 6 or 7, or by combining any one of claims 2 to 5 with 13. Also when any one of claims 2 to 5 is combined with claim 18 or 19, or any one of claims 8 to 12, or with any one of claims 9 to 12, or when any one of claims 2 to 5 is combined with claim 15 or 16, it is possible to prevent rupture from occurring during a production process, to prevent corrosion and a crack of corrosion from occurring after production of a grid for a battery plate, thereby preventing the capacity of a lead storage battery from being reduced, and the life of the battery from being shortened.
  • the invention can be implemented by combining claim 6 or 7 with claim 13, or by combining claim 18 or 19 with any one of claims 9 to 12.
  • the claims of the invention relates to one another as a whole.
  • These inventions belong to the same technique from the viewpoint that a crack of corrosion in a node of a grid which may occur during a process of producing a grid for a battery plate, or during use in a storage battery can be prevented from occurring so as to provide a storage battery of a long life.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Cell Electrode Carriers And Collectors (AREA)
US10/177,972 2001-06-22 2002-06-20 Grid for a battery plate, method of producing the same, and battery using the same Abandoned US20030082455A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US12/011,372 US7814628B2 (en) 2001-06-22 2008-01-25 Grid for a battery plate, method of producing the same, and battery using the same
US12/893,836 US8256075B2 (en) 2001-06-22 2010-09-29 Grid for a battery plate, method of producing the same, and battery using the same
US12/893,812 US8256074B2 (en) 2001-06-22 2010-09-29 Grid for battery plate, method of producing the same, and battery using the same

Applications Claiming Priority (12)

Application Number Priority Date Filing Date Title
JP2001190103A JP2003007307A (ja) 2001-06-22 2001-06-22 蓄電池用格子体の製造方法
JP2001-190103 2001-06-22
JP2001-215198 2001-07-16
JP2001-215197 2001-07-16
JP2001215198A JP4848598B2 (ja) 2001-07-16 2001-07-16 鉛蓄電池の製造方法及びその装置
JP2001215197A JP4848597B2 (ja) 2001-07-16 2001-07-16 鉛蓄電池の製造方法及びその装置
JP2001372429A JP4174649B2 (ja) 2001-12-06 2001-12-06 電池極板用格子体及びその製造方法
JP2001-372429 2001-12-06
JP2002057580A JP4453799B2 (ja) 2002-03-04 2002-03-04 電池極板用格子体及びその製造装置
JP2002-057580 2002-03-04
JP2002065639A JP2003263990A (ja) 2002-03-11 2002-03-11 電池極板用格子体及びその製造装置
JP2002-065639 2002-03-11

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US12/011,372 Division US7814628B2 (en) 2001-06-22 2008-01-25 Grid for a battery plate, method of producing the same, and battery using the same

Publications (1)

Publication Number Publication Date
US20030082455A1 true US20030082455A1 (en) 2003-05-01

Family

ID=27554960

Family Applications (4)

Application Number Title Priority Date Filing Date
US10/177,972 Abandoned US20030082455A1 (en) 2001-06-22 2002-06-20 Grid for a battery plate, method of producing the same, and battery using the same
US12/011,372 Expired - Fee Related US7814628B2 (en) 2001-06-22 2008-01-25 Grid for a battery plate, method of producing the same, and battery using the same
US12/893,836 Expired - Fee Related US8256075B2 (en) 2001-06-22 2010-09-29 Grid for a battery plate, method of producing the same, and battery using the same
US12/893,812 Expired - Fee Related US8256074B2 (en) 2001-06-22 2010-09-29 Grid for battery plate, method of producing the same, and battery using the same

Family Applications After (3)

Application Number Title Priority Date Filing Date
US12/011,372 Expired - Fee Related US7814628B2 (en) 2001-06-22 2008-01-25 Grid for a battery plate, method of producing the same, and battery using the same
US12/893,836 Expired - Fee Related US8256075B2 (en) 2001-06-22 2010-09-29 Grid for a battery plate, method of producing the same, and battery using the same
US12/893,812 Expired - Fee Related US8256074B2 (en) 2001-06-22 2010-09-29 Grid for battery plate, method of producing the same, and battery using the same

Country Status (4)

Country Link
US (4) US20030082455A1 (de)
CN (3) CN102005576B (de)
CA (1) CA2391043C (de)
DE (1) DE10227802A1 (de)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080163477A1 (en) * 2001-06-22 2008-07-10 Gs Yuasa Corporation Grid for a battery plate, method of producing the same, and battery using the same
US8741487B1 (en) * 2008-08-28 2014-06-03 Greatbatch Ltd. Electrode current collector with stress-relieving mesh structure
WO2016032651A1 (en) * 2014-08-27 2016-03-03 Google Inc. Battery containment mesh
US20200240139A1 (en) * 2019-01-28 2020-07-30 William E. Smith Pre-stressed sinusoidal member in assembly and applications
US11959277B1 (en) * 2019-01-28 2024-04-16 William E. Smith Pre-stressed sinusoidal member in assembly and applications

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP4540053B2 (ja) * 2002-08-09 2010-09-08 株式会社Ｇｓユアサ 電池極板用格子体の製造法および電池の製造法
CN112692102B (zh) * 2020-11-12 2022-07-08 天津市宝来宏通新能源科技有限公司 一种光伏支架生产用带钢边裂停料设备
CN114571695B (zh) * 2022-04-08 2025-02-07 河北恒塑丝网制造有限公司 一种一步法生产平面塑料网的成型设备及方法
CN118315599B (zh) * 2024-04-02 2024-12-17 浙江天能电池(江苏)有限公司 一种铅酸蓄电池交扣铅网及其制备方法

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4291443A (en) * 1978-10-31 1981-09-29 Cominco Ltd. Forming expanded mesh sheet from deformable strip

Family Cites Families (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA1106703A (en) * 1979-08-01 1981-08-11 John V. Marlow Asymmetrical shaping of slit segments of meshes formed in deformable strip
JP2568285B2 (ja) * 1989-12-28 1996-12-25 松下電器産業株式会社 展伸メッシュシートの製造方法とこれに用いる展伸メッシュシートの製造装置
JPH107953A (ja) * 1996-06-20 1998-01-13 Hideyuki Murakami 洗浄剤組成物
DE19632415A1 (de) 1996-08-05 1998-02-12 Samsung Display Devices Co Ltd Verfahren zur Herstellung von Maskenrahmen
JPH1079253A (ja) 1996-09-03 1998-03-24 Matsushita Electric Ind Co Ltd 鉛蓄電池
JP4030618B2 (ja) 1997-02-06 2008-01-09 松下電器産業株式会社 展伸メッシュシートの製造方法
JP3673073B2 (ja) * 1998-03-13 2005-07-20 松下電器産業株式会社 展延メッシュシートの製造方法及びその装置
JP4288730B2 (ja) * 1998-09-28 2009-07-01 パナソニック株式会社 鉛蓄電池の製造方法および鉛蓄電池用格子の製造装置
JP4006888B2 (ja) 1999-06-07 2007-11-14 松下電器産業株式会社 鉛蓄電池の製造法
JP4062817B2 (ja) 1999-06-07 2008-03-19 松下電器産業株式会社 鉛蓄電池及びその製造法
JP4092816B2 (ja) * 1999-06-14 2008-05-28 松下電器産業株式会社 鉛蓄電池用格子体およびその製造方法
CA2391043C (en) * 2001-06-22 2012-01-03 Japan Storage Battery Co., Ltd. Grid for a battery plate, method of producing the same, and battery using the same

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4291443A (en) * 1978-10-31 1981-09-29 Cominco Ltd. Forming expanded mesh sheet from deformable strip

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080163477A1 (en) * 2001-06-22 2008-07-10 Gs Yuasa Corporation Grid for a battery plate, method of producing the same, and battery using the same
US7814628B2 (en) * 2001-06-22 2010-10-19 Gs Yuasa Corporation Grid for a battery plate, method of producing the same, and battery using the same
US8741487B1 (en) * 2008-08-28 2014-06-03 Greatbatch Ltd. Electrode current collector with stress-relieving mesh structure
WO2016032651A1 (en) * 2014-08-27 2016-03-03 Google Inc. Battery containment mesh
US9786883B2 (en) 2014-08-27 2017-10-10 X Development Llc Battery containment mesh
US20200240139A1 (en) * 2019-01-28 2020-07-30 William E. Smith Pre-stressed sinusoidal member in assembly and applications
US11608632B2 (en) * 2019-01-28 2023-03-21 William E. Smith Pre-stressed sinusoidal member in assembly and applications
US11959277B1 (en) * 2019-01-28 2024-04-16 William E. Smith Pre-stressed sinusoidal member in assembly and applications

Also Published As

Publication number Publication date
US20110017035A1 (en) 2011-01-27
US7814628B2 (en) 2010-10-19
CN102005576B (zh) 2013-06-05
US20080163477A1 (en) 2008-07-10
CN102005575B (zh) 2013-02-27
DE10227802A1 (de) 2003-03-06
CN102005575A (zh) 2011-04-06
CN102005576A (zh) 2011-04-06
CN100388536C (zh) 2008-05-14
CN1396670A (zh) 2003-02-12
CA2391043C (en) 2012-01-03
CA2391043A1 (en) 2002-12-22
US8256074B2 (en) 2012-09-04
US8256075B2 (en) 2012-09-04
US20110017034A1 (en) 2011-01-27

Similar Documents

Publication Publication Date Title
US8256075B2 (en) Grid for a battery plate, method of producing the same, and battery using the same
US20110070502A1 (en) Storage battery
US8142935B2 (en) Apparatus for producing a battery plate expanded grid
US12496654B2 (en) Ultrasonic welding head and welding device
US3891459A (en) Negative lead-acid battery plates with expanded lead sheet grids
WO2001038812A2 (en) Heat exchanger tube with grooved inner surface, tube expansion method therefor, and device for manufacture thereof
EP1219364A1 (de) Metallblechstanzwalze, metallblechstanzvorrichtung mit einer solchen walze, metallblechstanzverfahren und gestanztes metallblech
CN1322616C (zh) 用于电池极板的栅体的制造法及电池的制造法
CN101257114A (zh) 电池板的栅板及其制造方法和使用这种栅板的电池
JP4848598B2 (ja) 鉛蓄電池の製造方法及びその装置
JP2003263990A (ja) 電池極板用格子体及びその製造装置
JP4132885B2 (ja) 電池極板用格子体の製造方法
JP4848597B2 (ja) 鉛蓄電池の製造方法及びその装置
JP2003234105A (ja) 蓄電池
JP2003223900A (ja) 蓄電池
CN101567463A (zh) 蓄电池、膨胀栅格及其制备方法
JP2004342477A (ja) 電池
JPH116695A (ja) 伝熱管用溝付条及び伝熱管用溝付条成形ロール
JPS60158916A (ja) 内面溝付管の製造方法

Legal Events

Date Code Title Description
AS Assignment

Owner name: JAPAN STORAGE BATTERY CO., LTD., JAPAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:FUJIWARA, YOSHIOMI;SAWAI, KEN;REEL/FRAME:013049/0073

Effective date: 20020614

AS Assignment

Owner name: GS YUASA CORPORATION, JAPAN

Free format text: CHANGE OF NAME;ASSIGNOR:JAPAN STORAGE BATTERY CO., LTD.;REEL/FRAME:017411/0445

Effective date: 20050720

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION