JP2019003763A - Method of manufacturing flat conductor - Google Patents

Method of manufacturing flat conductor Download PDF

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JP2019003763A
JP2019003763A JP2017115849A JP2017115849A JP2019003763A JP 2019003763 A JP2019003763 A JP 2019003763A JP 2017115849 A JP2017115849 A JP 2017115849A JP 2017115849 A JP2017115849 A JP 2017115849A JP 2019003763 A JP2019003763 A JP 2019003763A
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metal plate
groove
mold
flat conductor
manufacturing
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真一 柳原
Shinichi Yanagihara
真一 柳原
智史 菱倉
Satoshi Hishikura
智史 菱倉
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Yazaki Corp
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Yazaki Corp
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

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  • Non-Insulated Conductors (AREA)
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Abstract

To provide a method of manufacturing flat conductor improving a yield in comparison to a prior manufacturing method, dispensing with increase of a board thickness and superposition for securing a conductor sectional area, and capable of inexpensively producing a flat conductor.SOLUTION: The method of manufacturing a flat conductor includes: a metal plate-forming process of forming a rectangular metal plate 11 having an even thickness; a mold-clamping process of abutting a second metal mold 17 which covers an upset groove to a first metal mold 15 having a groove end opening 19 having a sectional shape same as that of the metal plate 11 on a front face 21, and formed with the upset groove having an enlarged part on an orthogonal plane adjacent to a front face 21; a metal plate-holding process of holding a base end side of the metal plate 11 with a pair of hold fixing dies 13 while leaving an insertion tip end which is longer than a distance from the groove end opening 19 to a groove end edge; a metal plate-enlarging process of broadening a width direction of the metal plate 11 following the enlarged part by inserting the metal plate 11 from an insertion tip end into the groove end opening 19 to press against a groove end edge, and thereafter further pressing in; and a releasing process of taking out a molded metal plate from the first metal mold 15.SELECTED DRAWING: Figure 1

Description

本発明は、平型導体の製造方法に関する。   The present invention relates to a method for manufacturing a flat conductor.

例えば電気接続箱は、ヒューズ等の種々の電気部品を接続する平型導体（バスバー）を備える（特許文献１、２等参照）。この平型導体には、特定の部位の断面積を大きくしたものもある。   For example, the electrical junction box includes a flat conductor (bus bar) that connects various electrical components such as fuses (see Patent Documents 1 and 2, etc.). Some of these flat conductors have a larger cross-sectional area at a specific portion.

特開平６−１１３４２８号公報JP-A-6-113428 特開平８−１１１１６５号公報Japanese Patent Laid-Open No. 8-111165

しかしながら、平型導体は、従来、導電性の金属からなる素板を一般的にプレス加工（例えば打ち抜き加工）して製造するため、特定の部位の断面積を大きくする拡幅部等を設けると、歩留まりが著しく悪くなる。これに対し、平型導体は、断面積を増加させるために板厚を増やしたり、折り曲げ等により重ね合わせたりすると、製造コストが上昇し、製品を大型化させる要因ともなる。   However, since a flat conductor is conventionally manufactured by pressing (for example, punching) a base plate made of a conductive metal, when a widened portion or the like that increases the cross-sectional area of a specific part is provided, Yield is significantly worse. On the other hand, if the flat conductor is increased in thickness in order to increase the cross-sectional area or overlapped by bending or the like, the manufacturing cost increases and becomes a factor of increasing the size of the product.

本発明は上記状況に鑑みてなされたもので、その目的は、従来製法に比べ歩留まりを向上させることができ、導体断面積の確保のための板厚の増加や重ね合わせが不要となり、平型導体を安価に製造できる平型導体の製造方法を提供することにある。   The present invention has been made in view of the above situation, and the purpose thereof is to improve the yield compared to the conventional manufacturing method, and it is not necessary to increase the thickness or superimpose for securing the conductor cross-sectional area. An object of the present invention is to provide a flat conductor manufacturing method capable of manufacturing a conductor at low cost.

本発明に係る上記目的は、下記構成により達成される。
（１） 均一厚の矩形状の金属板を成形する金属板形成工程と、前記金属板の長手方向に直交する断面形状と同一形状の溝端開口を正面に有し、前記正面に隣接する直交平面に前記溝端開口と同一の溝底面に連続して溝終端までの間に前記金属板の幅より大きい拡幅部を有するすえ込み溝が形成された第１金型に、前記すえ込み溝を覆う第２金型を前記直交平面に合わせる型締め工程と、前記溝端開口に、前記金属板を挿入先端から挿入して前記溝終端に押し当てた後に更に押し込んで前記金属板の幅方向を前記拡幅部に倣って広げて塑性変形させる金属板拡幅工程と、前記第２金型を前記直交平面から離間して拡幅された成形金属板を前記第１金型から取り出す離型工程と、を含むことを特徴とする平型導体の製造方法。 The above object of the present invention is achieved by the following configuration.
(1) A metal plate forming step for forming a rectangular metal plate having a uniform thickness, and an orthogonal plane adjacent to the front surface having a groove end opening having the same shape as the cross-sectional shape orthogonal to the longitudinal direction of the metal plate. A first mold having a swivel groove having a widened portion larger than the width of the metal plate between the groove bottom opening and the groove bottom opening to the end of the groove. A mold clamping step for fitting two molds to the orthogonal plane, and the metal plate is inserted into the opening of the groove from the insertion tip and pressed against the end of the groove, and then further pushed into the width direction of the metal plate. A metal plate widening step of spreading and plastically deforming following the above, and a mold release step of taking out the formed metal plate widened by separating the second die from the orthogonal plane from the first die. A method for producing a flat conductor.

上記（１）の構成の平型導体の製造方法によれば、先ず、均一厚で矩形状の金属板が成形される。この金属板の成形は、素板を切断や打ち抜きする従来製法により可能となる。次いで、第１金型の直交平面に、第２金型を合わせて型締めしておく。第１金型は、第２金型が合わせられることにより、拡幅部を有したすえ込み溝が、溝端開口のみで開放する閉塞空間となる。この溝端開口は、金属板の長手方向に直交する断面形状と同一形状となることにより、金属板を挿入先端から挿入可能とする。また、すえ込み溝は、溝端開口と同一の溝底面に連続する。即ち、閉塞空間の高さは、金属板の厚みと同一となる。金属板は、このすえ込み溝に、溝端開口から挿入先端が挿入される。すえ込み溝に挿入された金属板は、溝終端から反力を受け、厚み方向が第１金型のすえ込み溝と第２金型とに拘束されていることから、潰されることにより幅方向に広がる。押し込みは、幅方向の広がりが、すえ込み溝の拡幅部の内面に到達するまで行われる。その結果、金属板は、同一の板厚のままで、幅方向のみがすえ込み溝の拡幅部に倣った膨出幅広部となって成形される。そのため、従来製法で廃棄されていた膨出幅広部以外の部分で切り取られていた廃材が生じなくなる。   According to the method for producing a flat conductor having the configuration (1), a rectangular metal plate having a uniform thickness is first formed. The metal plate can be formed by a conventional manufacturing method in which a base plate is cut or punched. Next, the second mold is aligned with the orthogonal plane of the first mold and clamped. When the second mold is combined with the first mold, the upset groove having the widened portion becomes a closed space that is opened only by the groove end opening. The groove end opening has the same shape as the cross-sectional shape perpendicular to the longitudinal direction of the metal plate, so that the metal plate can be inserted from the insertion tip. Further, the upset groove is continuous with the same groove bottom surface as the groove end opening. That is, the height of the closed space is the same as the thickness of the metal plate. The insertion tip of the metal plate is inserted into the swaging groove from the groove end opening. The metal plate inserted in the upset groove receives a reaction force from the end of the groove, and since the thickness direction is constrained by the upset groove and the second mold of the first mold, To spread. Pushing is performed until the spread in the width direction reaches the inner surface of the widened portion of the upset groove. As a result, the metal plate is formed as a bulging wide portion that follows the widened portion of the swaging groove only in the width direction while maintaining the same plate thickness. Therefore, the waste material cut off at portions other than the bulging wide portion that has been discarded by the conventional manufacturing method does not occur.

（２） 上記（１）に記載の平型導体の製造方法であって、前記溝端開口から前記溝終端までの距離より長い前記挿入先端を残して前記金属板の基端側を一対の挟持固定型で挟持する金属板保持工程を有することを特徴とする平型導体の製造方法。 (2) The flat conductor manufacturing method according to the above (1), wherein the base end side of the metal plate is clamped and fixed while leaving the insertion tip longer than the distance from the groove end opening to the groove end. A method for producing a flat conductor, comprising a metal plate holding step of clamping with a mold.

上記（２）の構成の平型導体の製造方法によれば、すえ込み溝に挿入された金属板は、基端側を保持する一対の挟持固定型が、第１金型の正面に当接する前に、挿入先端がすえ込み溝の溝終端に当接する。つまり、挟持固定型は、押し込み代を有して金属板を保持している。挟持固定型は、この押し込み代を利用して金属板を更にすえ込み溝の溝終端に押し込む。従って、押し込まれた金属板は、座屈することなくすえ込み溝に挿入される。   According to the method of manufacturing a flat conductor having the configuration (2), the metal plate inserted into the upright groove has a pair of clamping fixed molds that hold the proximal end abut the front surface of the first mold. Before, the insertion tip comes into contact with the end of the swaging groove. That is, the sandwiching and fixing mold holds the metal plate with a push-in margin. In the clamping type, the metal plate is further pushed into the end of the swaging groove using this pushing allowance. Therefore, the pushed-in metal plate is inserted into the swaging groove without buckling.

（３） 上記（１）又は（２）に記載の平型導体の製造方法であって、前記成形金属板の膨出幅広部にボルト挿通穴を穿設する穴開け工程を有することを特徴とする平型導体の製造方法。 (3) The method for producing a flat conductor according to (1) or (2), further comprising a drilling step of drilling a bolt insertion hole in the bulging wide portion of the molded metal plate. A method for manufacturing a flat conductor.

上記（３）の構成の平型導体の製造方法によれば、成形金属板の膨出幅広部に、ボルト接続が可能となる。ボルト挿通穴を有した成形金属板は、膨出幅広部にボルト挿通穴が穿設されることにより、ボルト挿通穴の穿設により小さくなる断面積を、膨出幅広部による断面積の増加分で補うことができる。即ち、従来、膨出幅広部の幅で全幅を形成していた平型導体における膨出幅広部以外の部分の幅を狭くできる。このように、膨出幅広部にボルト挿通穴を穿設した平型導体によれば、膨出幅広部以外の部分で幅を狭くできる分、材料の使用量を低減することができる。   According to the method for producing a flat conductor having the configuration (3), a bolt can be connected to the bulging wide portion of the formed metal plate. A formed metal plate having bolt insertion holes has a cross-sectional area that is reduced by drilling the bolt insertion holes when the bolt insertion holes are drilled in the bulging wide part, and an increase in cross-sectional area due to the bulging wide part. Can be supplemented with. That is, conventionally, the width of the portion other than the bulging wide portion in the flat conductor that has formed the full width by the width of the bulging wide portion can be reduced. Thus, according to the flat conductor in which the bolt insertion hole is formed in the bulging wide portion, the amount of material used can be reduced as much as the width can be narrowed in the portion other than the bulging wide portion.

（４） 上記（１）〜（３）の何れかに記載の平型導体の製造方法であって、前記成形金属板の長手方向に沿って複数のボルト挿通穴が同一のピッチで穿設され、前記ピッチが、一対の電極端子を有する複数の単電池を並設した電池パックの隣接する前記単電池の電極端子同士の離間距離であることを特徴とする平型導体の製造方法。 (4) The method for manufacturing a flat conductor according to any one of (1) to (3), wherein a plurality of bolt insertion holes are formed at the same pitch along the longitudinal direction of the formed metal plate. A method for producing a flat conductor, wherein the pitch is a distance between electrode terminals of adjacent unit cells of a battery pack in which a plurality of unit cells having a pair of electrode terminals are arranged side by side.

上記（４）の構成の平型導体の製造方法によれば、穿設した複数のボルト挿通穴のピッチが、電池パックにおいて並設される隣接する単電池の電極端子同士の離間距離となる。従って、成形金属板は、複数の単電池を接続するバスバーとして利用が可能となる。その際、成形金属板は、長手方向に沿った所望の単電池間における断面積を、膨出幅広部により板厚を増やすことなく大きくできる。   According to the method for manufacturing a flat conductor having the configuration (4), the pitch of the plurality of bolt insertion holes formed is the distance between the electrode terminals of adjacent unit cells arranged side by side in the battery pack. Therefore, the molded metal plate can be used as a bus bar for connecting a plurality of single cells. At that time, the formed metal plate can increase the cross-sectional area between desired single cells along the longitudinal direction without increasing the plate thickness by the bulging wide portion.

本発明に係る平型導体の製造方法によれば、従来製法に比べ歩留まりを向上させることができ、導体断面積の確保のための板厚の増加や重ね合わせが不要となり、平型導体を安価に製造できる。   According to the method for producing a flat conductor according to the present invention, the yield can be improved as compared with the conventional manufacturing method, and it is not necessary to increase the thickness or superimpose for securing the conductor cross-sectional area. Can be manufactured.

以上、本発明について簡潔に説明した。更に、以下に説明される発明を実施するための形態（以下、「実施形態」という。）を添付の図面を参照して通読することにより、本発明の詳細は更に明確化されるであろう。   The present invention has been briefly described above. Further, the details of the present invention will be further clarified by reading through a mode for carrying out the invention described below (hereinafter referred to as “embodiment”) with reference to the accompanying drawings. .

本発明の一実施形態に係る平型導体の製造方法に用いられる金属板及び成形金型の分解斜視図である。It is a disassembled perspective view of the metal plate and molding die which are used for the manufacturing method of the flat type | mold conductor which concerns on one Embodiment of this invention. 図１に示した第１金型の下面を上にして見た斜視図である。It is the perspective view which looked at the lower surface of the 1st metal mold | die shown in FIG. 1 up. 金属板が、型締めされた第１金型及び第２金型に押し込まれる金属板拡幅工程の説明図である。It is explanatory drawing of the metal plate widening process in which a metal plate is pushed into the 1st metal mold | die clamped and the 2nd metal mold | die. すえ込み溝の拡幅部における金属板の変形状況を表す説明図である。It is explanatory drawing showing the deformation | transformation condition of the metal plate in the wide part of a setup groove. 膨出幅広部が成形された成形金属板の要部斜視図である。It is a principal part perspective view of the shaping | molding metal plate in which the bulging wide part was shape | molded. 膨出幅広部にボルト挿通穴が穿設された成形金属板の要部斜視図である。It is a principal part perspective view of the shaping | molding metal plate by which the bolt penetration hole was drilled in the bulging wide part. 複数のボルト挿通穴が穿設された成形金属板の要部斜視図である。It is a principal part perspective view of the shaping | molding metal plate in which the some volt | bolt penetration hole was pierced. （ａ）は打ち抜き加工により成形された比較例に係る成形金属板の斜視図、（ｂ）は（ａ）に示した成形金属板の打ち抜き時の板取を表す素板の斜視図である。(A) is a perspective view of the shaping | molding metal plate which concerns on the comparative example shape | molded by stamping, (b) is a perspective view of the base plate showing the boarding at the time of the stamping of the shaping | molding metal plate shown to (a).

以下、本発明に係る実施形態を図面を参照して説明する。
図１は本発明の一実施形態に係る平型導体の製造方法に用いられる金属板１１及び成形金型の分解斜視図である。
本実施形態に係る平型導体の製造方法は、例えばバスバーの製造に用いて好適となる。なお、平型導体は、バスバーに限定されない。 Embodiments according to the present invention will be described below with reference to the drawings.
FIG. 1 is an exploded perspective view of a metal plate 11 and a molding die used in a method for producing a flat conductor according to an embodiment of the present invention.
The method for manufacturing a flat conductor according to the present embodiment is suitable for use in manufacturing a bus bar, for example. The flat conductor is not limited to the bus bar.

本実施形態に係る平型導体の製造方法には、一対の挟持固定型１３と、第１金型１５と、第２金型１７と、が主要な型部材として用いられる。   In the flat conductor manufacturing method according to the present embodiment, the pair of clamping and fixing molds 13, the first mold 15, and the second mold 17 are used as main mold members.

本実施形態に係る平型導体の製造方法では、先ず、金属板形成工程において、均一厚の矩形状の金属板１１を成形する。この金属板形成工程は、周知の切断や打ち抜きにより行われる。この金属板形成工程により得られる金属板１１は、矩形状であるので例えば打ち抜き加工により得ても歩留まりは良好となる。金属板１１の材質としては、導電性及び延展性の良好な銅、銅合金、アルミ、アルミ合金等が用いられる。   In the flat conductor manufacturing method according to the present embodiment, first, in the metal plate forming step, a rectangular metal plate 11 having a uniform thickness is formed. This metal plate forming step is performed by known cutting or punching. Since the metal plate 11 obtained by this metal plate forming step has a rectangular shape, for example, even if it is obtained by punching, the yield is good. As the material of the metal plate 11, copper, copper alloy, aluminum, aluminum alloy or the like having good conductivity and spreadability is used.

一対の挟持固定型１３は、この金属板１１を板表裏から挟んで固定する。一対の挟持固定型１３には、金属板１１を固定状態に保持するロック機構（図示略）が設けられる。金属板１１を挟持固定した挟持固定型１３は、ハンマー、機械プレス、油圧プレスにより押圧される。
更に、一対の挟持固定型１３のそれぞれの挟持面には、金属板１１と嵌合する保持溝が形成されていてもよい。挟持固定型１３は、保持溝が設けられることにより、設備から加えられた力を、位置ずれを生じさせることなく、金属板１１へ加えることが可能となる。 The pair of clamping and fixing molds 13 fixes the metal plate 11 by sandwiching the metal plate 11 from the front and back sides. The pair of clamping and fixing molds 13 are provided with a lock mechanism (not shown) that holds the metal plate 11 in a fixed state. The clamping / fixing die 13 that clamps and fixes the metal plate 11 is pressed by a hammer, a mechanical press, or a hydraulic press.
Furthermore, a holding groove for fitting with the metal plate 11 may be formed on each holding surface of the pair of holding and fixing molds 13. Since the holding and fixing mold 13 is provided with the holding groove, it is possible to apply the force applied from the equipment to the metal plate 11 without causing a positional shift.

図２は図１に示した第１金型１５の下面を上にして見た斜視図である。
第１金型１５は、金属板１１の長手方向に直交する断面形状と同一形状の溝端開口１９を正面２１に有する。即ち、溝端開口１９は、横長の矩形状となる。この第１金型１５は、正面２１に隣接する直交平面２３に、すえ込み溝２５が型彫りされて形成されている。すえ込み溝２５は、溝端開口１９と同一の溝底面２７に連続して溝終端２９まで形成される。従って、すえ込み溝２５は、溝底面２７から直交平面２３までの高さが、金属板１１の厚みと一致している。 2 is a perspective view of the first mold 15 shown in FIG.
The first mold 15 has a groove end opening 19 on the front surface 21 having the same shape as the cross-sectional shape orthogonal to the longitudinal direction of the metal plate 11. That is, the groove end opening 19 has a horizontally long rectangular shape. The first mold 15 is formed by engraving a setting groove 25 in an orthogonal plane 23 adjacent to the front surface 21. The upset groove 25 is formed to the groove end 29 continuously to the groove bottom surface 27 which is the same as the groove end opening 19. Therefore, the height of the swaging groove 25 from the groove bottom surface 27 to the orthogonal plane 23 matches the thickness of the metal plate 11.

すえ込み溝２５は、溝終端２９と溝端開口１９との間に、金属板１１の幅より大きい拡幅部３１を有する。本実施形態の拡幅部３１は、金属板１１の長手方向に沿う両側縁から外側に円弧形状に突出するように形成されている。なお、拡幅部３１の形状は、円弧形状に限らず、三角形、四角形、台形等であってもよい。また、拡幅部３１は、金属板１１の長手方向に沿う片縁からのみ外側に突出するものであってもよい。また、拡幅部３１は、片縁に複数が設けられてもよい。   The upset groove 25 has a widened portion 31 larger than the width of the metal plate 11 between the groove end 29 and the groove end opening 19. The widened portion 31 of the present embodiment is formed so as to protrude in an arc shape outward from both side edges along the longitudinal direction of the metal plate 11. Note that the shape of the widened portion 31 is not limited to an arc shape, and may be a triangle, a quadrangle, a trapezoid, or the like. Further, the widened portion 31 may protrude outward only from one edge along the longitudinal direction of the metal plate 11. A plurality of widened portions 31 may be provided on one edge.

第２金型１７は、すえ込み溝２５の上方を覆うように、第１金型１５の直交平面２３に合わせられる。第２金型１７の合わせ面は、図１に示すように、平坦面３３で形成される。第２金型１７は、第１金型１５と同一の外形状で形成することができる。   The second mold 17 is aligned with the orthogonal plane 23 of the first mold 15 so as to cover the upper part of the upset groove 25. The mating surface of the second mold 17 is formed of a flat surface 33 as shown in FIG. The second mold 17 can be formed with the same outer shape as the first mold 15.

第１金型１５と第２金型１７とには、双方を合わせた状態で固定する型締め機構（図示略）が設けられる。第１金型１５は、第２金型１７が型締めされることにより、すえ込み溝２５が、溝端開口１９のみで開放する閉塞空間となる。この閉塞空間に、溝端開口１９から金属板１１が押し込まれることになる。   The first mold 15 and the second mold 17 are provided with a mold-clamping mechanism (not shown) that fixes both of them together. When the second mold 17 is clamped, the first mold 15 becomes a closed space in which the upset groove 25 is opened only by the groove end opening 19. The metal plate 11 is pushed into the closed space from the groove end opening 19.

図３は金属板１１が、型締めされた第１金型１５及び第２金型１７に押し込まれる金属板拡幅工程の説明図である。
溝端開口１９に押し込まれる金属板１１は、金属板保持工程により、上記一対の挟持固定型１３により挟持される。この金属板保持工程では、一対の挟持固定型１３が、溝端開口１９から溝終端２９までの距離より長い挿入先端を残して、金属板１１の基端側を挟持する。 FIG. 3 is an explanatory diagram of a metal plate widening process in which the metal plate 11 is pushed into the first mold 15 and the second mold 17 that are clamped.
The metal plate 11 pushed into the groove end opening 19 is held by the pair of holding and fixing molds 13 in the metal plate holding step. In this metal plate holding step, the pair of clamping and fixing dies 13 clamp the proximal end side of the metal plate 11 while leaving the insertion tip longer than the distance from the groove end opening 19 to the groove end 29.

一対の挟持固定型１３により挟持固定された金属板１１は、金属板拡幅工程で、第２金型１７と型締めされた第１金型１５の溝端開口１９に挿入される。金属板拡幅工程では、溝端開口１９に、金属板１１を挿入先端から挿入する。挿入した金属板１１は、挿入先端が溝終端２９に押し当てられる。その後に、一対の挟持固定型１３は、金属板１１を更に押し込む。   The metal plate 11 clamped and fixed by the pair of clamping molds 13 is inserted into the groove end opening 19 of the first mold 15 clamped to the second mold 17 in the metal plate widening step. In the metal plate widening step, the metal plate 11 is inserted into the groove end opening 19 from the insertion tip. The inserted metal plate 11 has its insertion tip pressed against the groove end 29. Thereafter, the pair of clamping and fixing dies 13 pushes the metal plate 11 further.

この際、金属板１１は、基端側を保持する一対の挟持固定型１３が、第１金型１５の正面２１に当接する前に、挿入先端がすえ込み溝２５の溝終端２９に当接する。即ち、挟持固定型１３は、押し込み代を有して金属板１１を保持している。挟持固定型１３は、この押し込み代を利用して金属板１１を更にすえ込み溝２５の溝終端２９に押し込む。従って、押し込まれた金属板１１は、座屈することなくすえ込み溝２５に挿入される。   At this time, the metal plate 11 comes into contact with the groove end 29 of the swaging groove 25 before the pair of clamping and fixing molds 13 holding the base end comes into contact with the front surface 21 of the first mold 15. . That is, the clamping and fixing die 13 holds the metal plate 11 with a push-in margin. The clamping and fixing die 13 further pushes the metal plate 11 into the groove end 29 of the swaging groove 25 using this pushing allowance. Therefore, the pushed metal plate 11 is inserted into the swaging groove 25 without buckling.

押し込み代は、板厚の数倍以下で設定される。押し込み代が大きい場合には、溝端開口１９の手前で金属板１１に座屈が生じる可能性がある。平型導体に用いられる薄厚の金属板１１では、押し込み代は、膨出幅広部３５（図５参照）の体積と比例する。従って、膨出幅広部３５の体積を大きく確保したい場合には、一対の挟持固定型１３により挟持固定を複数回に分け、複数回の押し込みで行うことで、押し込み代を大きく確保してもよい。   The push-in allowance is set to be several times less than the plate thickness. If the push-in margin is large, the metal plate 11 may be buckled before the groove end opening 19. In the thin metal plate 11 used for the flat conductor, the push-in allowance is proportional to the volume of the bulging wide portion 35 (see FIG. 5). Therefore, when it is desired to secure a large volume of the bulging wide portion 35, the clamping margin may be divided into a plurality of times by the pair of clamping and fixing molds 13, and the pushing margin may be ensured by performing a plurality of times of pushing. .

図４はすえ込み溝２５の拡幅部３１における金属板１１の変形状況を表す説明図である。
溝終端２９に挿入先端が当接した金属板１１は、更に押し込まれることにより、溝終端２９から反力を受けて潰れる。この際、金属板１１は、第１金型１５のすえ込み溝２５の溝底面２７と第２金型１７とにより厚み方向に拘束されているので、厚みは変化せずに、幅方向に広がる。その結果、金属板１１は、拡幅部３１に倣って幅方向に広げられて塑性変形する。 FIG. 4 is an explanatory diagram showing the deformation state of the metal plate 11 in the widened portion 31 of the upset groove 25.
The metal plate 11 with the insertion tip in contact with the groove end 29 is crushed in response to a reaction force from the groove end 29 when further pushed. At this time, the metal plate 11 is restrained in the thickness direction by the groove bottom surface 27 of the upset groove 25 of the first mold 15 and the second mold 17, so that the thickness does not change and spreads in the width direction. . As a result, the metal plate 11 is expanded in the width direction following the widened portion 31 and plastically deformed.

塑性変形が完了した金属板１１は、離型工程により取り出される。離型工程では、第１金型１５の直交平面２３から第２金型１７が離間される。第２金型１７が離間した第１金型１５は、すえ込み溝２５で成形の完了した金属板１１が第１金型１５から取り出し可能となる。   The metal plate 11 having undergone plastic deformation is taken out by a mold release process. In the mold release step, the second mold 17 is separated from the orthogonal plane 23 of the first mold 15. In the first mold 15 separated from the second mold 17, the metal plate 11 that has been formed in the upset groove 25 can be taken out from the first mold 15.

図５は膨出幅広部３５が成形された成形金属板３７の斜視図である。
すえ込み溝２５から取り出された金属板１１は、長手方向の一部分に膨出幅広部３５が形成された成形金属板３７（平型導体）となる。 FIG. 5 is a perspective view of a formed metal plate 37 on which the bulging wide portion 35 is formed.
The metal plate 11 taken out from the upset groove 25 becomes a formed metal plate 37 (flat conductor) in which a bulging wide portion 35 is formed in a part in the longitudinal direction.

図６に示すように、この成形金属板３７は、例えば膨出幅広部３５に、ボルト挿通穴３９を穿設することができる。
また、図７に示す成形金属板４０のように、長手方向に沿って複数のボルト挿通穴３９が同一のピッチＰで穿設されてもよい。この場合、ピッチＰは、例えば一対の電極端子を有する複数の単電池を並設した電池パック（図示略）の隣接する単電池の電極端子同士の離間距離とすることができる。 As shown in FIG. 6, the formed metal plate 37 can be formed with a bolt insertion hole 39 in the bulging wide portion 35, for example.
Moreover, like the formed metal plate 40 shown in FIG. 7, a plurality of bolt insertion holes 39 may be formed at the same pitch P along the longitudinal direction. In this case, the pitch P can be set, for example, as a distance between electrode terminals of adjacent unit cells of a battery pack (not shown) in which a plurality of unit cells having a pair of electrode terminals are arranged in parallel.

次に、上記した構成の作用を説明する。
本実施形態に係る平型導体の製造方法の作用の説明に先立ち、膨出幅広部５３５を有した平型導体を打ち抜き加工により得る比較例に係る平型導体の製造方法を説明する。
図８の（ａ）は打ち抜き加工により成形された比較例に係る成形金属板５４１の要部斜視図、図８（ｂ）は図８の（ａ）に示した成形金属板４１の打ち抜き時の板取を表す素板５４３の斜視図である。
この比較例に係る成形金属板５４１は、上記実施形態とほぼ同様の円弧形状の膨出幅広部５３５が、両側縁から突出する。比較例では、この成形金属板５４１を、打ち抜き加工により成形する。打ち抜き加工では、プレス加工により図８の（ｂ）に示す矢印の方向に打ち抜きを必要とする。このため、矩形状を打ち抜く場合に比べ、円弧形状により素板５４３の歩留まりが悪くなる。 Next, the operation of the above configuration will be described.
Prior to the description of the operation of the method for producing a flat conductor according to the present embodiment, a method for producing a flat conductor according to a comparative example in which a flat conductor having a bulging wide portion 535 is obtained by punching will be described.
FIG. 8A is a perspective view of a main part of a formed metal plate 541 according to a comparative example formed by punching, and FIG. 8B is a view when the formed metal plate 41 shown in FIG. It is a perspective view of the base plate 543 showing planing.
In the formed metal plate 541 according to this comparative example, the arc-shaped bulged wide portion 535 substantially the same as that of the above embodiment protrudes from both side edges. In the comparative example, the formed metal plate 541 is formed by punching. In punching, punching is required in the direction of the arrow shown in FIG. For this reason, the yield of the base plate 543 is deteriorated due to the arc shape compared to the case of punching a rectangular shape.

これに対し、本実施形態に係る平型導体の製造方法では、先ず、均一厚で矩形状の金属板１１が成形される。この金属板１１の成形は、素板５４３を切断や打ち抜きする従来製法により可能となる。この金属板１１の幅Ｗは、上記の比較例に係る成形金属板５４１の膨出幅広部５３５が形成されていない部分の幅Ｗ１と同じである。   In contrast, in the flat conductor manufacturing method according to the present embodiment, first, the rectangular metal plate 11 having a uniform thickness is formed. The metal plate 11 can be formed by a conventional manufacturing method in which the base plate 543 is cut or punched. The width W of the metal plate 11 is the same as the width W1 of the portion where the bulging wide portion 535 of the formed metal plate 541 according to the comparative example is not formed.

次いで、第１金型１５の直交平面２３に、第２金型１７を合わせて型締めしておく。第１金型１５は、第２金型１７が合わせられることにより、拡幅部３１を有したすえ込み溝２５が、溝端開口１９のみで開放する閉塞空間となる。この溝端開口１９は、金属板１１の長手方向に直交する断面形状と同一形状となることにより、金属板１１を挿入先端から挿入可能とする。また、すえ込み溝２５は、溝端開口１９と同一の溝底面２７に連続する。即ち、閉塞空間の高さは、金属板１１の厚みと同一となる。   Next, the second mold 17 is aligned with the orthogonal plane 23 of the first mold 15 and clamped. The first mold 15 becomes a closed space in which the upset groove 25 having the widened portion 31 is opened only by the groove end opening 19 when the second mold 17 is matched. The groove end opening 19 has the same shape as the cross-sectional shape orthogonal to the longitudinal direction of the metal plate 11 so that the metal plate 11 can be inserted from the insertion tip. Further, the upset groove 25 continues to the same groove bottom surface 27 as the groove end opening 19. That is, the height of the closed space is the same as the thickness of the metal plate 11.

金属板１１は、このすえ込み溝２５に、溝端開口１９から挿入先端が挿入される。すえ込み溝２５に挿入された金属板１１は、基端を保持する一対の挟持固定型１３が、第１金型１５の正面２１に当接する前に、挿入先端がすえ込み溝２５の溝終端２９に当接する。つまり、挟持固定型１３は、押し込み代を有して金属板１１を保持している。挟持固定型１３は、この押し込み代を利用して金属板１１を更にすえ込み溝２５の溝終端２９に押し込む。   In the metal plate 11, the insertion tip is inserted into the set-up groove 25 from the groove end opening 19. The metal plate 11 inserted into the upset groove 25 has an insertion tip at the groove end of the upset groove 25 before the pair of clamping and fixing molds 13 holding the base end come into contact with the front surface 21 of the first mold 15. 29 abuts. In other words, the clamping and fixing die 13 holds the metal plate 11 with a push-in margin. The clamping and fixing die 13 further pushes the metal plate 11 into the groove end 29 of the swaging groove 25 using this pushing allowance.

押し込まれた金属板１１は、溝終端２９から反力を受け、厚み方向が第１金型１５のすえ込み溝２５と第２金型１７とに拘束されていることから、潰されることにより幅方向に広がる。押し込みは、幅方向の広がりが、すえ込み溝２５の拡幅部３１の内面に到達するまで行われる。その結果、金属板１１は、同一の板厚のままで、幅方向のみがすえ込み溝２５の拡幅部３１に倣った膨出幅広部３５を有する成形金属板３７となる。そのため、従来製法で廃棄されていた膨出幅広部以外の部分で切り取られていた廃材が生じなくなる。   The pressed metal plate 11 receives a reaction force from the groove end 29 and the thickness direction is constrained by the upset groove 25 and the second mold 17 of the first mold 15. Spread in the direction. The pushing-in is performed until the spread in the width direction reaches the inner surface of the widened portion 31 of the upset groove 25. As a result, the metal plate 11 becomes a formed metal plate 37 having a bulging wide portion 35 that follows the widened portion 31 of the swaging groove 25 only in the width direction while maintaining the same plate thickness. Therefore, the waste material cut off at portions other than the bulging wide portion that has been discarded by the conventional manufacturing method does not occur.

また、図６に示した本実施形態の平型導体の製造方法では、成形金属板３７の膨出幅広部３５に、ボルト接続が可能となる。ボルト挿通穴３９を有した成形金属板３７は、膨出幅広部３５にボルト挿通穴３９が穿設されることにより、ボルト挿通穴３９の穿設により小さくなる断面積を、膨出幅広部３５による断面積の増加分で補うことができる。即ち、従来、膨出幅広部３５の幅で全幅を形成しなければならなかった平型導体における膨出幅広部以外の部分の幅を幅Ｗに狭くすることができる。このように、膨出幅広部３５にボルト挿通穴３９を穿設した平型導体では、膨出幅広部３５以外の部分で幅を狭くできる分、材料の使用量を低減することができる。   Further, in the manufacturing method of the flat conductor according to the present embodiment shown in FIG. The formed metal plate 37 having the bolt insertion holes 39 has a cross-sectional area that is reduced by the drilling of the bolt insertion holes 39 when the bolt insertion holes 39 are formed in the expansion wide portions 35. It can be compensated for by the increase in cross-sectional area. That is, the width of the portion other than the bulging wide portion in the flat conductor, which has conventionally been required to form the entire width with the width of the bulging wide portion 35, can be reduced to the width W. Thus, in the flat conductor having the bolt insertion hole 39 formed in the bulging wide portion 35, the amount of material used can be reduced by the amount that the width can be narrowed at portions other than the bulging wide portion 35.

更に、図７に示した本実施形態の平型導体の製造方法では、穿設した複数のボルト挿通穴３９のピッチＰが、図示しない電池パックにおいて並設される隣接する単電池の電極端子同士の離間距離となるように製造される。従って、この成形金属板４０は、複数の単電池を接続するバスバーとして利用が可能となる。その際、成形金属板４０は、長手方向に沿った所望の単電池間における断面積を、膨出幅広部３５により板厚を増やすことなく大きくできる。   Further, in the flat conductor manufacturing method of the present embodiment shown in FIG. 7, the pitch P of the plurality of bolt insertion holes 39 formed between the electrode terminals of adjacent unit cells arranged in parallel in a battery pack (not shown). It is manufactured so that it may become a separation distance. Therefore, this molded metal plate 40 can be used as a bus bar for connecting a plurality of single cells. At this time, the formed metal plate 40 can increase the cross-sectional area between desired single cells along the longitudinal direction without increasing the plate thickness by the bulging wide portion 35.

従って、本実施形態に係る平型導体の製造方法によれば、従来製法に比べ歩留まりを向上させることができ、導体断面積の確保のための板厚の増加や重ね合わせが不要となり、平型導体を安価に製造できる。   Therefore, according to the method for producing a flat conductor according to the present embodiment, the yield can be improved as compared with the conventional production method, and it is not necessary to increase the thickness of the plate or to superimpose the conductor cross-sectional area. Conductors can be manufactured at low cost.

そして、この平型導体の製造方法により製造された成形金属板３７，４０によれば、導体断面積の確保のために、板厚を増加させたり、導体を重ね合わせたりする必要がないので、製造コストンの上昇や製品の大型化を抑制することができる。   And according to the molded metal plates 37 and 40 manufactured by this flat conductor manufacturing method, it is not necessary to increase the plate thickness or to overlap the conductors in order to ensure the conductor cross-sectional area. An increase in manufacturing cost and an increase in product size can be suppressed.

本発明は上記の実施形態に限定されるものではなく、実施形態の各構成を相互に組み合わせることや、明細書の記載、並びに周知の技術に基づいて、当業者が変更、応用することも本発明の予定するところであり、保護を求める範囲に含まれる。   The present invention is not limited to the above-described embodiments, and the configurations of the embodiments may be combined with each other, or may be modified or applied by those skilled in the art based on the description of the specification and well-known techniques. The invention is intended and is within the scope of seeking protection.

例えば上記の構成例では、金属板の基端側を一対の挟持固定型で挟持固定して溝端開口に押し込む構成を説明したが、この押し込みは挟持固定型を用いなくてもよい。この場合、すえ込み溝の溝終端までの距離が金属板より長くなるように第１金型及び第２金型を形成する。そして、すえ込み溝に挿入した金属板の基端を、溝端開口に挿入した別部材のポンチ等により加圧する。このような構成とした場合には、座屈の生じる押し込み代を考慮する必要がなくなる。   For example, in the configuration example described above, the base end side of the metal plate is clamped and fixed with a pair of clamping and fixing types and pushed into the groove end opening. However, the pressing may not be performed using the clamping and fixing type. In this case, the first mold and the second mold are formed so that the distance to the groove end of the upset groove is longer than that of the metal plate. Then, the base end of the metal plate inserted into the upset groove is pressed with a punch or the like of another member inserted into the groove end opening. In such a configuration, it is not necessary to consider the push-in allowance for buckling.

ここで、上述した本発明に係る平型導体の製造方法の実施形態の特徴をそれぞれ以下［１］〜［４］に簡潔に纏めて列記する。
［１］ 均一厚の矩形状の金属板（１１）を成形する金属板形成工程と、
前記金属板（１１）の長手方向に直交する断面形状と同一形状の溝端開口（１９）を正面（２１）に有し、前記正面（２１）に隣接する直交平面（２３）に前記溝端開口（１９）と同一の溝底面（２７）に連続して溝終端（２９）までの間に前記金属板（１１）の幅（Ｗ）より大きい拡幅部（３１）を有するすえ込み溝（２５）が形成された第１金型（１５）に、前記すえ込み溝（２５）を覆う第２金型（１７）を前記直交平面（２３）に合わせる型締め工程と、
前記溝端開口（１９）に、前記金属板（１１）を挿入先端から挿入して前記溝終端（２９）に押し当てた後に更に押し込んで前記金属板（１１）の幅方向を前記拡幅部（３１）に倣って広げて塑性変形させる金属板拡幅工程と、
前記第２金型（１７）を前記直交平面（２３）から離間して拡幅された成形金属板（３７）を前記第１金型（１５）から取り出す離型工程と、
を含むことを特徴とする平型導体の製造方法。
［２］ 上記［１］に記載の平型導体の製造方法であって、
前記溝端開口（１９）から前記溝終端（２９）までの距離より長い前記挿入先端を残して前記金属板（１１）の基端側を一対の挟持固定型（１３）で挟持する金属板保持工程を有することを特徴とする平型導体の製造方法。
［３］ 上記［１］又は［２］に記載の平型導体の製造方法であって、
前記成形金属板（３７）の膨出幅広部（３５）にボルト挿通穴（３９）を穿設する穴開け工程を有することを特徴とする平型導体の製造方法。
［４］ 上記［１］〜［３］の何れか１つに記載の平型導体の製造方法であって、
前記成形金属板（３７）の長手方向に沿って複数のボルト挿通穴（３９）が同一のピッチ（Ｐ）で穿設され、
前記ピッチ（Ｐ）が、一対の電極端子を有する複数の単電池を並設した電池パックの隣接する前記単電池の電極端子同士の離間距離であることを特徴とする平型導体の製造方法。 Here, the features of the embodiment of the flat conductor manufacturing method according to the present invention described above are briefly summarized in [1] to [4] below.
[1] A metal plate forming step of forming a rectangular metal plate (11) having a uniform thickness,
The groove end opening (19) having the same shape as the cross-sectional shape orthogonal to the longitudinal direction of the metal plate (11) is provided in the front surface (21), and the groove end opening (in the orthogonal plane (23) adjacent to the front surface (21) is provided. 19 is a groove groove (25) having a widened portion (31) larger than the width (W) of the metal plate (11) between the groove bottom surface (27) and the groove end (29). A mold clamping step of fitting a second mold (17) covering the upset groove (25) to the orthogonal plane (23) to the formed first mold (15);
The metal plate (11) is inserted into the groove end opening (19) from the insertion tip, pressed against the groove end (29), and further pushed into the width direction of the metal plate (11) to the widened portion (31). ) And a metal plate widening process that is plastically deformed by spreading according to
A mold releasing step of taking out the formed metal plate (37) widened by separating the second mold (17) from the orthogonal plane (23) from the first mold (15);
The manufacturing method of the flat type conductor characterized by including.
[2] A method for producing a flat conductor according to [1] above,
A metal plate holding step of holding the base end side of the metal plate (11) with a pair of clamping and fixing dies (13) leaving the insertion tip longer than the distance from the groove end opening (19) to the groove end (29). A method for producing a flat conductor, comprising:
[3] A method for producing a flat conductor according to [1] or [2] above,
A method for producing a flat conductor, comprising a step of drilling a bolt insertion hole (39) in a bulging wide portion (35) of the molded metal plate (37).
[4] The method for producing a flat conductor according to any one of [1] to [3] above,
A plurality of bolt insertion holes (39) are formed at the same pitch (P) along the longitudinal direction of the formed metal plate (37),
The method for producing a flat conductor, wherein the pitch (P) is a distance between the electrode terminals of adjacent unit cells of a battery pack in which a plurality of unit cells having a pair of electrode terminals are arranged side by side.

１１…金属板
１３…挟持固定型
１５…第１金型
１７…第２金型
１９…溝端開口
２１…正面
２３…直交平面
２５…すえ込み溝
２７…溝底面
２９…溝終端
３１…拡幅部
３７…成形金属板（平型導体） DESCRIPTION OF SYMBOLS 11 ... Metal plate 13 ... Clamping fixed type | mold 15 ... 1st metal mold | die 17 ... 2nd metal mold | die 19 ... Groove end opening 21 ... Front 23 ... Orthogonal plane 25 ... Set-up groove 27 ... Groove bottom surface 29 ... Groove end 31 ... Widening part 37 ... Molded metal plate (flat conductor)

Claims (4)

均一厚の矩形状の金属板を成形する金属板形成工程と、
前記金属板の長手方向に直交する断面形状と同一形状の溝端開口を正面に有し、前記正面に隣接する直交平面に前記溝端開口と同一の溝底面に連続して溝終端までの間に前記金属板の幅より大きい拡幅部を有するすえ込み溝が形成された第１金型に、前記すえ込み溝を覆う第２金型を前記直交平面に合わせる型締め工程と、
前記溝端開口に、前記金属板を挿入先端から挿入して前記溝終端に押し当てた後に更に押し込んで前記金属板の幅方向を前記拡幅部に倣って広げて塑性変形させる金属板拡幅工程と、
前記第２金型を前記直交平面から離間して拡幅された成形金属板を前記第１金型から取り出す離型工程と、
を含むことを特徴とする平型導体の製造方法。 A metal plate forming step of forming a rectangular metal plate of uniform thickness;
The groove end opening having the same shape as the cross-sectional shape orthogonal to the longitudinal direction of the metal plate is provided on the front surface, and the groove plane is adjacent to the groove bottom opening on the orthogonal plane adjacent to the front surface until the groove end. A mold clamping step of fitting a second mold covering the upset groove to the orthogonal plane to the first mold in which the upset groove having a widened portion larger than the width of the metal plate is formed;
A metal plate widening step in which the metal plate is inserted into the groove end opening from the insertion tip and pressed against the end of the groove, and then further pushed to expand the width direction of the metal plate following the widened portion and plastically deform,
A mold releasing step of taking out the formed metal plate widened by separating the second mold from the orthogonal plane from the first mold;
The manufacturing method of the flat type conductor characterized by including. 請求項１に記載の平型導体の製造方法であって、
前記溝端開口から前記溝終端までの距離より長い前記挿入先端を残して前記金属板の基端側を一対の挟持固定型で挟持する金属板保持工程を有することを特徴とする平型導体の製造方法。 It is a manufacturing method of the flat type conductor according to claim 1,
Production of a flat conductor characterized by having a metal plate holding step of holding a base end side of the metal plate with a pair of holding and fixing molds leaving the insertion tip longer than the distance from the groove end opening to the groove end. Method. 請求項１又は２に記載の平型導体の製造方法であって、
前記成形金属板の膨出幅広部にボルト挿通穴を穿設する穴開け工程を有することを特徴とする平型導体の製造方法。 It is a manufacturing method of the flat type conductor according to claim 1 or 2,
A method for producing a flat conductor, comprising a step of drilling a bolt insertion hole in a bulging wide portion of the formed metal plate. 請求項１〜３の何れか１項に記載の平型導体の製造方法であって、
前記成形金属板の長手方向に沿って複数のボルト挿通穴が同一のピッチで穿設され、
前記ピッチが、一対の電極端子を有する複数の単電池を並設した電池パックの隣接する前記単電池の電極端子同士の離間距離であることを特徴とする平型導体の製造方法。 A method for producing a flat conductor according to any one of claims 1 to 3,
A plurality of bolt insertion holes are drilled at the same pitch along the longitudinal direction of the formed metal plate,
2. The flat conductor manufacturing method according to claim 1, wherein the pitch is a distance between electrode terminals of adjacent unit cells of a battery pack in which a plurality of unit cells having a pair of electrode terminals are arranged side by side.
JP2017115849A 2017-06-13 2017-06-13 Method of manufacturing flat conductor Pending JP2019003763A (en)

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JP2006000884A (en) * 2004-06-17 2006-01-05 Daido Steel Co Ltd Method and apparatus for producing forged product having flange parts at both end parts
WO2006126622A1 (en) * 2005-05-26 2006-11-30 Showa Denko K.K. Punching method and punching device
JP2012071321A (en) * 2010-09-28 2012-04-12 Toyota Motor Corp Method and device for manufacturing bus bar
JP2012182864A (en) * 2011-02-28 2012-09-20 Togo Seisakusho Corp Bus bar and method for manufacturing the same
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS63101036A (en) * 1986-10-15 1988-05-06 Mitsuboshi Seisakusho:Kk Screw lever with spherical couplor and its manufacture
JP2004141895A (en) * 2002-10-22 2004-05-20 Daido Steel Co Ltd Multistage forging device
JP2006000884A (en) * 2004-06-17 2006-01-05 Daido Steel Co Ltd Method and apparatus for producing forged product having flange parts at both end parts
WO2006126622A1 (en) * 2005-05-26 2006-11-30 Showa Denko K.K. Punching method and punching device
JP2012071321A (en) * 2010-09-28 2012-04-12 Toyota Motor Corp Method and device for manufacturing bus bar
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