JP4216044B2 - Ultrasonic welding equipment for metal foil - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an ultrasonic welding apparatus that joins a plurality of metal sheets, such as a foil or a long sheet made of copper, aluminum, or the like, and more particularly to an apparatus that continuously welds a plurality of metal sheets.
[0002]
[Prior art]
Metal sheet materials such as copper foil are widely used in the manufacture of electronic devices and parts thereof. For example, a printed wiring board used in an electronic device uses a copper clad laminate in which a copper foil is laminated on an insulating substrate such as a glass fiber reinforced resin prepreg or a polymer film. However, handling of metal foils such as copper foils is not always easy because, for example, wrinkles easily enter. Therefore, for example, in the manufacture of a copper clad laminate, the copper foil before lamination is handled in a state of being bonded to a carrier such as an aluminum sheet (a state of a laminated sheet). If handled in such a state, generation of wrinkles and adhesion of dust in the copper foil can be prevented.
[0003]
By the way, as a manufacturing method of the lamination sheet by which copper foil and a carrier are joined, there exists a method of using an adhesive agent (for example, refer patent document 1). However, when the laminated sheet manufactured by this method is used, an adhesive, that is, an organic substance remains on the copper foil side when the copper foil is placed at a predetermined position or the carrier is peeled off by pasting or the like. Sometimes. If the organic substance remains on the copper foil, there is a possibility that a defect such as an etching failure may occur after the etching process for forming a wiring pattern. In addition, if the adhesive is attached to the surface of the carrier collected after using the laminated sheet, the purity of the metal obtained when this is recycled is lowered. If the purity is lowered, it is not preferable because the reuse is limited. In addition to the method using an adhesive, for example, there is a method in which the laminated copper foil and the carrier are bent and mechanically joined, etc., but mechanical means are easy to peel off, etc. Not necessarily expensive.
[0004]
As a joining method proposed in order to solve such a problem, there is a method by ultrasonic welding (see, for example, Patent Document 2). In this method, generally, a long copper foil and a carrier (aluminum sheet) are overlapped so that, for example, both ends thereof are aligned, and in this state, the overlapped copper foil and the end of the carrier are overlapped. This is a method of continuously welding through an ultrasonic welding unit. Inside the ultrasonic welding unit, a horn, which is a disc-shaped vibrating body, and a disc-shaped anvil installed opposite to the horn are provided, and the laminated copper foil and carrier are connected to the horn and the anvil. It can be continuously welded by pressing between the two. If it does in this way, a long lamination sheet which consists of copper foil and a carrier can be manufactured continuously, without using an adhesive agent.
[0005]
[Patent Document 1]
US Pat. No. 5,153,050
[Patent Document 2]
Japanese Patent Laid-Open No. 10-291080
[0006]
[Problems to be solved by the invention]
However, it is extremely difficult to continuously produce a laminated sheet containing a foil-like metal, such as a laminated sheet obtained by laminating a copper foil and its carrier used in a printed wiring board, with a conventional ultrasonic welding apparatus. It is. This is because metal foil such as copper foil is a material in which wrinkles easily enter, and conventional devices cannot prevent wrinkles generated in the manufacturing process including the welding process.
[0007]
The present invention has been made in view of the above problems, and continuously laminates a laminated sheet made of a plurality of long metal sheets such as a copper foil and an aluminum sheet without causing wrinkles. It is an object of the present invention to provide an ultrasonic welding apparatus that can be manufactured.
[0008]
[Means for Solving the Problems]
In order to solve such problems, the inventors of the present invention examined the cause of wrinkles. As a result, it was found that there is a part that is particularly prone to wrinkles. For example, there is a portion to be pressed by sandwiching a long sheet overlapped by a horn and an anvil and thereby ultrasonically welding. Therefore, the device structure of the part where wrinkles are likely to occur was examined, and the following invention was made.
[0009]
The present invention includes an ultrasonic welding unit having a horn that is a disk-shaped vibrating body that is rotatably installed, and a disk-shaped anvil that is rotatably installed in a state facing the horn. In an ultrasonic welding device that sandwiches a plurality of metal long sheets fed in a state of being superposed in a sonic welding unit between a horn and an anvil and pressurizes and joins them continuously, it is fed into the ultrasonic welding unit And a support means for supporting the sheets so that the feeding direction of the plurality of long sheets in the stacked state coincides with the feeding direction of the laminated sheets welded and sent out from the ultrasonic welding unit. The first long sheet of at least one of the two long sheets arranged on both outer layers of the plurality of long sheets is sandwiched with a tension in the width direction applied. And tensioning means to allow the pressure, and having means for tuning the peripheral speed of the outer peripheral surface of the horn in contact with the long sheet feeding speed of the long sheet, the.
[0010]
In the ultrasonic welding apparatus according to the present invention, before feeding a plurality of superposed long sheets into an ultrasonic welding unit (hereinafter also referred to as “welding unit”), it is once installed upstream in the feed direction of the welding unit. It is supported by the upstream support means. As the support means, for example, a roller provided along the feeding path of the long sheet can be used. When the support means is installed, first, there is an advantage that the feeding direction of the long sheet into the welding unit is stabilized. Then, the plurality of long sheets are sandwiched between a horn and an anvil at a predetermined position in the welding unit and pressurized and ultrasonically welded, whereby a laminated sheet in which the plurality of long sheets are welded is obtained. This laminated sheet is once supported by downstream support means installed on the downstream side in the feed direction of the welding unit, and further sent downstream. If it does in this way, the delivery direction from the welding unit of a lamination sheet will become stable. The laminated sheet is then sent out in a direction as needed and cut (panelized). For example, in the case where both side end portions extending in the longitudinal direction of the laminated sheet are continuously welded, a rectangular panel obtained by subsequent cutting is obtained by welding two opposite sides out of four sides.
[0011]
Further, the support means is installed at a predetermined position so that the feeding direction and the feeding direction of the plurality of long sheets with respect to the welding unit can be matched. For example, the upstream support means supports a plurality of stacked long sheets over the entire width, and the downstream support means supports the laminated sheets obtained by ultrasonic welding over the entire width. Yes. When each support means is installed in this way, a plurality of stacked long sheets or laminated sheets are fed into the ultrasonic unit in a state where they are spread horizontally without causing slack or the like at the center in the width direction, and Sent from ultrasonic welding. That is, both support means are installed such that the long sheet is fed along the same plane in a section (welding unit installation section) sandwiched between both support means. To do this, for example, the long sheet feed path surface in the welding unit installation section with the welding unit removed, and the welding unit are installed and the horn and anvil sandwich the long sheet and pressurize it. The relative positions of the welding unit and both support means are determined so that the contact surface (tangent) of the outer peripheral surface of the horn and / or anvil at the position is located on the same plane. If it does in this way, a plurality of piled long sheets can be ultrasonically welded by being sandwiched between a horn and an anvil without causing bending or slack in the feeding direction or width direction (while maintaining a flat state). If ultrasonic welding can be performed while maintaining a plurality of long sheets in a flat state, generation of wrinkles can be suppressed. For example, when using the roller mentioned above as a support means, it is not necessary to install a dedicated roller used as a support means, and other functions such as a feed roller for feeding a long sheet and a feed roller for guidance, etc. For this reason, it is possible to use the roller installed for the purpose.
[0012]
Further, in the apparatus according to the present invention, a plurality of long sheets stacked in a state where a tension in the width direction is applied to a position where at least the first long sheet (one of the long sheets disposed in the outermost layer) is welded. The sheet is pressurized and ultrasonically welded. The tension applying means for applying the tension in the width direction to the first long sheet is, for example, the position upstream of the welding unit in the feeding direction and the position where the first long sheet is welded is set on both sides in the width direction. One having a set (or a plurality of sets) of skew rollers in contact with the surface of the first elongate sheet at a position sandwiched between the first and second sheets. Each skew roller is installed so that the downstream side in the feed direction faces outward. That is, both skew rollers are installed so as to have a substantially letter-shaped shape (a state of spreading toward the end) so that the distance between the rollers increases toward the downstream side in the feed direction. In other words, each skew roller is mounted such that the crossing position of the extension line of the rotation axis of each skew roller is at least downstream in the feed direction from the contact position between the skew roller and the first long sheet. Yes. In addition, the crossing position here refers to the position where both the extension lines literally cross, as well as when either one of the rotation axes and the extension line are translated in the vertical direction (direction perpendicular to the long sheet). The obtained intersection position is included (including the so-called three-dimensional intersection state).
[0013]
When the tension applying means having such a set of skew rollers is installed, the first long sheet comes into contact with the skew rollers before being fed into the welding unit. Each skew roller forming a set is installed so that the downstream side in the feeding direction faces outward, and the width direction is set in a region sandwiched between both skew rollers of the first long sheet, that is, a region including a position to be welded. Tension is applied. And a 1st elongate sheet | seat is sent in to a welding unit in the state to which the tension of the width direction was provided. The first long sheet, which is a long sheet disposed in the outermost layer, is likely to cause wrinkles, but generation of wrinkles is suppressed if ultrasonic welding is performed with a tension in the width direction applied.
[0014]
The preferred orientation of each skew roller varies depending on conditions such as the thickness and feed speed of the long sheet, but according to the results of tests and studies, the rotation direction of the skew roller and the width direction of the long sheet Is preferably 5 ° to 30 °.
[0015]
The installation position of the pair of skew rollers, particularly the position in the sheet width direction, is not particularly limited as long as the position where the first long sheet is welded is sandwiched from both sides in the width direction by both skew rollers. However, if a pair of skew rollers are provided so as to be in contact with both side edge positions of the sheet (see FIG. 6), a tension in the width direction can be applied to all the welding positions by the pair of skew rollers. In addition, since the tension in the feeding direction is basically applied to the long sheet, the skew roller can be provided without providing auxiliary means such as another roller for sandwiching the long sheet in cooperation with the skew roller. As long as the first long sheet is placed in contact with the first long sheet, a reaction force is generated from the first long sheet to the skew roller, and a tension in the width direction can be applied to the first long sheet. If it is not necessary to provide auxiliary means, a simple structure is preferable. However, if an auxiliary means such as a roller is installed and the tension in the width direction is applied while sandwiching the long sheet in cooperation with the skew roller, there is an advantage that a larger tension in the width direction can be applied. is there.
[0016]
Moreover, it is possible to use the horn used for ultrasonic welding as a tension | tensile_strength provision means to provide the tension | tensile_strength of the width direction to a 1st elongate sheet | seat. For example, if two or more horns are provided, two of them can be used as a set of tension applying means.
[0017]
For example, when two installed horns are used as tension applying means, the two horns are formed in a so-called C shape (end-spread state) so that the distance between the two horns increases as the skew roller is installed, that is, the downstream side in the feed direction. In addition, the skew roller is installed so as to be in another state.
[0018]
By installing the horn in this way, when this horn is used as a tension applying means, a plurality of long sheets including the first long sheet are horned while applying a tension in the width direction to the first long sheet. And pressurize with anvil to apply ultrasonic waves. And if it does in this way, a plurality of long sheets can be ultrasonically welded while suppressing the generation of wrinkles in the first long sheet, and a laminated sheet without wrinkles can be obtained after welding after completion of welding.
[0019]
In addition, when using a horn as a tension | tensile_strength provision means, it is preferable to set the angle which the rotation axis direction of a horn and the width direction of a elongate sheet | seat make to 0.286 degrees-1.146 degrees. When the horn is used as the tension applying means, there is an advantage that it is not necessary to separately provide a skew roller.
[0020]
Furthermore, the apparatus according to the present invention has means for synchronizing the peripheral speed of the outer peripheral surface of the horn in contact with the long sheet with the feed speed of the long sheet. For example, there is provided a power transmission mechanism including a driving unit such as a motor for applying a rotational force to the horn and a transmission power limiting unit such as a clutch or a torque limiter installed in a section for transmitting the rotational force from the driving unit to the horn. Thus, both speeds can be synchronized. The horn, which is the target of speed tuning, is in contact with the first long sheet where wrinkles are likely to occur during ultrasonic welding. Therefore, if the peripheral speed of the horn and the feeding speed of the long sheet are synchronized, the generation of wrinkles in the first long sheet is suppressed. In addition, it is preferable to synchronize the peripheral speed of the outer peripheral surface of the anvil with the feed speed of the long sheet as well as the horn. This is because ultrasonic welding is reliably performed without slipping between the horn, the anvil, and the long sheet.
[0021]
As can be seen from the above description, in the ultrasonic welding apparatus of the present invention, the long sheet is held in a state of being spread horizontally by the support means, and the feeding direction and the feeding direction of the long sheet to the welding unit are stabilized, and the tension is maintained. Applying a tension in the width direction to the first long sheet by the applying means, and adjusting the peripheral speed of the outer peripheral surface of the horn to the feed speed of the long sheet by the speed tuning means, Sonic welding is performed, and in this way, a plurality of long sheets can be joined while suppressing generation of wrinkles, and a laminated sheet without wrinkles can be manufactured.
[0022]
By the way, as a method of moving the plurality of stacked long sheets relative to the welding unit, for example, a plurality of the long sheets are stacked and fixed at a predetermined position, and along the longitudinal direction of the fixed long sheets. There are a method of moving a welding unit and a method of passing a long sheet through a fixed welding unit. Comparing the two, the latter method is a method of continuously feeding a long sheet, so the welding efficiency is higher than the former, and the welding efficiency can be increased relatively easily by increasing the feeding speed. Has the advantage. However, in the latter method, wrinkles are likely to occur at a position where the long sheet is fed. The means for feeding the long sheet is, for example, a feeder-like means (feed means). Therefore, as a result of examining the feed means from the viewpoint of preventing wrinkles, it was found that the following means is preferably used.
[0023]
In other words, the ultrasonic welding apparatus superimposes the long sheet to be joined from the winding roll and feeds the upstream sheet feeding means to the ultrasonic welding unit side and the laminated sheet obtained by welding with the ultrasonic welding unit. And a downstream feed unit that pulls out from the sonic welding unit, and the downstream feed unit includes a pair of feed rollers that sandwich a plurality of stacked long sheets, and these feed rollers Of the pair of feed rollers, and at least one of the feed rollers in contact with the first long sheet is provided on the outer circumferential surface of the first long sheet. A plurality of cylindrical portions that are in rolling contact with each other, and each cylindrical portion is continuously formed on the laminated sheet in cooperation with the other feed roller. Preference is arranged at a position capable of pinching the minute.
[0024]
When a plurality of long sheets are continuously ultrasonically welded by fixing the welding unit and feeding the long sheet, as described above, at least one each on the upstream side and the downstream side in the feed direction of the welding unit. It is preferable to install feed means such as a feeder. By balancing the operating state of both feeders, the longitudinal tension of the long sheet at the position of the welding unit can be stabilized, thereby enabling continuous welding of the long sheet while suppressing the occurrence of wrinkles. Because.
[0025]
Also, one of the feed rollers of the downstream feed means that contacts the first long sheet is formed of a plurality of cylindrical portions, and a welded portion of the laminated sheet is formed by the cooperation of each cylindrical portion and the other feed roller. However, this is because it is possible to prevent wrinkles from being generated in the laminated sheet by passing through the downstream feed means. This point will be described in more detail. As already described, a laminated sheet is obtained by ultrasonically welding a plurality of stacked long sheets. For example, a copper foil used for manufacturing a copper-clad laminate and a carrier sheet made of aluminum or the like are super A laminated sheet such as a copper foil with a carrier formed by sonic welding is obtained by welding only both end portions of a plurality of long sheets. In other words, for example, one belt-like welded portion is provided at each of the positions near both ends. As described above, in the laminated sheet that is only partially welded, the non-welded portion may be slack for some reason (for example, the poor balance between the tensions applied to the long sheets). If the laminated sheet is slack, when the laminated sheet is sandwiched by a pair of feed rollers, the slack is crushed by the feed roller and wrinkles are likely to occur. In particular, a region that is farther from the welded portion (for example, the central region of the laminated sheet) is more likely to be loosened, and wrinkles are likely to occur.
[0026]
In this regard, in the ultrasonic welding apparatus according to the present invention, as described above, among the feed rollers forming a pair of downstream feed means, at least one of the feed rollers in contact with the first long sheet is the first long A plurality of cylindrical portions that are in rolling contact with the outer peripheral surface of the sheet are provided, and each cylindrical portion is disposed at a position sandwiching the welded portion in cooperation with the other feed roller. If it does in this way, when applying tension | tensile_strength by pinching | stacking a lamination sheet with a feed means, it can avoid pinching the non-welded part of the lamination sheet which may have produced slack with a feed roller. If it is possible to avoid pinching the non-welded portion, the occurrence of wrinkles due to the slack is suppressed regardless of whether or not the slack has occurred.
[0027]
The installation position of the upstream feed means is not particularly limited as long as it is upstream of the welding unit. However, when a tensile force is applied across a plurality of stacked long sheets, slip may occur between the sheets. In addition, if an upstream feed means is provided for each long sheet to be joined, it may be difficult to balance the tension applied to each long sheet. For this reason, the upstream feed unit is positioned upstream of the position where the long sheets are stacked, and a tensile force is applied to the thickest second long sheet among the plurality of long sheets. Thus, a position where feeding can be applied is preferable. In this way, slippage between the long sheets can be prevented, and there is no need to balance the pulling force. The thickest second long sheet has the advantage that it has the greatest strength against tension and does not cause problems such as deformation. In addition, you may attach the torque control means which gives a fixed torque or stabilizes a torque to the support shaft of the winding roller of a 2nd elongate sheet and another elongate sheet. Providing such torque control means stabilizes the amount of each long sheet pulled out from each winding roller, makes it difficult for slackness and the like to occur, and further suppresses the generation of wrinkles.
[0028]
Further, as can be seen from the above description, the ultrasonic welding apparatus according to the present invention does not require an adhesive, so that no organic substance remains on the copper foil. Therefore, for example, an etching failure due to the remaining organic substance does not occur during the etching process for pattern formation. For example, in the case of a laminated sheet such as a copper foil with a carrier made of a copper foil and an aluminum sheet, the adhesive is not attached to the surface of the sheet. At the time of collection, an operation for removing the adhesive or the like is unnecessary. Therefore, only copper foil and a carrier sheet can be efficiently recovered.
[0029]
In addition, although the metal foil which is ultrasonic welding object has difficulty in welding, it is not specifically limited. However, so-called soft metals, more specifically, copper, aluminum, noble metals such as gold, silver, platinum, and panadium are the metals that are most easily ultrasonically welded.
[0030]
DETAILED DESCRIPTION OF THE INVENTION
DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments of an ultrasonic welding apparatus according to the invention will be described with reference to the drawings.
[0031]
The ultrasonic welding apparatus 1 shown in FIG. 1 includes a carrier W1 (second long sheet, 250 μm thickness) made of aluminum (A3004P-H19, JIS H 4000), copper foil W2 (18 μm thickness), and copper to be joined. It is an apparatus for producing a laminated sheet S by ultrasonically welding a foil W3 (18 μm thick), and is roughly composed of a first roll support unit 10 that supports a roll (winding roll) R1 of a carrier W1, and a roll R1. A decurler unit 20 for correcting the curl of the drawn carrier W1, a second roll support unit 30 for supporting a plurality of copper foil rolls R2, R3, a carrier W1 drawn from each roll R1, R2, R3, Two ultrasonic welding units 40 and 50 (hereinafter referred to as “welding units”) for welding the copper foil W2 on the side and the copper foil W3 on the upper side in a laminated state; Having a cutter unit 60 for cutting the laminate sheet S of the strip obtained, the piling unit 70 for stocking the panel P of the resulting rectangle (sheet) by cutting by.
[0032]
Moreover, the ultrasonic welding apparatus 1 has a drive unit that pulls out a long sheet such as the carrier W1 from the roll and sends it to the downstream side in the feed direction T (see FIG. 1 and the like). Specifically, a first drive unit (upstream feed means) 80 is installed between the decurler unit 20 and the second roll support unit 30, and the second drive unit 50 is disposed downstream of the second welding unit 50. A drive unit (downstream feed means) 90 is installed. These driving means feed the carrier W1, the copper foils W2, W3 or the laminated sheet S.
[0033]
Hereinafter, each part of the ultrasonic welding apparatus 1 will be described in order from the upstream side in the feed direction T of the carrier W1.
[0034]
As shown in FIG. 1, the first roll support unit 10 rotatably supports the roll R <b> 1 by a support shaft 11. A torque control device (not shown) for applying a predetermined magnitude of torque and controlling the magnitude is attached to the support shaft 11. In the present embodiment, a powder clutch is used. The direction of the torque is a direction that prevents the carrier W1 from being pulled out from the roll R1, and thereby a predetermined tension in the feeding direction is applied to the carrier W1 that is pulled out from the roll R1. The carrier W1 drawn out from the roll R1 is fed into the decurler unit 20 on the downstream side in a state of receiving tension. In addition, the 1st roll support unit 10 and the below-mentioned 2nd roll support unit 30 can install the sheet | seat of the width dimension of 750 mm or less.
[0035]
The decurler unit 20 is conventionally used. The thing of this embodiment has the four rollers 21, 22, 23, and 24 arranged in a row. In the unit 20, the carrier W1 is passed in a state where the rollers 21, 22, 23, 24 are alternately in contact with the upper surface or the lower surface thereof. Each of the rollers 21, 22, 23, and 24 can adjust the vertical position independently, and the carrier W <b> 1 passes through the unit 20 while being waved in an S shape. Thereby, the curl attached to the carrier W1 is corrected.
[0036]
The first drive unit 80 includes a first feed roller 82 that is rotated by a motor 81 and a second feed roller 83 that sandwiches the carrier W <b> 1 in cooperation with the first feed roller 82. Both feed rollers 82 and 83 are cylindrical and contact the carrier W1 over its entire width. When the motor 81 is operated to rotate both the feed rollers 82 and 83, a force pulling to the downstream side in the feed direction T is applied to the carrier W1, and the feed in the direction T is applied. The motor 81 includes a rotation speed adjusting means. The adjusting means is used for adjusting the feeding speed of the carrier sheet W1.
[0037]
The second roll support unit 30 rotatably supports two rolls R2 and R3 (for copper foils W2 and W3). Like the first roll support unit 10, each of the support shafts 32 and 33 has a torque. A control device (not shown) is attached. When torque of a predetermined magnitude is applied to the support shafts 32 and 33 by the torque control device, tension in the feed direction is applied to the drawn copper foils W2 and W3.
[0038]
On the downstream side of the second roll support unit 30, a plurality of rollers that support the copper foils W2, W3 drawn from the rolls R2, R3 are installed. Among these rollers, the roller 39 installed immediately upstream of the first welding unit 40 also functions as a means for superimposing the lower copper foil W2 on the lower side of the carrier W1.
[0039]
As shown in FIG. 2, the first welding unit 40 includes a horn 41 that is a disk-shaped vibrating body that is installed below the copper foil W2, and a disk-shaped anvil 42 that is installed above the carrier W1. It has welding means 40a provided with. And as FIG. 3 shows, the 1st welding unit 40 has the two welding means 40a for convenience, one in the position corresponding to the both-ends part of the carrier W1. Each horn 41 and anvil 42 are rotatably supported by their respective support shafts, and are rotated by the power of the motor 43.
[0040]
The rotation of the motor 43 is transmitted to each horn 41 and the anvil 42 via a power transmission mechanism such as a slip clutch (means for synchronizing the feed speed) 44, a pulley 45a, a belt 45b, or gears 46a to 46c. As described above, if the slip clutch is interposed in the rotation transmission path, excessive rotational force is not transmitted to the horn 41 and the anvil 42, and the horn 41 and the anvil 42 are connected to the peripheral speed of these outer peripheral surfaces and the carrier. It is possible to rotate while always matching the feed speed of W1. If the two velocities can be matched, it is possible to prevent unnecessary pulling force or excessive force from being applied from the horn 41 or the anvil 42 to the carrier W1 or the copper foil W2 during welding, and thus the generation of wrinkles is more sure. To be suppressed.
[0041]
The two pairs of horns 41 and anvils 42 are opposed to each other so that they can be sandwiched and pressed while rotating the positions of the laminated carrier W1 and copper foil W2 near both ends (see FIGS. 4 and 5). Although not shown, the support shaft of the anvil 42 is supported by the unit via an arm. This arm has a structure in which one end is rotatably fixed and the support shaft of the anvil 42 is attached to the other end. Further, an urging force in the arm rotation direction can be applied to the arm. Therefore, the carrier W1 and the copper foils W2, W3 can be sandwiched between the horn 41 and the anvil 42 by the weight of the anvil 42 and the applied urging force.
[0042]
Each horn 41 is given mechanical vibration in the width direction of the carrier W1 via a transducer (not shown). The annular outer peripheral surface of the horn 41 is processed smoothly over the entire circumference, and as shown in FIGS. 4 and 5, the outer peripheral portion of the annular outer peripheral surface is a circular arc having a convex cross-sectional shape. It is shaped to be a surface (curved surface). When such a horn 41 is vibrated, the outer peripheral surface of the horn 41 in contact with the copper foil W2 vibrates, and the position of the laminated carrier W1 and copper foil W2 between the horn 41 and the anvil 42 is ultrasonic. Welding is performed to form a belt-like welded portion Se (regions indicated by oblique lines intersecting in FIG. 4).
[0043]
As shown in FIG. 2, on the upstream side of the welding means 40a, a skew roller (tension applying means) 47a and an assist roller 47b sandwiching the carrier W1 and the copper foil W2 by cooperation with the skew roller 47a. A set of rollers is installed. In FIG. 3, the skew roller 47a and the like are not shown. As shown in FIG. 2, the skew roller 47a is rotatably supported by the arm 47c, and the outer peripheral surface of the skew roller 47a is covered with rubber (elastic body). Therefore, a nip force can be effectively applied to the copper foil W2 when the skew roller 47a is pressed against the copper foil W2.
[0044]
As shown in FIG. 6, one set of skew roller 47a and assist roller 47b (only skew roller 47a is shown in FIG. 6) is installed at a position near both ends of carrier W1. . The skew roller 47a is attached obliquely so that the downstream side in the feed direction T faces the outside in the width direction. When such a skew roller 47a is pressed against the copper foil W2 fed to the downstream side in the feed direction T, a force F that pulls outward in the width direction is applied from each skew roller 47a to the copper foil W2. The direction of the tensile force F applied from both skew rollers 47a is opposite, and a tension in the width direction is applied between the skew rollers of the copper foil W2 to which both tensile forces F are applied. Further, as shown in FIG. 6, the positions of both skew rollers 47a are closer to the side edge of the sheet than the welded portion Se, and are installed at positions where the positions to be welded can be sandwiched. Therefore, the tension in the width direction can be applied to the position where the skew roller 47a is reliably welded. Generation of wrinkles is suppressed when ultrasonic welding is performed with a tension in the width direction applied. An actuator 47e is connected to the arm 47d that supports the skew roller 47a (see FIG. 2), so that the pressing force can be adjusted. In the present embodiment, the assist roller 47b is installed at a position facing the skew roller 47a with the carrier W1 and the copper foil W2 interposed therebetween. When the skew roller 47a is pressed against the copper foil W2, the force is applied to the copper foil W2. F is effectively applied. However, the assist roller 47b may not be provided. When the skew roller 47a is pressed against the copper foil W2, a reaction force from the carrier W1 to which the tension is applied is generated, and the copper foil W2 can be sandwiched between the assist roller 47b and the carrier W1, and the skew roller 47a contacts the copper foil W2. This is because the tension can be applied by applying the force F. In this embodiment, the orientation of the skew roller 47a is set so that the angle formed with the feed direction T is 10 °.
[0045]
Further, as shown in FIG. 2, support rollers (support means) 48 a and 48 b that support the carrier W <b> 1 and the copper W <b> 2 in a stacked state are installed on the upstream side and the downstream side in the feed direction of the first welding unit 40. ing. When these support rollers 48a and 48b are installed, feeding and feeding of the long sheet into the first welding unit 40 is stabilized. Moreover, although both the support rollers 48a and 48b are in contact with the copper foil W2 at their upper ends, they are installed so that they can contact the copper foil W2 at the same height as the contact position between the horn 41 and the copper foil W2. . When both the support rollers 48a and 48b are installed at such positions, the carrier W1 and the copper foil W2 can be fed along one plane between the both support rollers 48a and 48b (first welding unit installation section). Thus, in the apparatus of the embodiment, the feeding direction and the feeding direction of the carrier W1 and the copper foil W2 with respect to the first welding unit 40 coincide with each other.
[0046]
The second welding unit 50 is installed on the downstream side of the first welding unit 40, and ultrasonically welds the upper copper foil W3 superimposed on the carrier W1 at the position of the roller 49 to the carrier W1. . In the second welding unit 50, the horn 51 is installed on the upper side of the copper foil W3, and the anvil 52 is installed on the lower side of the carrier W1. As described above, the arrangement of each member is upside down with respect to the first welding unit 40, but the installed members and operations are the same. Therefore, detailed description of the operation is omitted. In FIG. 2, reference numeral “55a” denotes a pulley, “55b” denotes a power transmission belt, “56a” to “56c” denote gears, “57a” denotes a skew roller, “57b” denotes an assist roller, and “58a” denotes a first roller. 2 A support roller installed on the upstream side in the feed direction of the welding unit 50, “58b” is a support roller installed on the downstream side. Since the plan view is omitted, the motor and slip clutch are not shown.
[0047]
As shown in FIG. 1, the second drive unit 90 includes a motor 91 and a pair of feed rollers 92 and 93, similar to the first drive unit 80. When the motor 91 is operated, both the feed rollers 92 and 93 are rotated to feed the laminated sheet S sandwiched between the two feed rollers 92 and 93, and thereby the laminated sheet S is welded to the welding unit 40. , 50 and sent to the cutter unit 60 etc. on the downstream side in the feed direction. As described above, the second drive unit 90 has the same basic structure as the first drive unit 80, but differs from the first drive unit in that the shape of the feed rollers 92 and 93 and the support unit are provided.
[0048]
As shown in FIGS. 7A and 7B, one feed roller 92 of the second drive unit 90 has a shaft body 92a that is rotatably supported, and the shaft body 92a has a divided feed. Two rollers (cylindrical portions) 92b are attached. Each divided feed roller 92b is disposed at a position corresponding to a welded portion Se (see also FIG. 4) near the side end of the laminated sheet S. Similarly to the feed roller 92, the other feed roller 93 also has a shaft body 93a that is rotatably supported and two divided feed rollers 93b attached to the shaft body 93a. Each of the rollers 93b is disposed at a position corresponding to the welded portion Se of the laminated sheet S. As described above, the second drive unit 90 applies a tensile force to the laminated sheet S across the welded portion Se that is a part of the laminated sheet S by the cooperation of the two divided feed rollers 92b and 93b, and sends the laminated sheet S to the laminated sheet S. It is something to apply. That is, the second drive unit 90 can feed the laminated sheet S without sandwiching the region (non-welded region) other than the welded portion Se between the feed rollers 92 and 93. Since the non-welded area of the laminated sheet S is an area where the sheets constituting the laminated sheet S are not joined to each other, one of the sheets may be in a slack state, but like the second drive unit 90 If the feed can be applied without sandwiching the non-welded area, the occurrence of wrinkles due to the slack (the wrinkles caused by pinching the slack portion) is minimized, regardless of whether slack has occurred. Is done. The divided feed rollers 92b and 93b can be fixed to the shaft bodies 92a and 93a by tightening screws (not shown).
[0049]
As can be seen from the above description, each of the feed rollers 92 and 93 of the second drive unit 90 includes a plurality of divided feed rollers 92b and 93b. This is because the laminated sheet S is formed by welding copper foils W1 and W2 on both surfaces (both outer layers) of the carrier W1, and both the feed rollers 92 and 93 are in contact with the welded copper foils W2 and W3. (See FIG. 7C). In addition, although each division | segmentation feed roller 92b, 93b of an embodiment can be attached or detached independently, respectively, you may form integrally.
[0050]
As shown in FIG. 2, support rollers (support means) 94 a and 94 b are installed on the upstream side and the downstream side in the feed direction of the second drive unit 90. These support rollers 94a and 94b are the same as the support rollers 48a and 48b installed in the first welding unit 40 and the like, and detailed description thereof is omitted. When these support rollers 94a and 94b are installed, the laminated sheet S that is drawn into the second drive unit 90 and sent out can be moved along one plane. When the laminated sheet S is kept flat, the occurrence of slack caused by bending is suppressed, and the generation of wrinkles due to the slack when passing through the second drive unit 90 is suppressed.
[0051]
As shown in FIG. 1, the cutter unit 60 is a conventionally used device, and is installed on the downstream side of the second welding unit 50 and the second drive unit 90. The cutter unit 60 includes a shear cutter that cuts the fed long laminated sheet S into a rectangular panel P. As a result, a panel P in which only two of the four sides are ultrasonically welded is obtained. In the cutter unit 60, the feeding of the long laminated sheet S sent through the second drive unit 90 is temporarily stopped, and the cutting part of the laminated sheet S is fixed to the cutter unit 60 in a long state. A desired position of the laminated sheet S is cut. Then, the panel P is manufactured.
[0052]
As shown in FIG. 1, the ultrasonic welding apparatus 1 includes a buffer region B that can store a long laminated sheet S between the second drive unit 90 and the cut-out unit 60. With such a structure, the laminated sheet S fed from the second drive unit 90 can be stored in the buffer region B when the feeding of the laminated sheet S is temporarily stopped in the cutter unit 60. Therefore, even during the cutting operation in the cutter unit 60, the long laminated sheet S can be continuously manufactured without stopping the welding unit. This improves the productivity of the panel P. The apparatus denoted by reference numeral “59” includes a sensor that detects the slackness of the laminated sheet S. Based on signals from the sensors, the feeding speed of the carrier sheet W1 and the copper foils W2 and W3, and the cutter unit 60 operation intervals can be controlled.
[0053]
The piling unit 70 is installed on the downstream side of the cutter unit 60. The piling unit 70 has a table on which a panel P obtained by cutting with the cutter unit 60 is placed. The table 71 includes pantograph-like legs 72, and each time the panel P is stacked, the table 71 gradually moves downward. Therefore, the panels P can be stacked only by feeding the panels P to the same position. The piling unit 70 is widely used in various panel manufacturing apparatuses, and detailed description thereof is omitted.
[0054]
A procedure for manufacturing a panel using such an ultrasonic welding apparatus 1 will be described.
[0055]
First, rolls R1, R2, and R3 are installed on the support units 10 and 30, and the carrier W1 and the copper foils W2 and W3 drawn from the rolls R1, R2, and R3 are rolled along a predetermined path. Then, the motors 81 and 91 of both the drive units 80 and 90 are operated, and the carrier W1 and the copper foils W2 and W3 are continuously drawn out from the rolls R1, R2 and R3, and fed. At this time, the rotational speed of the motor is adjusted using the adjusting means of both the drive units 80 and 90 according to the manufacturing conditions, etc., to adjust the feed speed of the carrier sheet W1 and the copper foils W2 and W3, or to drive both The tension of the carrier sheet W1 and the copper foils W2, W3 located between the parts is adjusted. The feed rate is not particularly limited, but is 6 m / min in this embodiment.
[0056]
The carrier W1 drawn out from the roll R1 is first fed into the decurler unit 20, where the curl is corrected. Thereafter, the carrier W1 is superposed on the copper foil W2 at the position of the roller 39 and fed into the first welding unit 40. The carrier W1 and the copper foil W2 fed into the first welding unit 40 are ultrasonically welded at positions near both side ends here, and the belt-like welded portion Se (the region indicated by the oblique lines intersecting in FIGS. 4 and 5) ) Is formed continuously. In the first welding unit 40, conditions such as an input voltage were appropriately set according to welding conditions and the like. In this embodiment, a unit having an output of 600 W (input voltage 200 V, frequency of about 19 kHz) was used as the first welding unit 40, and ultrasonic welding was performed by adjusting the input voltage to 110 V to 115 V using a slidac. Further, 10 kg was applied as a load for sandwiching the carrier W1 and the copper foil W2 between the horn and the unbuilt.
[0057]
The carrier sheet W1 and the copper foil W2 are sent along a single plane between the roller 39 and the roller 49 (first welding unit installation section), and in the width direction by the skew roller 47a installed on the upstream side of the horn 41. The tension is given. Further, the peripheral speeds of the outer peripheral surfaces of the horn 41 and the anvil 42 coincide with the feed speeds of the carrier W1 and the copper foil W2, as described above. When ultrasonic welding is performed by the first welding unit 40 in such a state, generation of wrinkles in the copper foil W2 during welding is suppressed.
[0058]
Subsequently, in the second welding unit 50, similarly to the first welding unit 40, the positions from both side ends of the carrier W <b> 1 and the copper foil W <b> 3 are continuously ultrasonically welded. The carrier sheet W1 and the copper foil W3 are fed along a single plane between the roller 49 and the roller 58 (second welding unit installation section), and in the width direction by the skew roller 57a installed on the upstream side of the horn 41. The tension is given. Further, the peripheral speeds of the outer peripheral surfaces of the horn 51 and the anvil 52 are the same as the feed speeds of the carrier W1 and the copper foil W3 as in the first welding unit 40. When ultrasonic welding is performed by the second welding unit 50 in such a state, generation of wrinkles in the copper foil W3 during welding is suppressed. In addition, since the welding conditions in the 2nd welding unit 40 are the same as that of the 1st welding unit 40, the description is abbreviate | omitted.
[0059]
The laminated sheet S manufactured by ultrasonic welding in both the welding units 40 and 50 is then pulled out from the second welding unit 50 by the second drive unit 90 and sent to the cutter unit 60. The second drive unit 90 feeds the laminated sheet S with the welded portion Se of the laminated sheet S sandwiched between the divided feed rollers 92b and 93b. Therefore, even if looseness occurs in the non-welded non-joined area, the second drive unit 90 of this embodiment does not pinch the loosened portion, and wrinkles due to the looseness are generated. Is prevented. The laminated sheet S sent to the cutter unit 60 is cut into a panel P having a predetermined size here. In the present embodiment, a long laminated sheet S having a width of 750 mm was cut every 750 mm to obtain a square panel P. The obtained panel P is sent to the pyring unit 70, stacked there and stocked.
[0060]
Thus, when the panel P was manufactured, the panel P without a wrinkle was manufactured. It was also found that the peel strength can be adjusted by adjusting the input voltage and the load between the horn and the anvil. For example, by adjusting the welding conditions represented by these, it was possible to obtain a welded portion having a peel strength of 8 g (gram) to 13 g. In addition, although the square panel P manufactured with the apparatus of this embodiment is what ultrasonically welded two of the four sides, if the ultrasonic welding apparatus of this embodiment is used, a wrinkle will not arise in a sheet | seat. Since the panel P can be manufactured, it is possible to minimize dust and the like from entering between the sheets from the side end portions of the sides that are not welded. In addition, you may join the side edge part of the edge | side which is not ultrasonically welded, for example using spot welding etc. as needed. In this way, the entry of dust or the like between the sheets can be prevented more reliably.
[0061]
【The invention's effect】
As described above, if the ultrasonic welding apparatus according to the present invention is used, a plurality of metal long sheets containing a foil-like metal such as a copper foil are laminated without causing wrinkles. Easy and reliable joining.
[Brief description of the drawings]
FIG. 1 is a side view showing a schematic overall structure of an ultrasonic welding apparatus of an embodiment.
FIG. 2 is a side view showing a welding unit and a second drive unit.
FIG. 3 is a plan view showing a first ultrasonic welding unit.
FIG. 4 is a plan view showing a welded portion obtained by ultrasonic welding.
5 is a front view showing a welded portion as seen from the direction of arrow B in FIG.
6 is a plan view showing the position of the skew roller as seen from the direction of arrow A in FIG. 2. FIG.
FIG. 7 is a perspective view showing a feed roller of a second drive unit and a cross-sectional view showing the structure of a laminated sheet.
[Explanation of symbols]
1 Ultrasonic welding equipment
10 First roll support unit
20 decurler unit
30 Second roll support unit
40, 50 Welding unit (welding unit)
41, 51 horn
42,52 anvil
44 Slip clutch (means to synchronize feed speed)
47a, 57a Skew roller (tensioning means)
48a, 48b, 58a, 58b Support roller (support means)
60 Cutter unit
70 Piling unit
80 1st drive part (upstream feed means)
90 Second drive section (downstream feed means)
92, 93 Feed roller
92b, 93b Split feed roller (cylindrical part)
94a, 94b Support roller (support means)
T Feed direction
R1, R2, R3 roll (winding roll)
W1 carrier (second long sheet)
W2, W3 copper foil (first long sheet)
S Laminated sheet
Se welded part
P panel

Claims (2)

An ultrasonic welding unit having a horn that is a disk-shaped vibrating body that is rotatably installed and a disk-shaped anvil that is rotatably installed facing the horn is provided in the ultrasonic welding unit. In an ultrasonic welding apparatus that sandwiches a plurality of long metal sheets fed in a state of being stacked on a horn and an anvil and pressurizes them continuously,
Supporting these sheets so that the feeding direction of a plurality of stacked long sheets fed into the ultrasonic welding unit matches the feeding direction of the laminated sheets welded and sent out from the ultrasonic welding unit Support means,
It is possible to sandwich and pressurize at least one first long sheet of two long sheets arranged on both outer layers in a plurality of stacked long sheets with a tension in the width direction applied. At least one set of skew rollers, which are tension applying means
Means for synchronizing the peripheral speed of the outer peripheral surface of the horn in contact with the long sheet with the feed speed of the long sheet;
An ultrasonic welding apparatus for metal foil, characterized by comprising: An upstream feed means for pulling out a long sheet to be joined from the winding roll and feeding it to the ultrasonic welding unit side, and a laminated sheet obtained by welding both end portions of the ultrasonic welding unit from the ultrasonic welding unit. A downstream feed means for drawing out,
The downstream feed means has a pair of feed rollers that sandwich a plurality of stacked long sheets, and feeds the plurality of long sheets by rotating these feed rollers. ,
Of the feed rollers forming a pair, at least one of the feed rollers in contact with the first long sheet includes a plurality of cylindrical portions that are in rolling contact with the first long sheet on the outer peripheral surface,
2. The ultrasonic welding for metal foil according to claim 1, wherein each cylindrical portion is disposed at a position where a welded portion continuously formed on the laminated sheet can be sandwiched by cooperation with the other feed roller. apparatus.

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