Manufacturing method for metal products

Abstract

The present invention provides a method for manufacturing metal products that can produce metal products that can ensure the desired performance. [Solution] A method for manufacturing a metal product includes a groove forming step of forming a plurality of grooves 3 by cutting the electrode material 2 in a metal body 10 having a resistive material 1 and an electrode material 2 laminated on the resistive material 1; a rolling step of rolling the metal body 10 with shape-retaining members 4 provided in each of the plurality of grooves 3; and a shape-retaining member removal step of removing the shape-retaining members 4 after the rolling step.

Description

Technical Field

[0004] , , ,

[0001] The present invention relates to a method for manufacturing metal processed products.

Background Art

[0002] Conventionally, methods for manufacturing metal processed products such as shunt resistors and shaped materials for connectors have been disclosed. Many shunt resistors are configured by forming a recess between one electrode and the other electrode, and the formation accuracy of the recess is important to ensure the accuracy of the resistance value. So far, methods for manufacturing shunt resistors with recesses formed therein are disclosed in, for example, Patent Document 1 and Patent Document 2.

[0003] The method for manufacturing a shunt resistor described in Patent Document 1 includes a bonding step of laminating a metal plate for a first electrode made of a copper alloy on a resistance alloy made of a nickel alloy or the like, and overlapping and laminating a metal plate for a second electrode made of an aluminum alloy or the like on a surface facing the bonding surface of the resistance alloy and bonding them, and a removing step of removing a predetermined range of the metal surface for the first electrode and a predetermined range of the metal surface for the second electrode by cutting. The method for manufacturing a shunt resistor described in Patent Document 2 includes brazing a copper plate to at least one surface of a resistance metal plate, removing an oxide film from the surface, forming a tin plating film over the entire surface of the copper plate to form an assembled multilayer plate body, cutting the assembled multilayer plate body into strips with a desired width, cutting approximately the center in the short side direction in the long side direction with a predetermined width from the surface of the strip-shaped multilayer plate body on which the tin plating film is formed, removing the tin plating film, the copper plate, the brazing material, and at least the diffusion layer between the resistance metal plate and the brazing material by cutting to form a recess, forming a protective film on the bottom surface of the recess, and then cutting the strip-shaped multilayer plate body into chips with a desired width.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

[0005] As described in Patent Documents 1 and 2, when manufacturing metal products having recesses, the recesses are formed by removing a predetermined area by cutting. However, when using cutting methods, it is difficult to adjust the cutting depth, and the cutting process is time-consuming, making it difficult to manufacture metal products such as shunt resistors with the desired performance in a short time. In addition, metal products that do not meet the desired performance are discarded, resulting in additional costs.

[0006] The present invention aims to provide a method for manufacturing metal products that can ensure desired performance. [Means for solving the problem]

[0007] The present invention relates to a method for manufacturing a metal product, comprising a metal body having a first metal body and a second metal body laminated on the first metal body, and comprising a groove forming step of forming a plurality of grooves by cutting the second metal body; a rolling step of rolling the metal body with shape-retaining members provided in each of the plurality of grooves; and a shape-retaining member removal step of removing the shape-retaining members after the rolling step.

[0008] The present invention relates to a method for manufacturing a metal product, characterized in that the shape-retaining member is made of metal, and in the rolling process, the shape-retaining member is inserted into the groove and rolled while the shape-retaining member is in contact with the bottom of the groove and the side surface of the shape-retaining member is in contact with the second metal body. [Effects of the Invention]

[0009] The manufacturing method for metal products according to the present invention involves inserting a shape-retaining member into a groove formed during the cutting process, performing rolling, and then removing the shape-retaining member. As a result, the irregularities at the bottom of the groove formed by cutting become extremely small in the rolled metal body, allowing it to maintain the desired shape. Therefore, the manufacturing method for metal products according to the present invention can be used to manufacture resistors and the like with the desired performance. Furthermore, in the manufacturing method for metal products according to the present invention, a shape-retaining member is inserted into each of the multiple grooves, and these shape-retaining members are removed after rolling. Therefore, a single metal body with multiple grooves can be manufactured. [Brief explanation of the drawing]

[0010] [Figure 1] This diagram illustrates the metal body manufacturing process of a method for manufacturing metal processed products according to an embodiment of the present invention. [Figure 2] This diagram illustrates the cutting process of a method for manufacturing a metal product according to an embodiment of the present invention. [Figure 3] This diagram illustrates the rolling process of a method for manufacturing metal products according to an embodiment of the present invention. [Figure 4] This diagram illustrates the step of removing the shape-retaining member in the manufacturing method of a metal processed product according to an embodiment of the present invention. [Figure 5] This figure shows a metal product manufactured by a metal product manufacturing method according to an embodiment of the present invention. [Modes for carrying out the invention]

[0011] The method for manufacturing metal products according to the present invention is used to manufacture metal products used in resistor chips, connectors, and the like. The method for manufacturing metal products according to this embodiment will be described below with reference to Figures 1 to 5.

[0012] The manufacturing method for a metal product according to this embodiment, as shown in Figures 1 to 3, includes a metal manufacturing step of producing a metal body 10 having a resistive material (first metal body) 1 and an electrode material (second metal body) 2 laminated and arranged on the resistive material 1; a groove forming step of forming a plurality of grooves 3 by cutting the electrode material 2; a rolling step of rolling the metal body 10 with shape-retaining members 4 provided in each of the plurality of grooves 3; a shape-retaining member removal step of removing the shape-retaining members 4 after the rolling step; and a heat treatment step of heat treating the metal body 10 after the rolling step. In the following, the metal body 10 in Figure 1 will be used as the reference point, with the shorter side being the left-right direction X, the longer side being the front-back direction Y, and the height direction being the up-down direction Z.

[0013] The following describes each step of the manufacturing method for metal processed products according to this embodiment.

[0014] [Metal body manufacturing process] In the metal body fabrication process, a metal body 10 is fabricated using a resistive material 1 and an electrode material 2. Specifically, the electrode material 2 is laminated on the upper side of the resistive material 1 in the vertical Z direction, and cladding is performed. In this way, a metal body 10 is fabricated in which dissimilar metal materials are bonded together. Rectangular parallelepiped and elongated metals are used for both the resistive material 1 and the electrode material 2, and the resistive material 1 and the electrode material 2 are metals of the same size. The size of these metal bodies 10 can be appropriately changed depending on the purpose. Furthermore, the method of bonding dissimilar metal materials together is not limited to cladding and may be performed by other methods.

[0015] For the resistive material 1, for example, a copper alloy (copper: 86%, manganese: 12%, nickel: 2%), a nickel alloy (nickel 57% or more, containing chromium, iron, and manganese), or nichrome can be used. For the electrode material 2, for example, pure copper can be used. Note that the resistive material 1 and electrode material 2 are not limited to the above-mentioned metals and can be selected as appropriate.

[0016] [Groove formation process] In the cutting process, a plurality of groove portions 3 are formed in the metal body 10. Specifically, by cutting the electrode material 2 with a cutting device, a plurality of groove portions 3 are formed along the front-rear direction Y (FIG. 2). At this time, cutting is performed until the bottom of the groove portion 3 becomes the resistance material 1. Therefore, irregularities are formed on the bottom of the groove portion 3. After cutting, the side portions of the groove portion 3 are composed of the electrode material 2, and the bottom of the groove portion 3 is composed of the resistance material 1. The width of the groove portion 3 in the left-right direction X is, for example, from 0.5 mm to 50 mm.

[0017] [Rolling process] After manufacturing the metal body 10 in which the groove portion 3 is formed, as shown in FIG. 3, a metal shape-retaining member 4 is provided in the groove portion 3, the lower surface of the shape-retaining member 4 abuts on the bottom of the groove portion 3, and the side surface of the shape-retaining member 4 abuts on the electrode material 2, respectively. This shape-retaining member 4 functions as a dummy material for retaining the desired shape of the groove portion 3 after the rolling process. The shape-retaining member 4 has substantially the same size as the groove portion 3, and in a state where the shape-retaining member 4 is inserted into the groove portion 3, the upper surface of the metal body 10 becomes substantially flat.

[0018] For the shape-retaining member 4, a material having work hardening similar to that of the resistance material 1, such as stainless steel, ferroalloy, copper alloy, etc., can be used, and it is appropriately selected according to the metals of the resistance material 1 and the electrode material 2. In this embodiment, a stainless steel shape-retaining member 4 is used. Since the resistance material 1 becomes hard by rolling, the above-mentioned work hardening similar to that of the resistance material 1 means the property of becoming hard by rolling in the same manner as the resistance material 1.

[0019] The rolling process is performed by a rolling device provided with rollers above and below, and while inserting the shape-retaining member 4 into the groove portion 3, the metal body 10 is pressed from the up-down direction Z at room temperature. At this time, the upper roller presses the electrode material 2 and the shape-retaining member 4 simultaneously. After the rolling process, as shown in FIG. 4(a), a rolled metal body 10 is manufactured.

[0020] [Shape-retaining member removal process] After the rolling process, a shape-retaining member removal process is performed. In this shape-retaining member removal process, as shown in Figure 4(b), the shape-retaining members 4 are removed from the multiple grooves 3 of the rolled metal body 10. These shape-retaining members 4 are removed along the front-to-back direction Y of the metal body 10 using the manufacturer's hands or machinery. With the shape-retaining members 4 removed, a metal body 10 with grooves 3 of the desired shape is produced, as shown in Figure 5.

[0021] [Heat treatment process] After the shape-retaining member removal process, a heat treatment process is performed. In this heat treatment process, the metal body 10 is heat-treated to adjust the material to the desired strength and other properties. By performing the heat treatment, the metal structure constituting the resistive material 1 and electrode material 2 can be made uniform.

[0022] Next, the effects and advantages of the method for manufacturing metal processed products according to this embodiment will be explained.

[0023] In the manufacturing method of metal products according to this embodiment, rolling is performed with the shape-retaining member 4 inserted into the groove 3, and then the shape-retaining member 4 is removed. By doing so, the irregularities at the bottom of the groove 3 formed by cutting are made extremely small in the metal body 10 after rolling, and the desired shape is maintained. Therefore, the manufacturing method of metal products can produce resistors and the like with the desired performance.

[0024] In the manufacturing method of metal products according to this embodiment, a shape-retaining member 4 is inserted into each of the multiple grooves 3, and after rolling, these shape-retaining members 4 are removed. Therefore, a single metal body 10 with multiple grooves 3 can be manufactured. Furthermore, since the width and size of the grooves 3 can be determined by the cutting conditions, multiple grooves 3 can be formed in the metal body 10 with desired widths and sizes.

[0025] Although this embodiment has been described above, it is possible to select or replace the configurations listed in the above embodiment, or to change them to other configurations as appropriate, as long as they do not deviate from the spirit of the present invention.

[0026] In this embodiment, a case in which two types of metal bodies are stacked has been described, but it is also possible to stack three or more types of metal bodies and apply the method to a metal body with three or more layers. Furthermore, in the method for manufacturing metal processed products according to the present invention, the heat treatment step is not essential, and the heat treatment step may not be performed after the shape-retaining member removal step. In addition, the metal body 10 in which multiple grooves 3 are formed may be cut to a desired size. The cross-sectional shape of the grooves 3 to be formed is not limited to a rectangular shape; for example, triangular grooves can also be formed.

[0027] The method for manufacturing metal processed products according to the present invention has been described above. This manufacturing method can be used for small-batch, high-mix production and can produce desired metal processed products at low cost. [Explanation of symbols]

[0028] 1 Resistance material (first metal body) 2 Electrode material (second metal body) 3 grooves 4 Shape-retaining member 10 Metal body X Left / right direction Y (forward / backward direction) Z vertical direction

Claims

1. A method for manufacturing metal products used in resistor chips and connectors, A metal body manufacturing process in which a second metal body is laminated onto a first metal body, and the first metal body and the second metal body are bonded together by cladding to produce a metal body, The process includes, after the metal body manufacturing process, a groove forming step in which the second metal body is cut to form a plurality of grooves in which the bottom portion is the first metal body and the sides portion is the second metal body, A method for manufacturing metal products, characterized by the following:

2. The width of the groove is 0.5 mm to 50 mm, and the groove is formed for the insertion of a removable metal member. The method for manufacturing a metal product according to feature 1.

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