Surface treatment method of conductive steel roller for copper foil

Abstract

The invention relates to the technical field of steel roller surface treatment, and discloses a surface treatment method of a conductive steel roller for copper foil, which comprises the following steps: S1, pretreating the surface of the conductive steel roller, including ultrasonic cleaning and absolute ethyl alcohol wiping; s2, setting laser average power, pulse frequency, pulse width, light spot diameter, axial feeding speed, radial feeding step pitch and scanning overlapping rate based on the preprocessed conductive steel roller according to initial roughness and target roughness of the conductive steel roller; and S3, based on the set online laser grinding, when the steel roller rotates, a laser machining head spirally scans the surface of the steel roller at the set feeding speed and step pitch in the axial direction and the radial direction, and surface convex peaks are removed through laser. By means of the laser grinding and real-time feedback control technology, accurate adjustment of the surface roughness and shape of the steel roller is achieved, the machining efficiency and the consistency of the surface quality are improved, and high precision and uniformity are ensured.

Description

Technical Field

[0001] The invention relates to the technical field of steel roller surface treatment, in particular to a surface treatment method of a conductive steel roller for copper foil. Background Art

[0002] In modern manufacturing, steel rollers are essential components in numerous precision machining and surface treatment processes, and are widely used in industries such as copper foil, batteries, and coatings. In these applications, the surface quality of the steel rollers directly impacts the performance and stability of subsequent products. Therefore, improving the precision, smoothness, and uniformity of the steel roller surface has become a key technical requirement.

[0003] Prior art methods for treating steel roller surfaces primarily rely on traditional processes such as mechanical grinding and chemical polishing. The advantages of these technologies are that mechanical grinding can effectively remove larger bumps and defects on the steel roller surface, while chemical polishing can improve surface smoothness and reduce friction. However, these methods often rely on manual operation and cannot guarantee consistent treatment results for every workpiece. While mechanical grinding has certain advantages in removing surface defects, it often lacks uniform surface smoothness. While chemical polishing can achieve a good smoothing effect, it struggles to meet the higher requirements for controlling the steel roller's surface precision.

[0004] However, there are still some shortcomings in the existing technology; first, mechanical grinding is inefficient and unstable, and relies on manual operation, which often cannot guarantee the precise control of roughness and shape during the processing, resulting in large differences between workpieces. Secondly, traditional processing methods often use linear scanning paths, which makes the surface treatment effect less than uniform, and easily leaves obvious processing marks or stripes on the surface of the steel roller, affecting the quality of subsequent processes. During the cleaning and post-processing process, the existing technology is also difficult to completely remove impurities on the surface, which easily causes residual water droplets or oil stains to interfere with subsequent detection, reducing the accuracy and stability of the surface treatment. These problems will affect the quality of the steel roller in production, resulting in instability and inconsistency in subsequent use. Summary of the Invention

[0005] In view of the shortcomings of the existing technology, the present invention provides a surface treatment method for a conductive steel roller for copper foil, which solves the problems of low surface treatment precision of steel rollers, uneven processing effects and frequent manual intervention in the existing technology.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions: A surface treatment method for a conductive steel roller for copper foil, comprising the following steps:

[0007] S1. Pre-treating the surface of the conductive steel roller, wherein the pre-treatment includes ultrasonic cleaning and wiping with anhydrous ethanol;

[0008] S2. Based on the pretreated conductive steel roller and according to the initial roughness and target roughness of the conductive steel roller, setting the laser average power, pulse frequency, pulse width, spot diameter, axial feed speed, radial feed step and scanning overlap rate;

[0009] S3, performing online laser grinding based on the settings, causing the steel roller to rotate while the laser processing head spirally scans the surface of the steel roller in the axial and radial directions at a set feed speed and step distance, removing surface peaks with the laser and gradually reducing the surface roughness to the target value;

[0010] S4, real-time monitoring and feedback, measuring the surface roughness of the steel roller during the laser grinding process, calculating the error based on the result of the measured surface roughness of the steel roller and adjusting the laser processing parameters;

[0011] S5, post-processing, after the steel roller grinding is completed, the surface of the conductive steel roller is sprayed with pure water to be cleaned and blown dry, and the surface roughness, cylindricity and copper foil thickness deviation of the conductive steel roller are tested.

[0012] Preferably, in step S1, the pre-treating of the surface of the conductive steel roller includes:

[0013] The conductive steel roller was placed in an ultrasonic cleaning tank and cleaned at room temperature for 5 minutes using ultrasonic waves at a frequency of 40 kHz and a power of 200 W.

[0014] After cleaning, use anhydrous ethanol with a water content of ≤0.1wt% to wipe the entire roller from the roller end to the roller body in a spiral direction;

[0015] After wiping with ethanol, use 0.6MPa dry compressed air to blow evenly from the inside to the outside until there is no visible liquid film on the surface.

[0016] Preferably, in step S2, the setting of the laser average power, pulse frequency, pulse width, spot diameter, axial feed speed, radial feed step and scanning overlap ratio includes:

[0017] Use a contact roughness meter to measure the initial roughness of the roller surface, and determine the machining allowance based on the target roughness given in the process specification;

[0018] Based on the machining allowance and material thermophysical properties, the average laser power is selected as 100W-500W by looking up the table;

[0019] Refer to the processing depth requirements, set the pulse frequency to 20Hz-100Hz, and the pulse width to 50ns-200ns;

[0020] According to the required removal volume and spot overlap rate, the spot diameter is determined to be 0.1mm-5mm, the radial feed step, and the scanning overlap rate is 50%-90%;

[0021] Considering the roller length and mechanical stiffness, the axial feed speed is set to 0.5mm / s-5mm / s.

[0022] Preferably, determining the machining allowance in combination with the target roughness given in the process specification includes:

[0023] According to the quality requirements of the copper foil production process, the required surface roughness range of the steel roller is obtained from the process specifications. This range corresponds to the adhesion and release performance requirements of the copper foil.

[0024] The target roughness is subtracted from the measured initial roughness of the roller surface, and the difference obtained is the actual processing allowance that needs to be removed. The processing allowance is used for the initial setting of subsequent laser processing parameters.

[0025] Preferably, in step S3, the laser processing head spirally scans the surface of the steel roller in the axial and radial directions at a set feed speed and pitch, including:

[0026] Under the coordination of the CNC system, the conductive steel roller rotates at a constant speed within a range determined by the selected processing parameters, and the laser processing head moves uniformly along the length of the roller at a preset axial feed speed.

[0027] After completing one circle, the circumferential offset of the laser beam is controlled by the radial feed step so that it covers the entire roller surface in a spiral manner; the scanning mode can be progressively layer by layer according to the change in surface roughness.

[0028] Preferably, controlling the circumferential offset of the laser beam by radial feed step comprises:

[0029] According to the relationship between the spot diameter and the required overlap rate, the radial feed step is selected to ensure that the energy overlap between adjacent scanning tracks meets the design requirements;

[0030] After completing each circle of axial movement, the numerical control system drives the laser processing head to move in the radial direction according to the radial feed step, so as to achieve calibration of the starting position of the next circle of scanning.

[0031] Preferably, in step S4, calculating the error based on the result of measuring the surface roughness of the steel roller and adjusting the laser processing parameters includes:

[0032] After the laser processing head completes a section of axial scanning, the roller surface is measured at multiple points using an online contact roughness measuring instrument. The measurement points are evenly distributed along the axial and circumferential directions of the roller body to obtain the spatial distribution data of the current surface roughness.

[0033] The spatial distribution data of the roughness is transmitted to a control system, and the deviation between the current roughness and the target roughness is calculated in each measurement cycle according to a proportional-integral control algorithm;

[0034] According to the deviation value, the average power of the laser is dynamically adjusted according to a preset adjustment strategy so that the energy input of the subsequent spiral scan matches the processing requirements.

[0035] Preferably, the dynamic adjustment of the average laser power includes:

[0036] Based on the calculated roughness deviation value, the average laser power is adjusted according to the predetermined increment and decrement steps to match the energy input with the processing requirements;

[0037] Dynamic adjustment is performed after each measurement cycle, which can be preset by the PLC to ensure that power adjustment and monitoring frequency remain synchronized during continuous spiral scanning.

[0038] Preferably, in step S5, detecting the surface roughness, cylindricity and copper foil thickness deviation of the conductive steel roller includes:

[0039] Use a laser scanning confocal profilometer to scan the profile of the roller surface that has been spray-cleaned and blow-dried in at least three sections parallel to the axial direction to obtain roughness parameters;

[0040] The conductive steel roller is mounted on a three-dimensional coordinate measuring machine fixture, and the cylindricity is measured at four equally divided angle positions at the end, middle, and tail sections of the roller body, and the cylindricity error of the entire section is calculated based on the measurement results;

[0041] Under the same unit environment, an actuated online thickness gauge is used to perform multi-point measurements on the rolled copper foil samples. The measurement area covers different positions along the width of the copper foil. The measured thickness data is compared with the process standard to determine the thickness deviation range.

[0042] The present invention also provides a surface treatment system for a conductive steel roller for copper foil, comprising:

[0043] A pretreatment module, used for placing the conductive steel roller to be processed in an ultrasonic cleaning tank and performing pretreatment, wherein the pretreatment includes ultrasonic cleaning, wiping with anhydrous ethanol and drying with compressed air;

[0044] a parameter setting module, which calculates and sets the laser average power, pulse frequency, pulse width, spot diameter, axial feed speed, radial feed step and scanning overlap rate based on the initial roughness of the pretreated conductive steel roller and the target roughness given in the process specification;

[0045] a laser grinding module, which performs online laser grinding based on the settings, rotates the conductive steel roller at a set speed, and drives the laser processing head to perform axial and radial spiral scanning according to the parameters;

[0046] An online monitoring module collects surface roughness data of the conductive steel roller in real time during the laser grinding process based on the set online laser grinding, and transmits the data to a control system to calculate deviations and issue parameter adjustment instructions;

[0047] The post-processing module is used to finally clean the ground conductive steel roller with pure water spray and dry it with compressed air, and to control the three-coordinate measuring machine and online thickness measuring instrument to complete the cylindricity and copper foil thickness deviation detection respectively.

[0048] The present invention provides a surface treatment method for a conductive steel roller for copper foil. It has the following beneficial effects:

[0049] 1. This invention utilizes a technical solution combining laser grinding with real-time monitoring and feedback to achieve precise control and automated adjustment of the steel roll surface roughness. Compared to conventional mechanical grinding methods, this invention enables real-time adjustment of laser parameters, effectively reducing manual intervention and ensuring efficiency and consistency in every production step, thereby improving product surface quality.

[0050] 2. This invention introduces a spiral scanning path design during the online laser polishing process, successfully resolving the surface unevenness issue encountered by traditional scanning methods. Compared to the linear or segmented scanning methods commonly used in existing technologies, this spiral scanning path not only improves the roller surface treatment coverage but also effectively avoids machining marks, resulting in a smoother steel roller surface and meeting higher precision requirements.

[0051] 3. This invention utilizes a pure water spray cleaning and drying system for post-treatment, improving the cleanliness and stability of the steel roller surface treatment. Compared to existing methods that rely solely on manual cleaning, this automated cleaning and drying process not only improves efficiency but also avoids surface residues caused by incomplete cleaning, effectively ensuring the accuracy of subsequent testing.

[0052] 4. This invention combines laser grinding with precision testing technology to comprehensively enhance the controllability and consistency of steel roll surface quality. Unlike traditional techniques that solely test surface roughness and cylindricity, this invention ensures precise adjustment of each step through multi-dimensional real-time data feedback. This overcomes the limitation of traditional methods that cannot simultaneously address multiple quality indicators, effectively improving the uniformity and stability of copper foil adhesion. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] Figure 1 Schematic diagram of the method flow of the present invention;

[0054] Figure 2 A schematic diagram of the rotation direction of the conductive steel roller of the present invention;

[0055] Figure 3A schematic diagram of the movement of the laser device of the present invention;

[0056] Figure 4 This is a system architecture diagram of the present invention. DETAILED DESCRIPTION

[0057] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the present specification. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0058] Please see the attached Figure 1 -Attached Figure 3 The embodiment of the present invention provides a surface treatment method for a conductive steel roller for copper foil, comprising the following steps:

[0059] S1. Pre-treating the surface of the conductive steel roller, wherein the pre-treatment includes ultrasonic cleaning and wiping with anhydrous ethanol;

[0060] In the aforementioned surface treatment method for the conductive steel roller used for copper foil, thorough and standardized pretreatment of the roller surface is typically required before the laser polishing step to remove impurities such as oil, particles, and liquid film, ensuring uniform laser energy transfer and stable processing results. This pretreatment process typically follows the confirmation of process parameters and initial equipment preparation, and is performed throughout the initial stages of the processing. This step not only ensures the cleanliness of the roller surface but also lays a solid foundation for subsequent laser spiral scanning, energy stacking, and roughness reduction.

[0061] Alternatively, pretreatment can be performed in conjunction with ultrasonic cleaning, wiping with anhydrous ethanol, and purging with compressed air. In one possible implementation, the efficiency and uniformity of the pretreatment phase can be further improved by appropriately setting the ultrasonic frequency, power, and duration parameters. Specifically, this step is described in detail below, combining the technical solutions of the present invention with existing experimental data.

[0062] Remove the conductive steel roller from the production unit and place it in a pre-prepared ultrasonic cleaning tank. The cleaning liquid is deionized water or high-purity water. The frequency of the ultrasonic cleaning tank is set to:

[0063] f us =40kHz;

[0064] Where, f us Indicates the ultrasonic frequency in kilohertz. The ultrasonic power is set to:

[0065] P us =200W;

[0066] Where, P us Indicates ultrasonic power in watts. Cleaning time is set to:

[0067] t us =5min;

[0068] Where, t us Indicates the duration of the cleaning process in minutes. During the cleaning process, the water temperature should be maintained at room temperature to avoid elevated temperatures that could cause dry spots on the liquid film. After the ultrasonic cleaning described above, the roller surface should be virtually free of visible oil stains and attached particles, and appear uniformly moist.

[0069] Generally, after ultrasonic cleaning, wipe with anhydrous ethanol immediately to prevent uneven spots from forming after residual water film dries. Use anhydrous ethanol with a purity of at least 99.9% and a water content of less than or equal to 0.1wt%. Wipe in a spiral motion, starting from the roller end and covering the surface evenly. Use a fiber-free, linting-free wiper, and the single wipe width should be at least twice the spot diameter to ensure that the subsequent laser path is not contaminated.

[0070] In some embodiments, in order to facilitate the subsequent process parameter setting and machining allowance calculation, the initial roughness Ra0 can be measured at three evenly distributed positions on the roller surface using a contact roughness meter immediately after the pretreatment is completed and recorded. The roughness measurement value can be used as the subsequent target roughness Ra t And the calculation basis of machining allowance ΔRa, the calculation formula is:

[0071] ΔRa=Ra0-Ra t ;

[0072] Where ΔRa represents the roughness difference; Ra0 represents the initial roughness; Ra t Indicates the target roughness.

[0073] In one possible implementation, the recording and detection of the pre-processing stage can be combined with barcode scanning and electronic recording systems to establish a roller surface status archive so as to track the processing history of each roller over a long period of time.

[0074] Specifically, after pretreatment, the steel roll should be immediately placed on a dust-free storage rack and, after subsequent process parameter input and equipment inspection, proceed to the next laser grinding process. At this point, the surface condition should meet the following requirements: no oil stains, liquid film, or particles when visually observed; the roughness measurement data should be stable and uniform; and the air humidity should be below the specified value.

[0075] S2, setting laser average power, pulse frequency, pulse width, spot diameter, axial feeding speed, radial feeding step and scanning overlap ratio based on the pre-processed conductive steel roller and according to conductive steel roller initial roughness and target roughness;

[0076] After the pre-treatment of the surface of the conductive steel roller is completed, in order to achieve stable and controllable processing effect in the subsequent laser polishing process, the parameters of the laser system need to be reasonably set in combination with the real state of the roller surface after the pre-treatment. Generally, this stage is carried out immediately after the pre-treatment is completed, and the parameter input and verification need to be completed before the laser processing equipment is put into operation. As an option, the initial roughness value of the conductive steel roller measured after the pre-treatment and the target roughness specified in the process specification are used to determine the laser average power, pulse frequency, pulse width, spot diameter, axial feeding speed, radial feeding step and scanning overlap ratio one by one through calculating the processing allowance and consulting the experience parameter table. In a possible implementation manner, the spot parameters and feeding speed can also be locally corrected in combination with the roller length and curvature radius, so as to ensure the uniformity of processing in different regions.

[0077] In this embodiment, first, the initial roughness value is measured at three uniform positions in the length direction of the conductive steel roller by using a contact type roughness meter, and the average value is taken as the initial roughness Ra0. According to the target roughness Ra t required in the copper foil production process specification, the actual processing allowance ΔRa is calculated as follows:

[0078] Generally, when ΔRa is less than 0.5 μm, a smaller laser power and a higher scanning overlap ratio are selected to avoid deep ablation of the surface; when ΔRa is greater than 0.5 μm, the power is appropriately increased, and the overlap ratio is reduced to ensure the processing efficiency. Specifically, the laser average power P L is usually selected to be between 100 W and 500 W according to the experience parameter table. As an option, if the roller material is stainless steel and ΔRa ≈ 0.4 μm, P L is selected to be 300 W.

[0079] In this embodiment, the pulse frequency f p is selected to be between 20 Hz and 100 Hz according to the required processing depth range, wherein f p represents the repetition frequency of laser pulses per unit time, and the unit is hertz (Hz). The pulse width τ p is set to be 50 ns-200 ns according to the thermal diffusion characteristics of the material, and the unit is nanosecond (ns).

[0080] Specifically, the spot diameter d f is selected to be between 0.1 mm and 5 mm according to the processing area and the curvature radius, and the unit is millimeter.

[0081] In a possible implementation, the spot diameter can also be slightly dynamically adjusted during the scanning process to adapt to the local morphology differences between the two ends and the middle of the conductive steel roller.

[0082] Axial feed speed v z Combined with the roller length, rigidity and equipment load capacity, the speed should be between 0.5mm / s and 5mm / s, in millimeters per second. r Matches the spot diameter and heavy snow rate, usually set between 0.01mm-0.05mm, in millimeters. Scan overlap rate η o Defined as the ratio of the energy coverage area between adjacent nanopaths, usually selected between 50% and 90%, expressed as a percentage. o The approximate calculation is done by the following formula:

[0083]

[0084] Where η o is the scanning overlap ratio; Δ r is the radial feed step; d f is the focused spot diameter.

[0085] In some embodiments, to ensure the rationality of the set parameters, the power and frequency ratio can be adjusted through preliminary research and testing, taking into account the thermophysical properties of the roller material (such as thermal diffusivity, melting point, and specific heat capacity). Alternatively, various parameters can be fine-tuned based on real-time roller surface monitoring data to optimize subsequent processing results, but the overall setting range should not deviate from the above range.

[0086] In one possible implementation, the parameter setting process can automatically record and archive each set value, creating a process parameter database that provides a reference for subsequent processing of rollers of the same specifications. Typically, after completing the settings, the operator will need to check each value against the control panel display to ensure that the input is correct before proceeding to the subsequent laser processing steps.

[0087] S3, performing online laser grinding based on the settings, causing the steel roller to rotate while the laser processing head spirally scans the surface of the steel roller in the axial and radial directions at a set feed speed and step distance, removing surface peaks with the laser and gradually reducing the surface roughness to the target value;

[0088] After completing the pretreatment of the conductive steel roller surface and reasonably setting the various process parameters for laser processing, the online laser grinding step can be started. Generally speaking, this step is implemented immediately after the parameter setting link. As the main process of the processing, it is responsible for removing surface peaks layer by layer according to the predetermined processing allowance and uniformly reducing the roughness. Specifically, under the action of the set parameters, by rotating the conductive steel roller at a constant speed, the laser processing head moves synchronously along the axial and radial segments at the set feed speed and step distance, thereby forming a spiral scanning track on the roller surface and completing the covering processing of the entire roller surface. As an option, this step uses a spiral trajectory instead of parallel or segmented scanning to ensure the continuity of the trajectory and the uniformity of coverage, and to reduce the phenomenon of residual stripes on the surface. In one possible implementation method, the spiral trajectory can also be locally adjusted in combination with real-time feedback data to further improve processing consistency.

[0089] In this embodiment, after confirming that the roller is stably installed and all parameters are set correctly, the servo motion control system is started to drive the conductive steel roller to rotate. r Adjust according to the preset value, the unit is revolutions per minute. At the same time, the laser processing head starts to feed along the axial direction of the roller at a predetermined feed speed v z Move at a constant speed. In the radial direction, the machining head moves according to the preset radial feed step Δ r After completing each scan, it moves one step toward the inner diameter to achieve layer-by-layer progress.

[0090] In general, a constant processing distance is maintained between the laser processing head and the steel roller, and the light spot is accurately focused on the roller surface. Under the coordination of the CNC system, the axial position z(t) and radial position r(t) of the laser processing head can be described by the following relationship:

[0091] z(t)=v z t;

[0092] r(t)=r0-i·Δ r ;

[0093] Where, t is the processing time; r0 is the initial radius of the roller; i is the current radial layer number; Δ r is the radial feed step; z(t) is the change in the axial position of the laser processing head; r(t) is the change in the position of the laser processing head in the radial direction.

[0094] Specifically, the rotation of the steel roller and the axial feed of the laser processing head jointly determine the pitch and overlap rate of the spiral trajectory. oThe overlap ratio is determined by a pre-set value to ensure sufficient energy overlap between adjacent revolutions without leaving unprocessed areas. In some embodiments, the overlap ratio can be set between 50% and 90%. The motion control of the laser processing head is displayed in real time on the control interface for easy operator monitoring.

[0095] Alternatively, to reduce localized deformation caused by heat buildup during processing, segmented scanning or short pauses between radial layers can be used during the scanning process. This helps evenly distribute the heat. In one possible implementation, by changing the processing sequence or adjusting the angle of the scanning start position, the circumferential texture can be prevented from aligning with the direction of subsequent copper foil deposition, thereby improving copper foil adhesion uniformity.

[0096] In this embodiment, as the spiral scan progresses, the surface microscopic peaks are gradually melted, vaporized and remelted by the laser. The roughness decreases approximately linearly according to the number of processing layers until it approaches or reaches the target roughness Ra t Normally, after completing each radial scan, the system will record the current processing layer number and the corresponding radius value r. i , for subsequent testing and verification.

[0097] The aforementioned spiral laser scanning process is closely aligned with the subsequent real-time detection and feedback process. The control system simultaneously receives roughness measurement data during the spiral scan, which it uses to determine whether parameters such as power or frequency need to be adjusted during the current machining process. This integration ensures that roughness uniformity, both axially and circumferentially, meets design requirements during machining.

[0098] S4, real-time monitoring and feedback, measuring the surface roughness of the steel roller during the laser grinding process, calculating the error based on the result of the measured surface roughness of the steel roller and adjusting the laser processing parameters;

[0099] During the laser grinding process, real-time monitoring and feedback technology is used to continuously track changes in the roughness of the steel roll surface and adjust laser processing parameters based on these real-time measurements. This step is crucial to the entire laser grinding process, ensuring that each layer accurately achieves the predetermined target roughness, thereby improving processing accuracy and efficiency. Typically, this monitoring process is synchronized with the real-time laser scanning process and integrated with the laser processing system's control system to form a closed-loop feedback mechanism.

[0100] In this embodiment, during the laser grinding process, a high-precision contact or non-contact roughness measuring instrument is used to measure the roughness value of the steel roller surface in real time. The measurement results are input into the system as feedback signals. In order to accurately reflect the quality of the steel roller surface processing, the roughness measurement is usually performed once after each completed number of revolutions or each radial feed step, and the current roughness value Ra is recorded. measured .

[0101] In this real-time monitoring process, error calculation is essential. According to the pre-set target roughness Ra t , calculate the error ΔRa between the actual roughness and the target roughness:

[0102] ΔRa=Ra measured -Ra t ;

[0103] Where ΔRa is the roughness error; Ra measured is the currently measured surface roughness value of the steel roller; Ra t is the target roughness.

[0104] Specifically, when the measurement error ΔRa is greater than the set allowable range, the control system will adjust the laser processing parameters according to this error. The adjustment method can be achieved by increasing or decreasing the average laser power P L , pulse frequency f p , pulse width τ p For example, if the measured roughness is too high, the system can automatically increase the laser power P L′ , thereby increasing the surface removal rate and accelerating the reduction of roughness; on the contrary, if the roughness is too low, over-processing may be avoided by reducing the laser power or adjusting the scanning speed.

[0105] During the implementation process, the real-time feedback system also monitors the feed speed v of the laser processing head. z and radial feed step Δ r , to ensure the uniformity of surface quality during the processing. Generally, the feed speed v z Depending on the width of the processing area, the rotation speed n of the steel roller r For example, when the error value ΔRa is large, the system may automatically slow down the feed speed to increase the laser's residence time on the roller surface, thereby improving the roughness removal effect.

[0106] As an option, if the system detects that there is a region with large fluctuations in local roughness on the surface, it can also choose to perform local processing on that region, that is, adjust the scanning trajectory or reset the spot diameter d f , in order to optimize the processing effect. Specifically, the roughness error ΔRa of the local area local It will be calculated according to the following formula:

[0107] ΔRa local =Ra measured,local -Ra t ;

[0108] Where Ra t is the target roughness; ΔRalocal is the roughness error of the local area; Ra measured,local Roughness value measured for a local area.

[0109] In one possible implementation, real-time data from the entire process is fed back to the operator via an industrial control system. The operator can use this feedback to determine whether further adjustments to the laser processing parameters are necessary. In some embodiments, the system can also provide a pre-set automatic adjustment mode. When the error exceeds a predetermined range, the system automatically adjusts the parameters and displays the adjusted results in real time.

[0110] This technical solution ensures that the surface roughness of the steel roll remains within the target range during machining, avoiding uneven surface quality or over-machining due to accumulated errors. Furthermore, the real-time monitoring and feedback mechanism is tightly integrated with the laser scanning control system, forming a complete closed-loop control process that not only improves machining accuracy but also optimizes production efficiency.

[0111] S5, post-processing, after the steel roller is polished, the surface of the conductive steel roller is sprayed with pure water and dried, and the surface roughness, cylindricity and copper foil thickness deviation of the conductive steel roller are tested;

[0112] Generally, after laser grinding is completed and real-time monitoring and feedback adjustments are performed, trace amounts of machining fluid or other impurities may remain on the surface of the steel roller. Thermal stress may also be generated during the machining process, requiring further optimization of the surface quality through post-processing. As an option, post-processing includes pure water spray cleaning and blow-drying operations, which not only removes residual impurities on the steel roller surface but also provides a clean surface for subsequent quality inspections. Specifically, this post-processing process can effectively remove dust, oil, and impurities remaining on the steel roller surface, ensuring that they do not affect subsequent surface quality inspections.

[0113] In this embodiment, the post-processing step begins by cleaning the surface of the conductive steel roller using a pure water spray system. The system's nozzles evenly cover the roller's surface, effectively removing any remaining particles and impurities with high-pressure water. During the cleaning process, the pure water flow rate and pressure are adjusted appropriately based on the roller's surface condition, typically within a pressure range of 2-5 bar. Adjusting the nozzle's spray angle and water flow rate ensures thorough cleaning of the roller's surface. After cleaning, any residual moisture on the roller's surface is completely removed using a drying system to ensure accurate subsequent measurements.

[0114] Specifically, the blow-drying process uses a high-temperature dry air flow, typically between 50°C and 100°C, combined with an appropriate wind speed to rapidly evaporate moisture from the steel roller surface. Optionally, the dry air is heated by an internal heating element and passed through a multi-filtration system to remove impurities, preventing any particles or water droplets from remaining on the roller surface. The drying process time and temperature settings are fine-tuned based on the roller material and surface roughness requirements to ensure no negative impact on surface quality.

[0115] After cleaning and drying, surface quality inspection is performed. This step not only measures the surface roughness of the steel roller, but also checks for cylindricity and copper foil thickness deviation. Specifically, the surface roughness of the steel roller is measured using a high-precision roughness meter to ensure compliance with pre-determined technical standards. The roughness measurement result must match the target roughness value. If it exceeds the allowable error range, the system triggers feedback to adjust the preceding processing steps.

[0116] The cylindricity of the steel roll is also a key indicator during post-processing. In some embodiments, this is typically measured using a laser scanner or coordinate measuring machine (CMM). These instruments can accurately measure the axial and radial shape of the roll to ensure it conforms to design requirements. Cylindricity deviations outside the specified range can affect the subsequent copper foil adhesion, so they must be strictly monitored to ensure they remain within the allowable tolerances.

[0117] As a supplement, copper foil thickness deviation detection is also an essential step in post-processing. Foil thickness measurement is typically performed using ultrasonic measurement or a coating thickness gauge to ensure that the foil is uniform across the entire surface and meets specified thickness requirements. If the test results indicate thickness deviations exceeding the allowable value, the steel roller in that area must be reprocessed to ensure foil uniformity and quality.

[0118] In one possible implementation, the cleaning, drying, and subsequent inspection processes can be automated. An integrated control system automatically records the quality inspection data for each workpiece and feeds the results back to the production line for adjustment and optimization. This integrated approach not only improves inspection efficiency but also ensures that every step of the post-processing process is executed accurately, allowing problems to be discovered and corrected promptly.

[0119] The surface treatment system for a conductive steel roll for copper foil described below and the surface treatment method for a conductive steel roll for copper foil described above can be referred to each other.

[0120] Please see the attached Figure 4 The present invention also provides a surface treatment system for a conductive steel roller for copper foil, comprising:

[0121] A pretreatment module, used for placing the conductive steel roller to be processed in an ultrasonic cleaning tank and performing pretreatment, wherein the pretreatment includes ultrasonic cleaning, wiping with anhydrous ethanol and drying with compressed air;

[0122] a parameter setting module, which calculates and sets the laser average power, pulse frequency, pulse width, spot diameter, axial feed speed, radial feed step and scanning overlap rate based on the initial roughness of the pretreated conductive steel roller and the target roughness given in the process specification;

[0123] a laser grinding module, which performs online laser grinding based on the settings, rotates the conductive steel roller at a set speed, and drives the laser processing head to perform axial and radial spiral scanning according to the parameters;

[0124] An online monitoring module collects surface roughness data of the conductive steel roller in real time during the laser grinding process based on the set online laser grinding, and transmits the data to a control system to calculate deviations and issue parameter adjustment instructions;

[0125] The post-processing module is used to finally clean the ground conductive steel roller with pure water spray and dry it with compressed air, and to control the three-coordinate measuring machine and online thickness measuring instrument to complete the cylindricity and copper foil thickness deviation detection respectively.

[0126] The system of this embodiment can be used to execute the above method embodiments, and its principles and technical effects are similar, so they will not be repeated here.

[0127] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A surface treatment method for a conductive steel roller for copper foil, characterized in that: The following steps are involved: S1. Pre-treating the surface of the conductive steel roller, wherein the pre-treatment includes ultrasonic cleaning and wiping with anhydrous ethanol; S2. Based on the pretreated conductive steel roller and according to the initial roughness and target roughness of the conductive steel roller, setting the laser average power, pulse frequency, pulse width, spot diameter, axial feed speed, radial feed step and scanning overlap rate; S3, performing online laser grinding based on the settings, causing the steel roller to rotate while the laser processing head spirally scans the surface of the steel roller in the axial and radial directions at a set feed speed and step distance, removing surface peaks with the laser and gradually reducing the surface roughness to the target value; S4, real-time monitoring and feedback, measuring the surface roughness of the steel roller during the laser grinding process, calculating the error based on the result of the measured surface roughness of the steel roller and adjusting the laser processing parameters; S5, post-processing, after the steel roller grinding is completed, the surface of the conductive steel roller is sprayed with pure water to be cleaned and blown dry, and the surface roughness, cylindricity and copper foil thickness deviation of the conductive steel roller are tested.

2. The surface treatment method of a conductive steel roller for copper foil according to claim 1, characterized in that: In step S1, the pretreatment of the surface of the conductive steel roller includes: The conductive steel roller was placed in an ultrasonic cleaning tank and cleaned at room temperature for 5 minutes using ultrasonic waves at a frequency of 40 kHz and a power of 200 W. After cleaning, use anhydrous ethanol with a water content of ≤0.1wt% to wipe the entire roller from the roller end to the roller body in a spiral direction; After wiping with ethanol, use 0.6MPa dry compressed air to blow evenly from the inside to the outside until there is no visible liquid film on the surface.

3. The surface treatment method of a conductive steel roller for copper foil according to claim 1, characterized in that: In step S2, the setting of the laser average power, pulse frequency, pulse width, spot diameter, axial feed speed, radial feed step and scanning overlap ratio includes: Use a contact roughness meter to measure the initial roughness of the roller surface, and determine the machining allowance based on the target roughness given in the process specification; Based on the machining allowance and material thermophysical properties, the average laser power is selected as 100W-500W by looking up the table; Refer to the processing depth requirements, set the pulse frequency to 20Hz-100Hz, and the pulse width to 50ns-200ns; According to the required removal volume and spot overlap rate, the spot diameter is determined to be 0.1mm-5mm, the radial feed step, and the scanning overlap rate is 50%-90%; Considering the roller length and mechanical stiffness, the axial feed speed is set to 0.5mm / s-5mm / s.

4. The surface treatment method of a conductive steel roller for copper foil according to claim 3, characterized in that: Determining the machining allowance in combination with the target roughness given in the process specification includes: According to the quality requirements of the copper foil production process, the required surface roughness range of the steel roller is obtained from the process specifications. This range corresponds to the adhesion and release performance requirements of the copper foil. The target roughness is subtracted from the measured initial roughness of the roller surface, and the difference obtained is the actual processing allowance that needs to be removed. The processing allowance is used for the initial setting of subsequent laser processing parameters.

5. The surface treatment method of a conductive steel roller for copper foil according to claim 1, characterized in that: In step S3, the laser processing head spirally scans the surface of the steel roller in the axial and radial directions at a set feed speed and pitch, including: Under the coordination of the CNC system, the conductive steel roller rotates at a constant speed. The speed range is determined by the selected processing parameters. The laser processing head moves uniformly along the length of the roller at a preset axial feed speed. After completing one circle, the circumferential offset of the laser beam is controlled by the radial feed step so that it covers the entire roller surface in a spiral manner; the scanning mode can be progressively layer by layer according to the change in surface roughness.

6. The surface treatment method of a conductive steel roller for copper foil according to claim 5, characterized in that: The controlling of the circumferential deviation of the laser beam by the radial feed step comprises: According to the relationship between the spot diameter and the required overlap rate, the radial feed step is selected to ensure that the energy overlap between adjacent scanning tracks meets the design requirements; After completing each circle of axial movement, the numerical control system drives the laser processing head to move in the radial direction according to the radial feed step, so as to achieve calibration of the starting position of the next circle of scanning.

7. The surface treatment method of a conductive steel roller for copper foil according to claim 1, characterized in that: In step S4, calculating the error based on the result of measuring the surface roughness of the steel roller and adjusting the laser processing parameters include: After the laser processing head completes a section of axial scanning, the roller surface is measured at multiple points using an online contact roughness measuring instrument. The measurement points are evenly distributed along the axial and circumferential directions of the roller body to obtain the spatial distribution data of the current surface roughness. The spatial distribution data of the roughness is transmitted to a control system, and the deviation between the current roughness and the target roughness is calculated in each measurement cycle according to a proportional-integral control algorithm; According to the deviation value, the average power of the laser is dynamically adjusted according to a preset adjustment strategy so that the energy input of the subsequent spiral scan matches the processing requirements.

8. The surface treatment method of a conductive steel roller for copper foil according to claim 7, characterized in that: The dynamic adjustment of the laser average power includes: Based on the calculated roughness deviation value, the average laser power is adjusted according to the predetermined increment and decrement steps to match the energy input with the processing requirements; Dynamic adjustment is performed after each measurement cycle, which can be preset by the PLC to ensure that power adjustment and monitoring frequency remain synchronized during continuous spiral scanning.

9. The surface treatment method of a conductive steel roller for copper foil according to claim 1, characterized in that: In step S5, detecting the surface roughness, cylindricity and copper foil thickness deviation of the conductive steel roller includes: Use a laser scanning confocal profilometer to scan the profile of the spray-cleaned and blow-dried roller surface in at least three sections parallel to the axial direction to obtain roughness parameters; The conductive steel roller is mounted on a three-dimensional coordinate measuring machine fixture, and the cylindricity is measured at four equally divided angular positions at the end, middle, and tail sections of the roller body, and the cylindricity error of the entire section is calculated based on the measurement results; Under the same unit environment, an actuated online thickness gauge is used to perform multi-point measurements on the rolled copper foil samples. The measurement area covers different positions along the width of the copper foil. The measured thickness data is compared with the process standard to determine the thickness deviation range.

10. A surface treatment system for a conductive steel roller for copper foil, according to a surface treatment method for a conductive steel roller for copper foil according to any one of claims 1 to 9, characterized in that: include: A pretreatment module, used for placing the conductive steel roller to be processed in an ultrasonic cleaning tank and performing pretreatment, wherein the pretreatment includes ultrasonic cleaning, wiping with anhydrous ethanol and drying with compressed air; a parameter setting module, which calculates and sets the laser average power, pulse frequency, pulse width, spot diameter, axial feed speed, radial feed step and scanning overlap rate based on the initial roughness of the pretreated conductive steel roller and the target roughness given in the process specification; a laser grinding module, which performs online laser grinding based on the settings, rotates the conductive steel roller at a set speed, and drives the laser processing head to perform axial and radial spiral scanning according to the parameters; An online monitoring module collects surface roughness data of the conductive steel roller in real time during the laser grinding process based on the set online laser grinding, and transmits the data to a control system to calculate deviations and issue parameter adjustment instructions; The post-processing module is used to finally clean the ground conductive steel roller with pure water spray and dry it with compressed air, and to control the three-coordinate measuring machine and online thickness measuring instrument to complete the cylindricity and copper foil thickness deviation detection respectively.

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