A method and system for improving thin film string bubbles

Abstract

The present application relates to a kind of methods for improving film string bubble, comprising the following steps: step 1, determine the function relationship f (x) of the tension of film and the length of the film that has been rolled: step 2, in the process of coating production, the length x of the film that has been rolled is obtained in real time / timing;Step 3, according to the function relationship of step 1 and the length of the film that has been rolled obtained in step 2, the theoretical tension value of film is calculated;Step 4, according to the theoretical tension value, adjust the position of tension floating roller, and change the tension of the film around the tension floating roller in real time / timing, so that it is equal to the theoretical tension value;The present application also relates to the system for realizing the method.The present application realizes the attenuation of the tension applied to the film before winding according to the length of the film that has been rolled, to offset the phenomenon that the outer layer film "dead" inner layer film after the increase of film roll diameter, so that the tension between the inner layer and the outer layer of film is consistent, thereby solving the film surface wrinkle or string bubble deformation of outer layer film, guarantee the quality of product.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of film production, in particular to a method and system for improving film bubble. BACKGROUND

[0002] Electroplating process refers to the process of depositing metal on the surface of a material, such as thin film electroplating. Thin film electroplating process includes unwinding stage, electroplating stage and winding stage.

[0003] In the winding stage, the film is wound on the winding roller to form a film roll, and the winding process must stretch and tension the film, and the force of tensioning the film is the tension. Most winding rollers use center winding, and the power is transmitted from the center of the winding roller outward. If the winding is done with constant tension, as the winding diameter / winding length increases, the outer layer of the film roll will "lock" the inner layer, that is, the force on the inner and outer layers of the film roll is not balanced. Because the stiffness of the winding roller and the inner layer of the film is large, the outer layer of the film will appear wrinkled or bubble deformation, affecting the product qualification rate.

[0004] In the existing equipment, only a pressure roller is arranged on the winding roller, which is tangent to the film surface on the winding roller and moves with the diameter change of the film roll, so that the pressure roller always presses against the film surface to flatten the film surface as much as possible. However, this structure cannot solve the problem of inconsistent tension between the inner and outer layers of the film roll in the later stage of film winding, so it still causes wrinkled or bubble deformation of the film surface.

[0005] The above problems need to be solved. SUMMARY

[0006] In order to overcome the problem that the inconsistent tension between the film layers on the film roll of the winding roller at the winding end causes inconsistent pressure between the film layers, resulting in wrinkled or bubble deformation of the film surface, the present application provides a method and system for improving film bubble.

[0007] The technical scheme of the present application is as follows:

[0008] A method for improving film bubble, comprising the following steps:

[0009] Step 1, determining the function relationship f(x) between the tension of the film and the length of the wound film;

[0010] Step 2, obtaining the length x of the wound film in real time / timely during the film plating production process;

[0011] Step 3, calculating the theoretical tension value of the film according to the function relationship of step 1 and the length of the wound film obtained in step 2;

[0012] Step 4, adjust the position of the tension floating roller according to the theoretical tension value, and change the tension of the film winding around the tension floating roller in real time / timely to equal the theoretical tension value.

[0013] According to the application of the above scheme, the function relationship f(x) between the tension of the film and the length of the rolled film in step 1 specifically comprises the following steps:

[0014] S101, determine the tension value of the film winding around the tension floating roller at the starting position;

[0015] S102, adjust the position of the tension floating roller to attenuate the tension value of the film every time a unit length is rolled;

[0016] S103, observe the surface state of the rolled film to determine whether there are wrinkles or bubbles on the film surface, and record the tension value when the film surface has no wrinkles or bubbles;

[0017] S104, repeat steps S102 and S103 until the rolling process of the entire film is completed;

[0018] S105, draw a step curve of the tension value-rolled film length value, and fit a smooth curve according to the step curve;

[0019] S106, determine the function relationship f(x) between the tension of the film and the length of the rolled film according to the smooth curve of the tension value-rolled film length value.

[0020] Further, the unit length in step 102 is 100 meters.

[0021] According to the application of the above scheme, in step 1, the function relationship f(x) between the tension of the film and the length of the rolled film is f(x)=6x10 -5 x 2 -0.274x+408.7.

[0022] According to the application of the above scheme, in step 4, the tension sensor detects the tension value of the film at the tension floating roller in real time and sends it to the control system, the control system compares the relationship between the film tension value and the calculated theoretical tension value, and realizes the closed-loop control of the tension floating roller.

[0023] The application also provides a system for improving film bubbles, which is used to realize the method for improving film bubbles in the above scheme, and comprises a tension floating roller and a control system for adjusting the position of the tension floating roller, the control system is used to calculate the theoretical tension value of the film according to the length x of the rolled film, and realize the adjustment control of the position of the tension floating roller to change the tension of the film winding around the tension floating roller.

[0024] According to the application of the above scheme, the system for improving film bubble string further comprises a tension sensor connected with the tension floating roller, which is used to detect the tension of the film around the tension floating roller.

[0025] According to the application of the above scheme, the system for improving film bubble string further comprises a passing roller, around which the film passes and drives the passing roller to rotate, and a counter installed inside the passing roller to record the rotation turns of the passing roller (used to calculate the film running length, and the control system obtains the length of the collected film).

[0026] According to the application of the above scheme, the system for improving film bubble string further comprises a screen control unit, which comprises the control system and a touch control screen.

[0027] Further, the control system is a PLC programmed controller.

[0028] According to the application of the above scheme, the tension floating roller comprises a middle roller body, a force applying roller body and a counterweight roller body respectively located on both sides of the middle roller body, and the force applying roller body and the counterweight roller body can rotate around the middle roller body.

[0029] According to the application of the above scheme, the system for improving film bubble string further comprises an unwinding end, an electroplating tank and a winding end, the film is unwound from the unwinding end, passes through the electroplating tank and then enters the winding end, and the winding end comprises an oven, an edge clamping wheel, a traction roller, a passing roller, the tension floating roller and a winding roller.

[0030] Further, a first flattening roller is arranged between the edge clamping wheel and the traction roller, and a second flattening roller is arranged between the tension floating roller and the winding roller.

[0031] Further, a winding pressure roller is arranged at the front end of the winding roller, which is used to extrude the film before winding to press the film against the winding roller.

[0032] According to the application of the above scheme, the beneficial effects are as follows:

[0033] The application realizes attenuation of the tension applied to the film before winding according to the length of the collected film, so as to offset the phenomenon that the outer film "locks" the inner film due to the increase of the film roll diameter, make the tension between the inner layer and the outer layer of the film consistent, and thus solve the film surface wrinkle or bubble string deformation of the outer film, and guarantee the product quality. BRIEF DESCRIPTION OF DRAWINGS

[0034] Figure 1 It is a relationship curve between the film tension value and the length value of the collected film in the application.

[0035] Figure 2 It is a system structure diagram of the application.

[0036] In the figure, 1, oven; 2, pinch roller; 3, first flattening roller; 4, traction roller; 5, over roller; 6, tension float roller; 61, intermediate roller body; 62, force roller body; 63, counterweight roller body; 7, second flattening roller; 8, winding roller; 81, winding pressure roller. DETAILED DESCRIPTION

[0037] In order to better understand the purpose, technical solution and technical effect of the present application, the following further explains the present application in combination with the drawings and examples. It is declared that the following described examples are only for explaining the present application, and not for limiting the present application.

[0038] It should be noted that when an element is referred to as "fixed to" or "disposed on" another element, it can be directly on the other element or there can be a mediating element. When an element is considered "connected" to another element, it can be directly connected to the other element or a mediating element can be present at the same time.

[0039] The terms "first", "second" are only for the purpose of convenient description, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features.

[0040] As shown in the figure, a method for improving film string bubble, comprising the following steps: Figure 1

[0041] Step 1, determining the function relationship f(x) of the tension of the film and the length of the wound film;

[0042] Step 2, obtaining the length x of the wound film in real time / timed during the film production process;

[0043] Step 3, calculating the theoretical tension value of the film according to the function relationship of step 1 and the length of the wound film obtained in step 2;

[0044] Step 4, adjusting the position of the tension float roller according to the theoretical tension value, and changing the tension of the film around the tension float roller in real time / timed, so that it is equal to the theoretical tension value.

[0045] In the present application, the function relationship f(x) of the tension of the film and the length of the wound film in step 1 specifically comprises the following steps:

[0046] S101, determining the tension value of the film around the tension float roller at the starting position;

[0047] ​The starting position of the scheme refers to the position at which the outer layer of the film starts to wrinkle after the film is continuously wound on the winding roller for a certain length under constant tension. Different films have different tolerances to tension due to differences in material, thickness, width, and performance, and the starting position of wrinkles varies, but it can be observed in practice. For example, in the present embodiment, the outer layer of the film starts to wrinkle after being wound on the winding roller for 600 meters, and the starting position is recorded as 600 meters.

[0048] In the process of recording the tension value of the film at this time: the film is withdrawn by half a unit length (50 meters in the present embodiment), and the tension value of the film at the tension floating roller is reduced by adjusting the setting of the tension floating roller, and the film surface is flattened again after winding to the starting position (i.e. 600 meters), and the surface state of the film is observed: if there is no wrinkle, the initial tension value (i.e. the tension value of the film at the starting position (600 meters)) can be determined; if wrinkles still appear, the film is withdrawn again, and the tension value is further attenuated, verified, and observed until the final tension value is obtained. The initial tension value of the present embodiment is 265 N, which can prevent the outer layer of the film from wrinkling at 600 meters.

[0049] By the above method, the final tension value is recorded as the tension value of the film around the tension floating roller at the starting position.

[0050] S102, adjust the position of the tension floating roller to attenuate the tension value of the film every time a unit length is wound;

[0051] During the winding of the film on the winding roller, the tension floating roller is adjusted to reduce the force applied to the film every time a unit length of the film is wound, thereby reducing the tension value of the film. In the present embodiment, the value of a unit length is 100 meters. In order to improve the accuracy of curve fitting, a unit length can also be less than 100 meters, such as 80 meters, 50 meters, 30 meters, etc.

[0052] For example, based on step S101 of the present embodiment, the film tension value is maintained at 265 N, and the winding continues to 700 meters, and the tension attenuation operation is performed.

[0053] S103, observe the surface state of the wound film to determine whether the film surface has wrinkles or bubbles, and record the tension value when the film surface has no wrinkles or bubbles.

[0054] The tension value is determined by using a similar operation method as step S101. Specifically:

[0055] The surface state of the wound film is observed to determine the tension value after attenuation. After attenuation to a certain value, if there is no wrinkle or bubble string, the tension value of the film at the tension floating roller is recorded; if wrinkles or bubble strings are found, the film is rewound to the previous stage (rewound by one unit length), the tension value is further reduced, the film surface is flattened and rewound until there is no wrinkle, and the tension value is recorded and continuously wound by one unit length.

[0056] S104, repeating step S102 and step S103 until the winding process of all films is completed;

[0057] In this embodiment, through multiple tests, it is recorded that the length of the wound film and the tension value without wrinkles on the film surface, as shown in the following table:

[0058]

[0059] S105, drawing a step curve of the tension value-wound film length value, and fitting a smooth curve according to the step curve;

[0060] According to the above table, a step curve of the tension value-wound film length value can be drawn, and data is imported into a function curve drawing tool, such as ZGrapher, to obtain a smooth curve, as shown in Figure 1 .

[0061] S106, determining the function relationship f(x) of the tension of the film and the length of the wound film according to the smooth curve of the tension value-wound film length value.

[0062] In this embodiment, it is obtained that the function relationship f(x) of the tension of the film and the length of the wound film is:

[0063] f(x) = 6 x 10 -5 x 2 -0.274x + 408.7.

[0064] In step 4 of the present application, the tension sensor is used to detect the film tension value at the tension floating roller in real time and send it to the control system, the control system compares the relationship between the film tension value and the calculated theoretical tension value, and realizes closed-loop control of the tension floating roller. Specifically, if the film tension value is less than the calculated theoretical tension value, the tension floating roller is controlled to increase the film tension at this position; if the film tension value is greater than the calculated theoretical tension value, the tension floating roller is controlled to reduce the film tension at this position; if the film tension value is equal to the calculated theoretical tension value, the position of the tension floating roller is maintained unchanged before the next attenuation stage.

[0065] As Figure 2The present application also provides a system for improving film bubble, which is used to realize the method for improving film bubble, and comprises a tension floating roller and a control system for adjusting the position of the tension floating roller, the control system is used to calculate the theoretical tension value of the film according to the length x of the wound film, and adjust and control the position of the tension floating roller to change the tension of the film around the tension floating roller.

[0066] In the present application, the system for improving film bubble further comprises a tension sensor connected with the tension floating roller, which is used to detect the tension of the film around the tension floating roller.

[0067] The system for improving film bubble further comprises a passing roller, the film passes through the passing roller and drives the passing roller to rotate, and the passing roller is internally provided with a counter for recording the number of rotation of the passing roller, so that the length of the film can be calculated, and the value is fed back to the control system in real time, and the control system obtains the length of the wound film.

[0068] In the present application, the system for improving film bubble further comprises a screen control unit, which comprises the control system and a touch control screen. The control system is a PLC programmed controller, and the user can edit / modify / delete the function relationship f(x) and operate through the touch control screen.

[0069] In the present application, the tension floating roller 6 comprises a middle roller body 61, a force applying roller body 62 and a counterweight roller body 63, the force applying roller body 62 and the counterweight roller body 63 are respectively located on both sides of the middle roller body 61, and the force applying roller body 62 and the counterweight roller body 63 can rotate around the middle roller body 61. The force applying roller body 62 cooperates with the middle roller body 61 to apply force to the film passing between the two roller bodies, so that the film is tensioned. In the embodiment, when the force applying roller body 62 rotates counterclockwise with the middle roller body 61 as the center, the tension value of the film becomes larger; when the force applying roller body 62 rotates clockwise, the tension value of the film becomes smaller; and the counterweight roller body 63 plays a balancing role, which can ensure that the force applying roller body can rotate stably and accurately.

[0070] The control system obtains the length of the wound film, and calculates the theoretical tension value of the film by using the function relationship between the tension of the film and the length of the wound film, so as to adjust the tension floating roller 6, specifically, adjust the rotation of the force applying roller body 62 around the middle roller body 61, so as to change the tension of the film, and make the tension value of the current film meet the theoretical tension value.

[0071] In the present application, the system for improving film bubble further comprises a winding end, an electroplating tank and a winding end, the film is discharged from the winding end, enters the winding end after passing through the electroplating tank, and the winding end further comprises an oven, an edge clamping wheel and a traction roller in addition to the above-mentioned tension floating roller, winding roller and passing roller.

[0072] The oven 1 is used for drying the thin film quickly after passing through the electroplating tank; the traction roller 4 is connected with a driving motor to provide power for the thin film; at least one film edge of the thin film is provided with the edge clamping wheel 2, and in the preferred embodiment, both film edges of the thin film are provided with the edge clamping wheel 2, the edge clamping wheel 2 is connected with the cathode to enable the thin film to be charged; the winding roller 8 is connected with a driving motor and has the same rotating speed as the driving motor of the traction roller 4, and is used for winding the thin film.

[0073] In one specific embodiment, the first flattening roller 3 is arranged between the edge clamping wheel 2 and the traction roller 4, and the second flattening roller 7 is arranged between the tension floating roller 6 and the winding roller 8. The first flattening roller 3 and the second flattening roller 7 are both used for flattening the thin film to eliminate longitudinal wrinkles of the thin film caused by the stretching force. The second flattening roller 7 includes an upper flattening roller and a lower flattening roller, which are respectively arranged on the front and back surfaces of the thin film to enable the thin film to be folded and to achieve the flattening effect of the thin film.

[0074] In one specific embodiment, the front end of the winding roller 8 is provided with a winding pressure roller 81, which is used for pressing the thin film against the winding roller 8. The winding pressure roller 81 is used for extruding the thin film before winding to extrude the air between the thin films and prevent the residual air between the thin films from deforming the thin film after winding. The winding pressure roller 81 can move along with the change of the diameter of the thin film roll to enable the winding pressure roller 81 to always be tangent to the outer surface of the thin film roll on the winding roller.

[0075] In summary, the present application strictly controls the tension of the thin film according to the length of the thin film by using the relationship between the tension of the thin film and the length of the wound thin film, so that the tension of each film layer on the winding roller is consistent (here, the "consistent" does not mean that the tension values of each film layer are completely equal, but it is ensured that the tension of the thin film between each film layer will not cause stringing bubbles), thereby solving the phenomenon of thin film wrinkles and stringing bubbles during the winding process and ensuring the quality of the product. The curve of the relationship is shown in Figure 1 The horizontal coordinate in the figure is the length of the wound thin film, and the vertical coordinate is the theoretical tension value of the thin film.

[0076] The technical features of the above embodiments can be combined arbitrarily, and in order to make the description concise, all possible combinations of the technical features in the above embodiments are not described, however, as long as the combinations of the technical features do not exist, they should be considered as the scope of the present application.

[0077] The above embodiments only express several implementation manners of the present application, and the description is more specific and detailed, but it should not be understood as a limitation on the scope of the patent. It should be pointed out that for ordinary skilled persons in the art, some modifications and improvements can be made without departing from the concept of the present application, and these all belong to the protection scope of the present application. Therefore, the protection scope of the patent of the present application should be subject to the appended claims.

Claims

1. A method for improving film cross-bubbling, characterized in that, Includes the following steps: Step 1: Determine the functional relationship f(x) between the tension of the film and the length of the wound film: ； Step 2: During the coating production process, acquire the length x of the wound film in real time / at regular intervals; Step 3: Calculate the theoretical tension value of the film based on the functional relationship in Step 1 and the length of the wound film obtained in Step 2. Step 4: Adjust the position of the tension floating roller according to the theoretical tension value, and change the tension of the film passing through the tension floating roller in real time / at regular intervals to make it equal to the theoretical tension value; Step 1, determining the functional relationship f(x) between the tension of the film and the length of the wound film, specifically includes the following steps: S101. Determine the tension value of the film passing through the tension floating roller when the starting position is determined; The starting position refers to the position where wrinkles begin to appear on the outer layer of the film after it has been continuously wound to a certain length under constant tension on the take-up roller. During the recording of the film tension value at this point: the film is retracted by half a unit length, and the tension value at the tension floating roller is reduced by adjusting the tension floating roller settings. After flattening the film surface, it is wound back to the starting position, and the surface condition of the film is observed. If there are no wrinkles, the tension value of the film at the starting position can be determined. If wrinkles still appear, the film is retracted again to further reduce the tension value. This process is repeated until the final tension value is obtained. The final tension value is the tension value of the film wound around the tension floating roller at that starting position. S102. Adjust the position of the tension floating roller for each unit length wound up to reduce the tension value of the film. S103. Observe the surface condition of the wound film to determine whether there are wrinkles or bubbles on the film surface, and record the tension value when there are no wrinkles or bubbles on the film surface. S104. Repeat steps S102 and S103 until the entire film winding process is completed. S105. Plot the stepped curve of tension value versus length of wound film, and fit a smooth curve based on the stepped curve. S106. Determine the functional relationship f(x) between the tension of the film and the length of the wound film based on the smooth curve of tension value - length of wound film.

2. The method for improving film cross-bubbling according to claim 1, characterized in that, One unit in step 102 has a length of 100 meters.

3. The method for improving film cross-bubbling according to claim 1, characterized in that, In step 4, the tension sensor detects the film tension value at the tension floating roller in real time and sends it to the control system. The control system compares the film tension value with the calculated theoretical tension value and realizes closed-loop control of the tension floating roller.

4. A system for improving thin film crosstalk, used to implement the method for improving thin film crosstalk according to any one of claims 1 to 3, characterized in that, The system includes a tension floating roller and a control system for adjusting the position of the tension floating roller. The control system is used to calculate the theoretical tension value of the film based on the length x of the wound film and to adjust the position of the tension floating roller to change the tension of the film wound around the tension floating roller. The tension floating roller includes an intermediate roller body, a force-applying roller body and a counterweight roller body located on both sides of the intermediate roller body, and the force-applying roller body and the counterweight roller body can rotate around the intermediate roller body.

5. The system for improving thin-film bubble crosstalk according to claim 4, characterized in that, The system for improving film bubble formation also includes a tension sensor connected to the tension floating roller for detecting the tension of the film passing through the tension floating roller.

6. The system for improving thin film cross-contamination according to claim 4, characterized in that, The system for improving film bubble crosstalk also includes a roller through which the film passes and drives the roller to rotate. A counter is installed inside the roller to record the number of rotations of the roller.

7. The system for improving thin film cross-contamination according to claim 4, characterized in that, The system for improving thin-film bubble crosstalk also includes a screen control unit, which includes the control system and a touch screen.

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