A copper plate roll forming device

Abstract

A copper plate rolling forming device includes a shaft, pressure rollers, a fixed frame, two arc-shaped frames, and a steel cylinder assembly. Each arc-shaped frame is mounted on the fixed frame, with the concave arc surfaces of the two arc-shaped frames facing each other. The two ends of the shaft in the steel cylinder assembly are respectively mounted in bearing seats within the steel cylinder. Three pressure rollers are located on the inner arc surface of each arc-shaped frame, with the two ends of each pressure roller fixed to the inner surface of each arc-shaped support plate. The circumferential surface of each pressure roller is tightly pressed against the outer surface of the steel cylinder by springs. This invention uses a precision-machined cathode roller steel cylinder as a mold, applying pressure to the copper plate through the pressure rollers to achieve a tight fit between the copper plate and the outer circumference of the cathode roller steel cylinder, thus achieving copper plate rolling. This invention is used for rolling copper plates with a diameter ≥1000mm, achieving high roundness and a copper layer thickness consistency of ≤0.3mm after precision machining, thereby ensuring the uniformity of the conductive copper layer in the copper-steel composite cathode roller core.

Description

Technical Field

[0001] This invention relates to the field of cathode roller technology, specifically a forming apparatus for forming a copper plate into a cylindrical shape for forming a cathode roller. Background Technology

[0002] With the rapid development of new energy vehicles, 5G communications, big data centers, and artificial intelligence technologies worldwide, the demand for electrolytic copper foil is growing rapidly. Moreover, as the performance requirements for copper foil in power lithium batteries and energy storage lithium batteries become increasingly stringent, the thickness of copper foil is trending towards thinner thicknesses, placing higher demands on the cathode rollers used in the production of electrolytic copper foil.

[0003] Electrolytic copper foil production employs a continuous roller electrolysis method. The principle involves immersing a cathode roller in a copper sulfate electrolytic solution and then applying a low-voltage, high-current DC power supply. This causes copper ions from the electrolytic solution to deposit onto the titanium surface of the cathode roller, forming copper foil. The rotation of the cathode roller then peels and winds the formed copper foil from its surface. Further surface treatment is then performed to create the final copper foil product. Therefore, the cathode roller used for high-precision lithium-ion battery foil is a core component directly affecting the yield and quality of copper foil.

[0004] Because the cathode roller plays a decisive role in copper foil production, its requirements are quite high: First, to increase copper foil production, the roller diameter should be as large as possible; the diameter of existing high-precision lithium battery foil cathode rollers has reached φ3000mm. Second, it requires good conductivity and must not have localized heating points due to poor conductivity. Furthermore, the requirements for surface roundness, straightness, and surface roughness are quite high; the surface must be resistant to corrosion by the electrolyte solution for a long time, and the overall balance and weight should be as light as possible. Currently, the high-precision lithium battery foil cathode roller adopts a three-layer composite structure of titanium, copper, and steel; that is, the outer ring is wrapped with titanium, the middle layer is copper for conductivity, and the inner layer is steel as the skeleton.

[0005] Currently, in the copper-steel structure of cathode rollers, copper and steel are composited using explosive welding to form a copper-steel composite plate, which is then rolled into a cylinder. After being fitted with side plates and a mandrel and machined, a titanium cylinder is fitted to form the cathode roller. In terms of manufacturing, due to the large diameter of the cylinder, the roundness tolerance of the copper-steel composite plate can only be ≥4mm during rolling. This makes it impossible to guarantee the uniform thickness of the copper during machining, resulting in localized poor conductivity and localized heating points. Furthermore, the special forming process of the copper-steel composite plate makes it particularly expensive. These numerous uncertainties in design and manufacturing make it difficult to guarantee the manufacturing quality of the cathode roller, thus severely impacting both the quality and quantity of copper foil produced.

[0006] In the invention application with application number 20211130785.5, a copper plate rolling control device, a copper cylinder preparation method, and a cathode roller preparation method are disclosed. The copper plate is first rolled into a circle using a rolling machine. Then, the rolled copper plate is assembled onto a rounding support device, and a rounding clamping device is installed on the outer circle of the copper plate. The rounding support device and the rounding clamping device work together to control the roundness of the rolled copper plate. After the rounding support device and the rounding clamping device round the copper plate, the longitudinal weld seam of the copper plate is welded to achieve the roundness of the copper plate. However, during the copper plate rolling process, because the rounding support device is a segmented support structure, the straightness of the copper cylinder in the width direction is relatively poor when the copper plate is rolled. This can easily cause the rounding clamping device to over-tighten the copper cylinder at the unrounded parts, resulting in localized depressions of 0.2-0.4 mm in the copper cylinder. Furthermore, the operation process is complex and involves many steps.

[0007] In the invention publication CN201588003U, a wire-wound cathode roller core was disclosed. This cathode roller copper-steel composite structure employs a wire-wound cathode roller core, with a copper cylinder body outside the steel cylinder. The copper cylinder body is formed by tightly winding copper wire onto the steel body to form a copper layer; the copper wire is square copper wire. Using this method, it is difficult to ensure that the copper strip adheres tightly to the steel cylinder body, and the axial tightness of the copper wire is also difficult to guarantee, easily leading to gaps.

[0008] The invention application with application number 2021112844311 discloses a method for manufacturing an ultra-large diameter cathode roller. The cathode roller is a copper-steel composite structure. The copper cylinder is heat-inserted onto the outside of the steel cylinder. The specific manufacturing method of the copper cylinder is not described.

[0009] In the U.S. patent application No. 4975169 filed by Japan, entitled "DRUM FOR ELECTRODEPOSITED METAL FOIL", the cathode roller is a copper-steel composite structure, but it does not describe how the copper cylinder and the steel cylinder are combined into one piece.

[0010] Therefore, based on the above analysis, it is urgent to design a high-precision forming device that can realize the copper-steel composite structure of the cathode roller, so as to achieve the uniformity of the copper layer thickness in the copper-steel composite structure of the cathode roller. Summary of the Invention

[0011] To overcome the problem of uneven copper cylinder thickness in the prior art and improve the conductivity uniformity of the copper cylinder, this invention proposes a copper plate rolling forming device.

[0012] This invention includes a shaft, a pressure roller, a fixed frame, two arc-shaped frames, and a steel cylinder assembly. Each arc-shaped frame is mounted on the fixed frame, with the concave arc surfaces of the two arc-shaped frames facing each other. The two arc-shaped frames are a first arc-shaped frame and a second arc-shaped frame, respectively. The upper ends of the two supports of the fixed frame are respectively provided with steel cylinder bearing seats, forming axial shaft support members. The two ends of the shaft in the steel cylinder assembly are respectively mounted in the steel cylinder bearing seats.

[0013] Each of the aforementioned arc-shaped frames is fixed to an arc-shaped frame mounting plate on the fixed frame, symmetrically distributed on both sides of the circumference of the steel cylinder, and the inner arc surfaces of the two arc-shaped frames form a spatial circle. Three pressure rollers are respectively located on the inner arc surface of each arc-shaped frame, and the two ends of the three pressure rollers are respectively fixed to the inner surface of the arc-shaped support plate. The circumferential surface of each pressure roller is in close contact with the outer surface of the steel cylinder, and is pressed together by a spring.

[0014] Each pressure roller has two springs at both ends, and the clamping force is controlled by adjusting the spring compression. The spring is compressed 10 turns, and a single spring generates a clamping force of 2345.8 N.

[0015] The three pressure rollers located on the second arc-shaped frame, clockwise from top to bottom, are the second pressure roller, the first pressure roller, and the sixth pressure roller; the three pressure rollers located on the first arc-shaped frame, counterclockwise from top to bottom, are the third pressure roller, the fourth pressure roller, and the fifth pressure roller. The second and third pressure rollers are positioned correspondingly on the spatial circle, the first and fourth pressure rollers are positioned correspondingly on the spatial circle, and the sixth and fifth pressure rollers are positioned correspondingly on the spatial circle. The center lines of each pressure roller are parallel to the center line of the steel cylinder.

[0016] The steel cylinder assembly is a workpiece that is rolled and combined with a copper plate, and also serves as a carrier when the copper plate is rolled; the two ends of the shaft in the steel cylinder assembly are respectively mounted in the steel cylinder bearing housing via bearings.

[0017] The positions of the three pressure rollers located on the second arc-shaped frame along the circumferential direction are as follows: the angle β1 between the spatial line connecting the center of the first pressure roller and the center of the cathode roller steel cylinder and the horizontal line is 10~15°; the angle β2 between the spatial line connecting the center of the second pressure roller and the center of the cathode roller steel cylinder and the horizontal line is 40~55°; and the angle β6 between the spatial line connecting the center of the sixth pressure roller and the center of the cathode roller steel cylinder and the horizontal line is -20~-30°.

[0018] The positions of the three pressure rollers located on the first arc-shaped frame along the circumferential direction are as follows: the angle β1 between the spatial line connecting the center of the fourth pressure roller and the center of the cathode roller steel cylinder and the horizontal line is 10~15°; the angle β2 between the spatial line connecting the center of the third pressure roller and the center of the cathode roller steel cylinder and the horizontal line is 40~55°; and the angle β6 between the spatial line connecting the center of the fifth pressure roller and the center of the cathode roller steel cylinder and the horizontal line is -20~-30°.

[0019] The steel cylinder in the steel cylinder assembly is a core mold mold made of rolled copper plate; the outer diameter tolerance of the steel cylinder is ≤0.10mm, the outer diameter runout is ≤0.05mm, the outer diameter straightness is ≤0.05mm, and the outer circumferential surface roughness is ≤Ra3.2um.

[0020] The steel cylinder has two rows of fixing holes, and the distribution of each fixing hole corresponds to the position of the fixing holes on the two short sides of the copper plate to be rolled.

[0021] The first and second arc-shaped frames have identical structures, each consisting of a pair of arc-shaped base plates and supports. The radius of the base plate is the same as the radius of the steel cylinder. The lower end of the base plate has a support, positioned on one side of the convex arc surface of the base plate. A protruding first arc-shaped frame slider is located on the outer surface of the support base plate; this first arc-shaped frame slider is fixedly connected to an arc-shaped frame mounting plate on one side of the fixed frame. The base plates are fixed together as a single unit by pressure rollers; reinforcing ribs are present between the base plates.

[0022] The fixed frame includes a pair of trapezoidal frames; the lower ends of each trapezoidal frame are fixedly connected by a base plate, forming a rectangular frame structure. The upper surface of each trapezoidal frame is used to mount the steel cylinder bearing seat. On the outer surfaces of both sides of each trapezoidal frame are arc-shaped frame mounting plates for mounting each arc-shaped frame; these mounting plates have grooves, and each groove is perpendicular to the center line of its respective arc-shaped frame. The first and second arc-shaped frames are located on either side of the fixed frame, and the sliders of the first and second arc-shaped frames are respectively inserted into the grooves, allowing each arc-shaped frame to move horizontally along the grooves.

[0023] The pressure roller bearing seat is pressed by a spring. The spring is fitted onto a screw, with one end pressing against the pressure roller bearing seat, and the other end of the screw passing through a spring washer and mounted on either the first or second arc-shaped frame fixing plate.

[0024] The spring is made of 65Mn steel with a wire diameter of 2.5mm, a spring mean diameter of 18mm, 20 effective coils, a free height H0 = 100mm, and a single-coil load of 234.58N.

[0025] Each spring applies pressure to the pressure roller bearing seat via a spring seat. Each spring seat includes a spring washer and two screws; each spring washer has through holes at both ends for mounting the screws. The upper ends of the two screws pass through screw holes on the arc-shaped frame fixing plate and the spring washer, respectively, and the lower ends pass through screw holes on the pressure roller bearing seat, thereby fixing the pressure roller to the arc-shaped frame. Each spring is fitted onto its respective screw and positioned between the spring washer and the pressure roller bearing seat.

[0026] This invention involves tightly winding a copper plate onto the outer circumference of a precision-machined cathode roller steel cylinder. A series of pressure rollers are used to ensure the copper plate is tightly adhered to the outer circumference of the cathode roller steel cylinder. By appropriately adjusting the spring compression, the pressure rollers apply tight pressure to the copper plate, ensuring a close fit between the copper plate and the outer circumference of the cathode roller steel cylinder. Finally, after the copper plate is rolled into a circle, the gaps formed by the rolling are welded to form a complete copper cylinder, thus achieving an effective composite of the cathode roller and the copper steel cylinder.

[0027] In this invention, the device enables precise rolling of copper plates into round shapes. During the rolling process, the steel cylinder rotates together with the outer ring of the bearing. Two arc-shaped frames are equipped with pressure rollers; each pressure roller is mounted on a pressure roller bearing seat at both ends via cylindrical roller bearings, and the clamping force applied to the copper plate surface is adjusted by regulating the compression of the springs.

[0028] Compared with the prior art, the beneficial effects of this invention are as follows: The proposed copper plate rolling device with a diameter ≥1000mm improves the traditional method of rolling and welding copper steel composite plates into copper steel cylinders, which results in poor roundness, inability to guarantee precision machining of the outer copper cylinder after rolling and welding, and significant differences in the remaining copper layer thickness after precision machining (2-3mm). This makes it impossible to guarantee the uniformity of the conductive copper layer in the copper steel composite cathode roller core, which has a significant impact on the conductivity of the high-precision copper steel composite roller core. This device achieves control over the rolling of copper plates, reduces the labor intensity of sheet metal rolling, improves labor efficiency, and greatly reduces the labor intensity of operators.

[0029] The specific advantages are: 1. The steel cylinder can achieve a very good roundness and straightness after machining. This device can ensure the smooth rolling of the copper plate. The copper cylinder is rolled into the outer circle of the steel cylinder and then precision machined to ensure that the thickness of the conductive layer of copper is very uniform; 2. This device greatly reduces the production cost and material cost and improves the production efficiency; 3. The copper cylinder formed by rolling the copper plate can ensure that the cathode roller has a good repair rate.

[0030] This device ensures that the copper plate roll is tightly fitted to the outer circumference of the steel cylinder, with a radial gap of ≤0.05mm. At the end of the copper plate rolling process, the copper plate weld is performed using a welding current of 650~700A, an arc welding voltage of 41~44V, a welding speed of 25cm / min, and SCU1898 welding wire with a diameter of 3.0~4.0mm. The welding speed is controlled between 0~150cm / min. After welding, insulation cotton is used to prevent cracks in the copper weld. The insulation time is 30~60min. After cooling to room temperature, the insulation layer is removed. Copper cylinders welded using this method can achieve a roundness control of ≤0.6mm, ensuring the geometric accuracy of the copper cylinder.

[0031] The copper plate selected in this invention is T2 pure copper material, which has soft properties and a hardness ≤70HV. The copper plate is a hot-rolled plate in a softened annealed state (O60), exhibiting good metal fluidity (i.e., good plasticity), a tensile strength ≥205MPa, and an elongation after fracture ≥30%. Due to its softened annealed state (O60), the bending angle can reach 180°, and the inner radius can be as small as 0.5 times the plate thickness. In this invention, the copper plate is bent and rolled along the direction of the copper plate rolling fibers perpendicular to the rolling direction. The inner curvature radius of the bent and rolled circle is large, and the rolling radius is generally ≥R500mm. The copper plate thickness is generally 3-12mm, and the rolling radius is much larger than the plate thickness. During bending and rolling, the bending and rolling direction is consistent with the copper plate rolling fiber direction, which enables the rolling of this type of copper plate.

[0032] The rolling principle of the copper plate rolling forming device is as follows: The metal material undergoes plastic deformation under force. Utilizing annealed and softened T2, which has good plasticity at room temperature, the copper plate is first fixed to the outer generatrix of the steel cylinder. The rotation of the steel cylinder drives the copper plate to rotate. Under pressure perpendicular to the outer circumference of the steel cylinder, the copper plate undergoes elastic-plastic deformation, adhering tightly to the outer circumference of the steel cylinder. Because the copper plate is pressed against the outer generatrix of the steel cylinder, the copper plate is in close contact with the steel cylinder and the pressure roller. The copper plate is limited both radially and internally, achieving a tight fit between the copper plate and the outer circumference of the steel cylinder in the direction of the generatrix. Furthermore, under the frictional force of the pressure roller, the portion of the copper plate passing through the roller is tightly fitted to the steel cylinder, preventing the copper plate already attached to the steel cylinder from loosening.

[0033] This copper plate rolling forming device produces high-precision copper-steel cylinders, which in turn produce high-precision copper-steel cylinder cathode rollers. The uniformity of the copper layer thickness on the outer circumference of the copper-steel cylinder is significantly improved, achieving a thickness consistency of ≤0.3mm. The gap between the copper layer and the outer surface of the inner steel cylinder is ≤0.05mm, effectively ensuring the uniformity of the copper layer thickness on the copper-steel cathode roller and improving its conductivity uniformity. This results in electrolytic copper foil with excellent weight uniformity, enhancing the grade and quality of the copper foil produced using this copper-steel cylinder cathode roller. See Table 1. Table 2 shows the deviation of the remaining copper layer thickness after machining the outer circumference of two randomly selected copper-steel cylinders. The copper layer thickness was measured along the outer circumference at 45° intervals, for a total of 8 outer circumference generatrices. Eight points were evenly selected along the width direction. Specific results are shown in Tables 1 and 2; the copper layer thickness consistency reaches ≤0.3mm.

[0034] Table 1. Copper layer thickness deviation of a certain copper-steel cylinder

[0035]

[0036] Table 2. Copper layer thickness deviation of a certain copper-steel cylinder

[0037]

[0038] Experiments verified that the electrolytic copper foil produced by this copper-steel cathode roller structure exhibits excellent weight uniformity, with a weight deviation of ≤1.5%. Using 50mm × 50mm electrolytic copper foil, eight outer circumference generatrices were inspected at 45° intervals along the circumference, with eight points evenly selected along the width. Specific results are shown in Tables 3 and 4. The weight deviation of the electrolytic copper foil is ≤1.5%, reaching the level of high-grade lithium battery copper foil.

[0039] Table 3. Weight of electrolytic copper foil produced by a copper-steel cylinder cathode roller (6µm electrolytic copper foil)

[0040]

[0041] Table 4. Weight of electrolytic copper foil produced by a copper-steel cylinder cathode roller (6µm electrolytic copper foil)

[0042] Attached Figure Description

[0043] Figure 1 This is the front view of the copper plate rolling forming device.

[0044] Figure 2 This is a BB cross-sectional view of a copper plate rolling forming device.

[0045] Figure 3 This is a left view of the copper plate rolling forming device.

[0046] Figure 4 This is a magnified view of part M in the BB cross-sectional view of the copper plate rolling forming device.

[0047] Figure 5 This is a cross-sectional view of the pressure roller.

[0048] Figure 6 It is an assembly drawing showing the assembly of an arc-shaped frame, a symmetrical arc-shaped frame, and reinforcing ribs.

[0049] Figure 7 The left view corresponds to the assembly drawing formed by assembling the arc-shaped frame, the symmetrical arc-shaped frame, and the reinforcing ribs.

[0050] Figure 8 The right view corresponds to the assembly drawing formed by assembling the arc-shaped frame, the symmetrical arc-shaped frame, and the reinforcing ribs.

[0051] Figure 9 This is the front view of the fixed frame.

[0052] Figure 10 This is a CC sectional view of the fixed frame.

[0053] Figure 11 This is a partial enlarged view of the main view P of the fixed frame.

[0054] Figure 12 This is a partial enlarged view of the main view Q of the fixed frame.

[0055] Figure 13 This is a 3D diagram of a copper plate rolling forming device.

[0056] In the diagram: 1. Shaft; 2. Steel cylinder bearing seat; 3. First arc-shaped frame; 4. Fixed frame; 5. Pressure roller; 6. Second arc-shaped frame; 7. Countersunk screw; 8. Copper cylinder formed by rolling copper plate; 9. Reinforcing rib; 11. Screw; 12. Spring; 13. Second arc-shaped frame fixing plate; 14. Steel cylinder; 15. First arc-shaped frame fixing plate; 16. Pressure roller bearing seat; 17. Spring washer; 18. First arc-shaped frame slider; 19. Second arc-shaped frame slider; 20. Arc-shaped frame mounting plate. Detailed Implementation

[0057] This embodiment is a forming device for rolling a copper plate into a circle and combining it with a steel cylinder. It includes a shaft 1, a pressure roller 5, a fixed frame 4, and two arc-shaped frames. Each arc-shaped frame is mounted on the fixed frame 4, with the concave arc surfaces of the two arc-shaped frames facing each other. The two arc-shaped frames are a first arc-shaped frame 3 and a second arc-shaped frame 6. The upper ends of the two supports of the fixed frame each have steel cylinder bearing seats 2, forming axial shaft supports. Both ends of the shaft 1 in the steel cylinder assembly are respectively installed in these steel cylinder bearing seats.

[0058] The steel cylinder assembly is a workpiece formed by rolling a copper plate and bonding it with the copper plate, and also serves as a carrier during the rolling process. The steel cylinder assembly includes a steel cylinder 14 and a shaft 1. End plates are located on both ends of the steel cylinder, and both ends of the shaft 1 are fixedly connected to the center holes of each end plate. The outer diameter of the steel cylinder is the same as the inner diameter of the copper cylinder 8 formed by rolling the copper plate. Both ends of the shaft 1 are mounted in bearing seats within the steel cylinder via bearings.

[0059] The cathode roller steel cylinder serves as the core mold for rolling copper plates, ensuring the inner diameter of the rolled copper plate. The outer circle of the cathode roller steel cylinder is precision machined to have good dimensional and positional tolerances. The outer diameter of the cathode roller steel cylinder is 2670mm, the dimensional tolerance of the outer circle of the cathode roller steel cylinder is ≤0.10mm, the circular runout of the outer circle of the cathode roller steel cylinder is ≤0.05mm, the straightness of the outer circle of the cathode roller steel cylinder is ≤0.05mm, and the roughness of the outer circle of the cathode roller steel cylinder is ≤Ra3.2um, providing a good core mold for rolling copper plates.

[0060] Each of the aforementioned arc-shaped frames is fixed to an arc-shaped frame mounting plate on the fixed frame 4, symmetrically distributed on both sides of the circumference of the steel cylinder, and the inner arc surfaces of the two arc-shaped frames form a spatial circle. Three pressure rollers 5 are respectively mounted on the inner arc surface of each arc-shaped frame, and the two ends of each pressure roller 5 are fixed to the inner surface of the respective arc-shaped support plate. The circumferential surface of each pressure roller is in close contact with the outer surface of the steel cylinder, compressed by a spring; the spring compression is 19mm. When the copper plate is rolled in, the spring compression is 25mm.

[0061] The three pressure rollers located on the second arc-shaped frame 6, clockwise from top to bottom, are the second pressure roller, the first pressure roller, and the sixth pressure roller; the three pressure rollers located on the first arc-shaped frame 3, counterclockwise from top to bottom, are the third pressure roller, the fourth pressure roller, and the fifth pressure roller. The positions of the second and third pressure rollers on the spatial circle are aligned, as are the positions of the first and fourth pressure rollers, and the positions of the sixth and fifth pressure rollers. The center lines of each pressure roller are parallel to the center line of the steel cylinder 14.

[0062] The positions of the three pressure rollers located on the second arc-shaped frame along the circumferential direction are as follows: the angle β1 between the spatial line connecting the center of the first pressure roller and the center of the cathode roller steel cylinder and the horizontal line is 10~15°; the angle β2 between the spatial line connecting the center of the second pressure roller and the center of the cathode roller steel cylinder and the horizontal line is 40~55°; and the angle β6 between the spatial line connecting the center of the sixth pressure roller and the center of the cathode roller steel cylinder and the horizontal line is -20~-30°.

[0063] In this embodiment, the positions of the three pressure rollers located on the second arc-shaped frame along the circumferential direction are as follows: the angle β1 between the spatial line connecting the center of the first pressure roller and the center of the cathode roller steel cylinder and the horizontal line is 10°; the angle β2 between the spatial line connecting the center of the second pressure roller and the center of the cathode roller steel cylinder and the horizontal line is 40°; and the angle β6 between the spatial line connecting the center of the sixth pressure roller and the center of the cathode roller steel cylinder and the horizontal line is -20°.

[0064] The positions of the three pressure rollers located on the first arc-shaped frame along the circumferential direction are as follows: the angle β1 between the spatial line connecting the center of the fourth pressure roller and the center of the cathode roller steel cylinder and the horizontal line is 10~15°; the angle β2 between the spatial line connecting the center of the third pressure roller and the center of the cathode roller steel cylinder and the horizontal line is 40~55°; and the angle β6 between the spatial line connecting the center of the fifth pressure roller and the center of the cathode roller steel cylinder and the horizontal line is -20~-30°.

[0065] In this embodiment, the positions of the three pressure rollers located on the first arc-shaped frame along the circumferential direction are as follows: the angle β1 between the spatial line connecting the center of the fourth pressure roller and the center of the cathode roller steel cylinder and the horizontal line is 10°; the angle β2 between the spatial line connecting the center of the third pressure roller and the center of the cathode roller steel cylinder and the horizontal line is 40°; and the angle β6 between the spatial line connecting the center of the fifth pressure roller and the center of the cathode roller steel cylinder and the horizontal line is -20°.

[0066] At the beginning and end of the copper plate rolling, 50mm from the short side and 50mm from the end face of the long side, 12 90° countersunk holes are evenly distributed. The depth of each 90° countersunk hole is t / 2, where t is the thickness of the copper plate. The center of each 90° countersunk hole is a φ7 through hole, which facilitates the use of countersunk screws 7 to fasten the copper plate to the outer surface of the cathode roller steel cylinder when rolling the copper plate. At the end of the copper plate rolling, countersunk screws are used to fasten the end of the copper plate to prevent the copper plate from loosening and to facilitate the welding of the copper plate at the end to form a complete circle.

[0067] The copper plate pressing is achieved by multiple sets of pressure rollers. After the copper plate rolling begins, it passes sequentially through the first, second, and sixth pressure rollers. These six sets of rollers are adjusted to be parallel to the center line of the outer circumference of the steel cylinder, with a parallelism ≤0.10mm. The six sets of rollers are parallel to each other and are all used to press the copper plate. The pressure rollers can be designed with a stepped shaft structure to press copper plates of different thicknesses rolled onto the surface of the steel cylinder. When the copper plate enters each pressure roller, it enters along the weld bevel, which acts as a guide. Under the pressing force of the rollers, the copper plate undergoes elastic-plastic deformation, tightly adhering to the outer surface of the steel cylinder. Because the pressure rollers provide compressive force for the spring compression, the pressing force of the rollers on the copper plate is a flexible, not rigid, pressing force. Although there are thickness and radial errors in the thickness direction of the copper plate, under the flexible pressing force of the rollers, the rollers can effectively press the copper plate onto the outer surface of the steel cylinder.

[0068] The first arc-shaped frame 3 consists of a pair of arc-shaped base plates and supports. The radius of the base plates is the same as the radius of the steel cylinder. The lower end of the base plate has a support, which is located on one side of the convex arc surface of the base plate. On the outer surface of the support base plate, there is a protruding first arc-shaped frame slider 18; the first arc-shaped frame slider is fixedly connected to the arc-shaped frame mounting plate 20 on one side of the fixed frame 4. The base plates are fixed together by pressure rollers; there are reinforcing ribs 9 between the base plates.

[0069] The second arc-shaped frame 6 consists of a pair of arc-shaped base plates and supports. The radius of the base plates is the same as the radius of the steel cylinder. The lower end of the base plate has a support, which is located on one side of the convex arc surface of the base plate. There is a protruding second arc-shaped frame slider 19 on the outer surface of the support base plate; the second arc-shaped frame slider is fixedly connected to the arc-shaped frame mounting plate 20 on the other side of the fixed frame 4. The base plates are fixedly connected as a whole by the pressure rollers; there are reinforcing ribs 9 between the base plates. The reinforcing ribs 9 are used to strengthen the rigidity and strength of the structure composed of the first arc-shaped frame 3, the second arc-shaped frame 6 and the pressure rollers 5, so that when the copper plate is rolled into a circle on the outer surface of the steel cylinder, the pressure rollers can tightly and reliably press the copper plate, so that the copper plate is tightly wrapped around the outer circle of the steel cylinder. The reinforcing ribs 9 are made of I-beams or channel steel, and the material is carbon steel. Rectangular steel plates are welded to both sides of the I-beams to facilitate drilling holes in the rectangular steel plates for assembly onto the first arc-shaped frame 3 and the second arc-shaped frame 6. To ensure the dimensional stability of the reinforcing rib, stress-relief annealing or artificial aging must be performed after the I-beam is welded to the steel plates on both sides to eliminate the stress generated by welding and ensure the dimensional stability of the reinforcing rib 9.

[0070] The fixed frame 4 includes a pair of trapezoidal frames; the lower ends of each trapezoidal frame are fixedly connected by a base plate, forming a rectangular frame structure. The upper surface of each trapezoidal frame is used to install the steel cylinder bearing seat 2. On the outer surfaces of both sides of each trapezoidal frame are arc-shaped frame mounting plates 20 for installing each arc-shaped frame; these mounting plates have grooves, and each groove is perpendicular to the center line of its respective arc-shaped frame. The first arc-shaped frame 3 and the second arc-shaped frame 6 are located on both sides of the fixed frame, and the first arc-shaped frame slider 18 and the second arc-shaped frame slider 19 are respectively inserted into the grooves, allowing each arc-shaped frame to move horizontally along the grooves. When the cathode roller steel cylinder is placed into or lifted out of the fixed frame 4, each arc-shaped frame moves along the grooves away from the working position a sufficient distance to ensure that the steel cylinder with the rolled copper cylinder can be lifted vertically. Each arc-shaped frame moves an appropriate distance of 150mm and stops, then is locked to the fixed frame. Before the copper plate is rolled into shape, each arc-shaped frame moves along the grooves to the working position and is locked in place by screws. Each arc-shaped frame uses a sliding groove structure to ensure that the parallelism between the pressure roller and the cathode roller steel cylinder does not change before and after each arc-shaped frame moves, so that the parallelism between the pressure roller and the steel cylinder generatrix is ​​maintained when the next steel cylinder rolls the copper plate.

[0071] The pressure roller 5 is used to achieve a tight fit between the copper plate and the surface of the cathode roller steel cylinder. The pressure roller 5 is a solid steel shaft, made of 45 steel or 40Cr, and is heat-treated to improve the overall mechanical properties of each pressure roller and obtain sufficient rigidity. The surface of each pressure roller is knurled to increase the friction between the pressure roller and the copper plate, so that the pressure roller can firmly press the copper plate against the outer circumference of the steel cylinder 14.

[0072] The pressure roller has two connecting ends, each of which is installed in a cylindrical roller bearing and fixed to the pressure roller bearing seat 16. The diameter of the pressure roller is 50~60mm, and the diameter of the connecting ends is 25~30mm.

[0073] The pressure roller bearing seat is pressed by a spring 12. The spring is fitted onto a screw 11, with one end pressing against the pressure roller bearing seat 16, and the other end of the screw passing through a spring washer 17 and mounted on a first arc-shaped frame fixing plate 15 or a second arc-shaped frame fixing plate 13.

[0074] When the assembled pressure roller presses the copper plate, the pressure roller rotates within the pressure roller bearing seat 16, so that the copper plate can be evenly pressed onto the surface of the steel cylinder.

[0075] The spring 12 is a helical compression spring made of 65Mn steel with a wire diameter of 2.5mm, a spring mean diameter of 18mm, an effective number of turns of 20, a free height H0 = 100mm, and a single-turn load of 234.58N. Each pressure roller 5 has two springs at each end, and the clamping force is controlled by adjusting the spring compression. The spring is compressed to 10 turns, with a single spring generating a clamping force of 2345.8N. The two springs at each end of the pressure roller generate a flexible clamping force of 4691.6N, thereby pressing the copper plate firmly against the surface of the cathode roller's steel cylinder.

[0076] Each spring 12 applies pressure to the pressure roller bearing seat 16 via a spring seat. There are multiple spring seats. Each spring seat includes a spring pad 17 and two screws 11; each spring pad has through holes at both ends for mounting the screws. The upper ends of the two screws 11 pass through screw holes on the first arc-shaped frame fixing plate 15 and the spring pad, respectively, and the lower ends pass through screw holes on the pressure roller bearing seat, thereby fixing the pressure roller to the arc-shaped frame. Each spring 12 is fitted onto its respective screw 11 and is located between the spring pad and the pressure roller bearing seat.

Claims

1. A copper sheet coiling and forming apparatus characterized by, The assembly includes a pressure roller, a fixed frame, two arc-shaped frames, and a steel cylinder assembly. Each arc-shaped frame is mounted on the fixed frame, with the inner arc surfaces of the two arc-shaped frames facing each other. The two arc-shaped frames are a first arc-shaped frame and a second arc-shaped frame, respectively. The upper ends of the two supports of the fixed frame are respectively provided with steel cylinder bearing seats, forming axial shaft support members. The steel cylinder assembly includes a steel cylinder and a shaft, with end plates on the end faces of the steel cylinder. The two ends of the shaft in the steel cylinder assembly are respectively mounted in the steel cylinder bearing seats. Each of the arc-shaped frames is fixed to the arc-shaped frame mounting plate on the fixed frame, symmetrically distributed on both sides of the circumference of the steel cylinder, and the inner arc surfaces of the two arc-shaped frames form a spatial circle; there are three pressure rollers on the inner arc surface of each arc-shaped frame, and the two ends of the three pressure rollers are fixed to the inner surface of each arc-shaped frame; the circumferential surface of each pressure roller is in close contact with the outer surface of the steel cylinder and is pressed by a spring; Each pressure roller has two springs at both ends. The clamping force is controlled by adjusting the spring compression. The spring compression is 10 turns, and a single spring generates a clamping force of 2345.8 N. The three pressure rollers located on the second arc-shaped frame, clockwise from top to bottom, are the second pressure roller, the first pressure roller, and the sixth pressure roller; the three pressure rollers located on the first arc-shaped frame, counterclockwise from top to bottom, are the third pressure roller, the fourth pressure roller, and the fifth pressure roller; the second and third pressure rollers are positioned correspondingly on the spatial circle, the first and fourth pressure rollers are positioned correspondingly on the spatial circle, and the sixth and fifth pressure rollers are positioned correspondingly on the spatial circle; the center lines of each pressure roller are parallel to the center line of the steel cylinder. The steel cylinder is a workpiece that is rolled into a circle and combined with a copper plate, and also serves as a carrier when the copper plate is rolled into a circle; the two ends of the shaft in the steel cylinder assembly are respectively mounted in the steel cylinder bearing housing through bearings. The three pressure rollers located on the second arc-shaped frame are positioned along the circumference as follows: the angle β1 between the spatial line connecting the center of the first pressure roller and the center of the steel cylinder and the horizontal line is 10~15°; the angle β2 between the spatial line connecting the center of the second pressure roller and the center of the steel cylinder and the horizontal line is 40~55°; and the angle β6 between the spatial line connecting the center of the sixth pressure roller and the center of the steel cylinder and the horizontal line is -20~-30°.

2. The copper sheet coiling and forming apparatus of claim 1 wherein, The three pressure rollers located on the first arc-shaped frame are positioned along the circumference as follows: the angle β1 between the spatial line connecting the center of the fourth pressure roller and the center of the steel cylinder and the horizontal line is 10~15°; the angle β2 between the spatial line connecting the center of the third pressure roller and the center of the steel cylinder and the horizontal line is 40~55°; and the angle β6 between the spatial line connecting the center of the fifth pressure roller and the center of the steel cylinder and the horizontal line is -20~-30°.

3. The copper plate rolling forming device as described in claim 1, characterized in that, The outer diameter tolerance of the steel cylinder is ≤0.10mm, the outer diameter runout is ≤0.05mm, the outer diameter straightness is ≤0.05mm, and the outer circumferential surface roughness is ≤Ra3.2um.

4. The copper plate rolling forming device as described in claim 1, characterized in that, The steel cylinder has two rows of fixing holes, and the distribution of each fixing hole corresponds to the position of the fixing holes on the two short sides of the copper plate to be rolled.

5. The copper plate rolling forming apparatus as described in claim 1, characterized in that, The first and second arc-shaped frames have the same structure, both consisting of a support and a pair of arc-shaped base plates; the radius of the base plate is the same as the radius of the steel cylinder; the lower end of the base plate has a support, which is located on one side of the convex arc surface of the base plate; there is a protruding arc-shaped frame slider on the outer surface of the base plate of the support; the arc-shaped frame slider is fixedly connected to the arc-shaped frame mounting plate on one side of the fixed frame; the base plates are fixedly connected as a whole by each pressure roller; there are reinforcing ribs between each base plate.

6. The copper plate rolling forming apparatus as described in claim 5, characterized in that, The fixed frame includes a pair of trapezoidal frames; the lower ends of each trapezoidal frame are fixedly connected by a base plate to form a rectangular frame structure; the upper surface of each trapezoidal frame is used to install the steel cylinder bearing seat; the outer surfaces of both sides of each trapezoidal frame have arc frame mounting plates for installing each arc frame; the arc frame mounting plate has a sliding groove, and each sliding groove is perpendicular to the center line of the arc frame; the sliders of each arc frame are respectively installed into the sliding grooves, so that each arc frame can move horizontally along the sliding grooves.

7. The copper plate rolling forming apparatus as described in claim 1, characterized in that, Each spring applies pressure to the pressure roller bearing seat through a spring seat. Each spring seat includes a spring washer and two screws. Each spring is fitted onto the screw and located between the spring washer and the pressure roller bearing seat, so that the spring presses the pressure roller bearing seat tightly. Each spring washer has screw holes at both ends for mounting the screws. The upper ends of the two screws pass through the screw holes on the arc frame fixing plate and the spring washer, respectively, and the lower ends of the two screws pass through the screw holes on the pressure roller bearing seat, thereby fixing the pressure roller to the arc frame.

8. The copper plate rolling forming apparatus as described in claim 1, characterized in that, The spring is made of 65Mn steel with a wire diameter of 2.5mm, a spring mean diameter of 18mm, an effective number of coils of 20, a free height H0=100mm, and a single coil load of 234.58N.

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