A method for repairing a liquid leakage of a cathode roll for electrolytic copper foil

Abstract

The application discloses a liquid leakage repairing method for a cathode roller for electrolytic copper foil, and belongs to the technical field of cathode roller repairing. The method can effectively avoid the risk of hydrogen in the roller during the repairing of the cathode roller, improve the overall safety during the repairing of the cathode roller, and realize the quick and effective repairing of the cathode roller through the adopted welding repairing. The liquid leakage repairing method for the cathode roller for electrolytic copper foil comprises the following steps: laser cleaning residual copper sulfate and oxide scales on a titanium side plate, punching through air holes on both sides of a shaft head of the cathode roller, then introducing inert gas to replace hydrogen, opening a manhole on the side plate, carrying out rust removal treatment on the inside of the cathode roller, carrying out weight matching on the cathode roller to ensure the balance degree, using a milling machine to process the titanium plate, the copper plate and the steel plate into a titanium round plate, a copper round plate and a steel round plate, using automatic welding equipment to sequentially weld the steel round plate, the copper round plate and the titanium round plate, manually welding the side plate at a defective position, completing the liquid leakage repairing, and transferring to other procedures.

Description

Technical Field

[0001] This invention belongs to the field of cathode roller repair technology, specifically relating to a method for repairing leakage in a cathode roller used for electrolytic copper foil. Background Technology

[0002] In the production of electrolytic copper foil, the cathode roller undoubtedly plays a crucial role. As one of the core pieces of equipment in the electrolytic copper foil production line, the cathode roller not only undertakes the task of reducing copper ions and converting them into metallic copper, but is also a key link in the continuous production of copper foil. However, the working environment of the cathode roller is quite harsh, as it is immersed in highly corrosive electrolyte for extended periods, making the side plates of the cathode roller susceptible to corrosion. As an important component of the cathode roller, the integrity of the side plates directly affects the overall performance of the cathode roller. Under the continuous erosion of the electrolyte, weak points such as welds on the side plates gradually become fragile, leading to cracks or defects. These cracks and defects act like tiny gateways, allowing the electrolyte to penetrate into the interior of the cathode roller. Once the electrolyte enters the interior of the cathode roller, it not only wastes electrolyte and increases production costs, but more importantly, it also affects the quality and yield of the electrolytic copper foil.

[0003] The accumulation of electrolyte inside the cathode roller gradually forms solid crystals. These crystals not only occupy the internal space of the cathode roller but may also block the flow channels, hindering the flow of electrolyte. More seriously, when the electrolyte reacts with the metal inside the cathode roller, it produces a large amount of hydrogen gas. Hydrogen is a flammable and explosive gas, and its presence poses a significant safety hazard to the maintenance of the cathode roller.

[0004] Currently, no publicly available patents propose effective repair methods for the leakage problem of cathode rollers used in electrolytic copper foil production. This is mainly due to the complexity and unique nature of the leakage problem, making traditional repair methods ineffective. Therefore, effectively solving the leakage problem of cathode rollers has become an urgent problem to be solved in the production process of electrolytic copper foil. To solve this problem, it is necessary not only to conduct in-depth research on the material, structure, and working environment of the cathode roller, but also to combine advanced materials and process technologies to explore more efficient and safer repair methods. Therefore, a highly safe, simple to operate, effective, and stable repair method for the leakage of cathode rollers used in electrolytic copper foil is needed to assist in solving this problem. Summary of the Invention

[0005] (1) Technical problems to be solved

[0006] To address the shortcomings of existing technologies, the present invention aims to provide a method for repairing leakage in cathode rollers used in electrolytic copper foil. This method effectively avoids the risks posed by hydrogen gas inside the roller during repair by using an opening method, minimizing the possibility of hydrogen explosions during subsequent repairs and improving the overall safety of cathode roller repair. Furthermore, the welding repair method enables rapid and effective repair of the cathode roller, quickly locating and sealing the leakage point with minimal repair time and minimal impact on production. Welding repair is applicable to various types and specifications of cathode rollers, both large and small, demonstrating strong adaptability. Compared to replacing the entire cathode roller, welding repair is less costly and faster, reducing economic losses caused by downtime.

[0007] (2) Technical solution

[0008] To address the aforementioned technical problems, this invention provides a method for repairing leakage in a cathode roller used for electrolytic copper foil. This method includes the following steps:

[0009] S1. Place the electrolytic copper foil on the support frame using a cathode roller and fix it in place;

[0010] S2. Impurities on the titanium side plate are cleaned by laser cleaning, and the parts to be processed are polished by a grinding machine.

[0011] S3. Open the ventilation holes on both sides of the cathode roller shaft head, and open the corresponding number and size of holes on the side plate of the cathode roller according to the different sizes of the cathode roller. The holes include air inlet holes and air outlet holes.

[0012] S4. Rotate the cathode roller and adjust it to the specified state. Inert gas is introduced into the cathode roller to replace the hydrogen. The hydrogen needs to be replaced to a safe concentration within a certain period of time. After the safe concentration is reached, the state of the cathode roller is adjusted again.

[0013] S5. Draw the area containing all the holes on the titanium side plate, and make a manhole of the corresponding size in the area. Then make manholes of the same size on the copper side plate and the steel side plate in sequence.

[0014] S6. Clean the electrolyte solid crystals and other impurities inside the cathode roller, and perform rust removal treatment on the inside of the cathode roller.

[0015] S7. Use the dye penetrant method to inspect the side plates and welds, and determine whether there are defects such as porosity and slag inclusions.

[0016] S8. Add counterweights to the cathode roller to ensure its balance;

[0017] S9. Measure, mark and cut the titanium plate, copper plate and steel plate respectively, and cut out titanium plate, copper plate and steel plate of corresponding size;

[0018] S10. Weld the steel plate, copper plate and titanium plate in sequence;

[0019] S11. Use dye penetrant testing to detect welding defects in titanium round plate welds and manually welded welds;

[0020] S12. After the leak is repaired, proceed to other processes.

[0021] As a further preferred embodiment, the impurities on the titanium side plate in S2 include residual copper sulfate and oxide scale, etc., and the parts in S2 that need to be processed include weld seams, cracks, and areas with potential hazards.

[0022] As a further preferred embodiment, S3 has one exhaust port located at the outer edge of the cathode roller, and S3 has 2-4 air inlets.

[0023] As a further preferred embodiment, the diameter range of the exhaust port and the air inlet port is 10-25mm and is denoted as φ1, and the air inlet port is within the range of 400-600mm of the exhaust port, denoted as φ2.

[0024] As a further preferred embodiment, the specified state in S4 refers to moving the cathode roller exhaust hole to the top to facilitate the subsequent replacement of hydrogen gas, and the secondary state of the cathode roller in S4 is that all holes in the side plate are moved to the bottom.

[0025] As a further preferred embodiment, the safe concentration of hydrogen in S4 is <1.5%.

[0026] As a further preferred embodiment, the color penetration method in S7 includes the following steps:

[0027] A1. Spray penetrant on the side plates and welds, then let it stand for a period of time;

[0028] A2. Use a cleaning agent to remove the surface penetrant, and allow it to dry for a period of time;

[0029] A3. After drying, apply developer to the side plates and welds, and wait for a period of time;

[0030] A4. Based on the location of the imaging, mark the locations of cracks and potential hazards;

[0031] A5. Use titanium welding rods to weld and repair cracks and potential hazards.

[0032] As a further preferred embodiment, the settling time in A1 is 15-20 minutes, the drying time in A2 is 8-10 minutes, and the waiting time in A3 is 3-5 minutes.

[0033] As a further preferred embodiment, the steel plate and copper plate in S9 are both round plates with a diameter of φ2-3mm and a bevel, and this dimension is denoted as φ3; the titanium plate is a round plate with a diameter of φ2+20mm, and this dimension is denoted as φ4.

[0034] As a further preferred embodiment, the welding in S10 includes the following steps:

[0035] B1. Grinding and polishing of steel plates, copper plates and titanium plates that need to be processed before welding;

[0036] B2. The sheet metal is initially fixed by manually spot welding four points;

[0037] B3. After initial fixation, the entire plate is welded together using an automatic welding machine.

[0038] (3) Beneficial effects

[0039] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0040] The present invention can effectively avoid the risks of hydrogen gas inside the cathode roller when repairing the cathode roller by using the opening method, and minimize the possibility of hydrogen gas causing explosions during subsequent repairs, thereby improving the overall safety of cathode roller repair.

[0041] The present invention utilizes welding repair, which enables rapid and effective repair of cathode rollers. It can quickly locate and seal leakage points, and the repair time is short, with minimal impact on production. At the same time, welding repair is applicable to various types and specifications of cathode rollers, whether large or small, with strong overall adaptability. Compared to replacing the entire cathode roller, welding repair is less costly and has a shorter repair time, which can reduce economic losses caused by downtime.

[0042] This invention, through multiple tests using the dye penetrant method before and after repair, can accurately pinpoint the leak while ensuring complete sealing of the leak point after welding repair. The weld joint is strong and has good sealing performance, thus effectively preventing the recurrence of leakage problems. Using high-performance corrosion-resistant titanium as the main material for welding repair can give the weld joint high strength and corrosion resistance, enabling long-term stable operation in harsh electrolytic environments and extending the service life of the cathode roller.

[0043] In summary, the cathode roller welding repair solution provided in this application aims to achieve efficient, stable, and reliable repair results by selecting suitable welding materials, introducing advanced welding technology and equipment, and emphasizing quality control and inspection. This will help reduce production interruptions and equipment damage caused by cathode roller leakage, thereby improving production efficiency and economic benefits. Attached Figure Description

[0044] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0045] Figure 1 This is a flowchart of the method of the present invention;

[0046] Figure 2 This is a side view of the cathode roller of the present invention with a manhole.

[0047] Figure 3 This is a layer diagram showing the relationship between the titanium plate, copper plate, and steel plate in this invention;

[0048] Figure 4 This is a schematic diagram of the structure of the present invention when sealing a manhole;

[0049] Figure 5 This is a cross-sectional view of the cathode roller side plate after welding is completed according to the present invention.

[0050] Figure descriptions: 1. Titanium side plate; 2. Manhole; 3. Titanium plate; 4. Copper plate; 5. Steel plate. Detailed Implementation

[0051] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0052] like Figure 1 As shown, this specific embodiment is a method for repairing leakage in a cathode roller used for electrolytic copper foil. The method includes the following steps:

[0053] S1. Place the electrolytic copper foil on the support frame using a cathode roller and fix it in place;

[0054] S2. The impurities on the titanium side plate 1 are cleaned by laser cleaning, and the parts to be processed are polished by a grinding machine.

[0055] S3. Open the ventilation holes on both sides of the cathode roller shaft head, and open the corresponding number and size of holes on the side plate of the cathode roller according to the different sizes of the cathode roller. The holes include air inlet holes and air outlet holes.

[0056] S4. Rotate the cathode roller and adjust it to the specified state. Inert gas is introduced into the cathode roller to replace the hydrogen. The hydrogen needs to be replaced to a safe concentration within a certain period of time. After the safe concentration is reached, the state of the cathode roller is adjusted again.

[0057] S5. Draw the area containing all the holes on the titanium side plate 1, and open a manhole 2 of the corresponding size in this area (e.g., Figure 2 and Figure 3 (as shown), and then make manholes 2 of the same size on the copper side plate and the steel side plate in sequence;

[0058] S6. Clean the electrolyte solid crystals and other impurities inside the cathode roller, and perform rust removal treatment on the inside of the cathode roller.

[0059] S7. Use the dye penetrant method to inspect the side plates and welds, and determine whether there are defects such as porosity and slag inclusions.

[0060] S8. Add counterweights to the cathode roller to ensure its balance;

[0061] S9. Measure, mark and cut the titanium plate 3, copper plate 4 and steel plate 5 respectively, and cut out titanium plate 3, copper plate 4 and steel plate 5 of corresponding size;

[0062] S10. Weld the steel plate 5, copper plate 4, and titanium plate 3 in sequence (e.g., ...). Figure 4 and Figure 5 (as shown);

[0063] S11. Use dye penetrant testing to detect welding defects in titanium round plate welds and manually welded welds;

[0064] S12. After the leak is repaired, proceed to other processes.

[0065] Specifically, the following embodiments are included.

[0066] Example 1: Includes the following steps:

[0067] Step 1: Place the electrolytic copper foil on the support frame using a cathode roller and fix it in place;

[0068] Step 2: Laser cleaning of residual copper sulfate and oxide scale on titanium side plate 1, and grinding treatment of weld seams, cracks and potential hazards. The process parameters of the laser cleaning machine are: laser line width of 50mm, laser pulse frequency of 3KHz, power adjustment range of 40%, fiber length of 8m, and minimum bending radius of fiber of 200mm.

[0069] Step 3: Open the ventilation holes on both sides of the cathode roller shaft head, drill a hole with a diameter of 25mm at the edge of the cathode roller side plate, and drill 3 more holes of the same size within a 600mm diameter range near this hole;

[0070] Step 4: Rotate the cathode roller to move the holes at the edge to the top, and then introduce nitrogen gas into the cathode roller through the other holes for 28 hours;

[0071] Step 5: Detect the hydrogen concentration. The hydrogen concentration is measured to be 1.1%. Rotate the hole downwards.

[0072] Step 6: Draw the area containing all the 25mm holes. First, make a 600mm diameter hole in this area on the titanium side plate 1. Then, make the same size hole 2 on the copper side plate and the steel side plate in sequence.

[0073] Step 7: Clean the electrolyte solid crystals and other impurities inside the cathode roller, and perform rust removal treatment on the inside of the cathode roller;

[0074] Step 8: Use the dye penetrant method to inspect the side plates and welds to determine whether there are defects such as porosity and slag inclusions. Spray penetrant on the side plates and welds, and then let it stand for 18 minutes.

[0075] Step 9: Use a cleaning agent to remove the surface penetrant, and wait 8 minutes;

[0076] Step 10: Apply developer to the side plates and welds, and wait 5 minutes;

[0077] Step 11: Based on the location of the imaging, mark the locations of cracks and potential hazards;

[0078] Step 12: Use titanium welding rods to weld and repair cracks and potential hazards;

[0079] Step 13: Add counterweights to the cathode roller to ensure its balance;

[0080] Step Fourteen: Measure, mark and cut the titanium plate 3, copper plate 4 and steel plate 5 respectively, and cut out steel round plate with a diameter of 597mm and a 30° bevel, copper round plate and titanium round plate with a diameter of 620mm.

[0081] Step 15: Repair the steel plate layer by welding with steel welding rods and steel round plates. First, manually spot weld four points for fixation; then use automatic welding to weld the entire circle of the steel round plate. The process parameters of the automatic welding equipment are: welding current 500A, welding voltage 34V, welding speed 300mm / min, wire feed speed 350mm / min. The parameters of the subsequent copper and titanium round plate welding equipment are the same as above.

[0082] Step 16: Use copper welding rods and copper round plates to weld and repair the copper plate layer. First, manually spot weld four points for fixation, and then use automatic welding to weld the entire circle of the copper round plate.

[0083] Step 17: Use titanium welding rods and titanium round plates to weld and repair titanium side plate 1. First, manually spot weld the titanium round plate and titanium side plate 1 at the joint, and then use automatic welding to weld the entire circle of titanium round plate.

[0084] Step 18: Spray penetrant onto the repaired weld and let it stand for 15 minutes;

[0085] Step 19: Use a cleaning agent to remove the surface penetrant, and wait 8 minutes;

[0086] Step 20: Apply developer to the weld, wait 4 minutes, and check for any residual penetrating fluid;

[0087] Step 21: After the leak is repaired, proceed to other processes.

[0088] Example 2 includes the following steps:

[0089] Step 1: Place the electrolytic copper foil on the support frame using a cathode roller and fix it in place;

[0090] Step 2: Laser cleaning of residual copper sulfate and oxide scale on titanium side plate 1, and grinding treatment of weld seams, cracks and potential hazards. The process parameters of the laser cleaning machine are: laser line width of 40mm, laser pulse frequency of 3KHz, power adjustment range of 50%, fiber length of 8m, and minimum bending radius of fiber of 200mm.

[0091] Step 3: Open the ventilation holes on both sides of the cathode roller shaft head, drill a hole with a diameter of 22mm at the edge of the cathode roller side plate, and drill two more holes of the same size within a 550mm diameter range near this hole;

[0092] Step 4: Rotate the cathode roller to move the holes at the edge to the top, and then introduce nitrogen gas into the cathode roller through the other holes for 30 hours;

[0093] Step 5: Detect the hydrogen concentration. The hydrogen concentration is measured to be 1.3%. Rotate the hole downwards.

[0094] Step 6: Draw the area containing all the 22mm holes. First, make a manhole 2 with a diameter of 550mm in this area on the titanium side plate 1. Then, make manholes 2 of the same size on the copper side plate and the steel side plate in sequence.

[0095] Step 7: Clean the electrolyte solid crystals and other impurities inside the cathode roller, and perform rust removal treatment on the inside of the cathode roller;

[0096] Step 8: Use the dye penetrant method to inspect the side plates and welds to determine whether there are defects such as porosity and slag inclusions. Spray penetrant on the side plates and welds, and then let it stand for 15 minutes.

[0097] Step 9: Use a cleaning agent to remove the surface penetrant, and wait 9 minutes;

[0098] Step 10: Apply developer to the side plates and welds, and wait 4 minutes;

[0099] Step 11: Based on the location of the imaging, mark the locations of cracks and potential hazards;

[0100] Step 12: Use titanium welding rods to weld and repair cracks and potential hazards;

[0101] Step 13: Add counterweights to the cathode roller to ensure its balance;

[0102] Step Fourteen: Measure, mark and cut the titanium plate 3, copper plate 4 and steel plate 5 respectively, and cut out steel round plate with a diameter of 547mm and a 30° bevel, copper round plate and titanium round plate with a diameter of 570mm;

[0103] Step 15: Use steel welding rods and steel round plates to weld and repair the steel plate layer. First, manually spot weld four points for fixation, and then use automatic welding to weld the entire circle of the steel round plate. The process parameters of the automatic welding equipment are: welding current 4800A, welding voltage 31V, welding speed 280mm / min, wire feed speed 320mm / min. The parameters of the subsequent copper round plate and titanium round plate welding equipment are the same as above.

[0104] Step 16: Use copper welding rods and copper round plates to weld and repair the copper plate layer. First, manually spot weld four points for fixation, and then use automatic welding to weld the entire circle of the copper round plate.

[0105] Step 17: Use titanium welding rods and titanium round plates to weld and repair titanium side plate 1. First, manually spot weld the titanium round plate and titanium side plate 1 at the joint, and then use automatic welding to weld the entire circle of titanium round plate.

[0106] Step 18: Spray penetrant onto the repaired weld and let it stand for 15 minutes;

[0107] Step 19: Use a cleaning agent to remove the surface penetrant, and wait 9 minutes;

[0108] Step 20: Apply developer to the weld, wait 4 minutes, and check for any residual penetrating fluid;

[0109] Step 21: After the leak is repaired, proceed to other processes.

[0110] All technical features in this embodiment can be freely combined according to actual needs.

[0111] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for repairing leakage in a cathode roller used for electrolytic copper foil, characterized in that, The method for repairing leakage in the cathode roller of electrolytic copper foil includes the following steps: S1. Place the electrolytic copper foil on the support frame using a cathode roller and fix it in place; S2. Impurities on the titanium side plate are cleaned by laser cleaning, and the parts to be processed are polished by a grinding machine. S3. Open the ventilation holes on both sides of the cathode roller shaft head, and open the corresponding number and size of holes on the side plate of the cathode roller according to the different sizes of the cathode roller. The holes include air inlet holes and air outlet holes. S4. Rotate the cathode roller and adjust it to the specified state. Inert gas is introduced into the cathode roller to replace the hydrogen. The hydrogen needs to be replaced to a safe concentration within a certain period of time. After the safe concentration is reached, the state of the cathode roller is adjusted again. S5. Draw the area containing all the holes on the titanium side plate, and make a manhole of the corresponding size in the area. Then make manholes of the same size on the copper side plate and the steel side plate in sequence. S6. Clean the electrolyte solid crystals and other impurities inside the cathode roller, and perform rust removal treatment on the inside of the cathode roller. S7. Use the dye penetrant method to inspect the side plates and welds, and determine whether there are defects such as porosity and slag inclusions. S8. Add counterweights to the cathode roller to ensure its balance; S9. Measure, mark and cut the titanium plate, copper plate and steel plate respectively, and cut out titanium plate, copper plate and steel plate of corresponding size; S10. Weld the steel plate, copper plate and titanium plate in sequence; S11. Use dye penetrant testing to detect welding defects in titanium round plate welds and manually welded welds; S12. After the leak is repaired, proceed to other processes.

2. The method for repairing leakage of a cathode roller for electrolytic copper foil according to claim 1, characterized in that, The impurities on the titanium side plate in S2 include residual copper sulfate and oxide scale. The areas in S2 that need to be processed include weld seams, cracks, and areas with potential hazards.

3. The method for repairing leakage of a cathode roller for electrolytic copper foil according to claim 1, characterized in that, The S3 has one exhaust hole located at the outer edge of the cathode roller, and the S3 has 2-4 air inlets.

4. The method for repairing leakage of a cathode roller for electrolytic copper foil according to claim 3, characterized in that, The diameter of the exhaust port and the air inlet port is 10-25mm and is denoted as φ1. The air inlet port is within the range of 400-600mm of the exhaust port, and the 400-600mm range is denoted as φ2.

5. The method for repairing leakage of a cathode roller for electrolytic copper foil according to claim 1, characterized in that, The specified state in S4 refers to moving the cathode roller exhaust hole to the top to facilitate the subsequent replacement of hydrogen. The secondary state of the cathode roller in S4 is that all holes in the side plate are moved to the bottom.

6. The method for repairing leakage of a cathode roller for electrolytic copper foil according to claim 1, characterized in that, The safe concentration of hydrogen in S4 is <1.5%.

7. The method for repairing leakage of a cathode roller for electrolytic copper foil according to claim 1, characterized in that, The color penetration method in S7 includes the following steps: A1. Spray penetrant on the side plates and welds, then let it stand for a period of time; A2. Use a cleaning agent to remove the surface penetrant, and allow it to dry for a period of time; A3. After drying, apply developer to the side plates and welds, and wait for a period of time; A4. Based on the location of the imaging, mark the locations of cracks and potential hazards; A5. Use titanium welding rods to weld and repair cracks and potential hazards.

8. A method for repairing leakage in a cathode roller for electrolytic copper foil according to claim 7, characterized in that, The settling time in A1 is 15-20 minutes, the drying time in A2 is 8-10 minutes, and the waiting time in A3 is 3-5 minutes.

9. A method for repairing leakage in a cathode roller for electrolytic copper foil according to claim 1, characterized in that, The steel plate and copper plate in S9 are both round plates with a diameter of φ2-3mm and a bevel, and this dimension is recorded as φ3. The titanium plate is a round plate with a diameter of φ2+20mm, and this dimension is recorded as φ4.

10. A method for repairing leakage in a cathode roller for electrolytic copper foil according to claim 1, characterized in that, The welding in S10 includes the following steps: B1. Grinding and polishing of steel plates, copper plates and titanium plates that need to be processed before welding; B2. The sheet metal is initially fixed by manually spot welding four points; B3. After initial fixation, the entire plate is welded together using an automatic welding machine.

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