Ultrathin copper foil and modified resin film online composite coating system

Abstract

The invention discloses an online composite coating system for an ultrathin copper foil and a modified resin film, and relates to the field of composite coating. The unwinding pretreatment module accurately controls tension and speed of a copper foil and a resin film and cleans and activates the copper foil; the coating liquid preparation and supply module adopts a neural network and other liquid control performance and conveying; the precision coating module controls film thickness by combining a bionic runner coating head with temperature; the composite pressing module intelligently controls a temperature roller and performs gradient cooling; the on-line detection and feedback control module carries out multi-modal detection and fusion data high-speed linkage adjustment on each module. Parameters of the ultrathin copper foil and modified resin film composite coating link are accurately controlled, defects are reduced, the film layer quality and adhesive force are improved, the system environment adaptability and stability are enhanced, the production efficiency and the product percent of pass are improved, and the cost is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of composite coating, and in particular to an on-line composite coating system for ultra-thin copper foil and modified resin film. Background Art

[0002] In the fields of electronic information, new energy, etc., the composite coating technology of ultra-thin copper foil and modified resin film is widely used. For example, in scenarios such as the manufacture of lithium battery electrodes and the production of printed circuit boards, the quality of the composite film directly affects the performance and reliability of the product. The traditional composite coating process mostly relies on manual operation or semi-automatic equipment. Manual operation is not only inefficient, but also affected by the experience and technical level of operators, making it difficult to ensure the uniformity and consistency of coating, resulting in a low product qualification rate and unable to meet the needs of large-scale industrial production.

[0003] With the development of automation technology, some enterprises have adopted some on-line composite coating equipment. However, there are many technical problems in the existing on-line composite coating system. In the unwinding pretreatment link, the tension and speed control of ultra-thin copper foil and modified resin film are not precise enough, which easily leads to stretching deformation or wrinkles of the material, affecting the subsequent coating quality. The cleaning and activation treatment effect on the copper foil surface is not good, resulting in insufficient adhesion between the coating and the copper foil, and the coating is prone to peeling off during use. In terms of coating solution preparation and supply, traditional equipment is difficult to accurately control the composition and performance of the coating solution, unable to adjust in time according to different production requirements, and prone to pressure fluctuations during the transportation process, affecting the stability and uniformity of coating.

[0004] In the coating and composite pressing process, the existing technology has problems of low film thickness control accuracy and difficult precise adjustment of composite pressure and temperature. For materials such as ultra-thin copper foil and modified resin film that are sensitive to process parameters, small parameter deviations may cause defects such as bubbles, scratches, and missing plating on the composite film, reducing the product quality. At the same time, the on-line detection link can often only perform single-dimensional detection, unable to comprehensively and timely monitor the quality of the composite film. When quality problems are found, a large number of products have been scrapped, resulting in increased production costs. With the continuous improvement of the industry's requirements for product quality and production efficiency, there is an urgent need for an on-line composite coating system for ultra-thin copper foil and modified resin film with high precision, intelligence and adaptable to different production requirements. Summary of the Invention

[0005] The on-line composite coating system for ultra-thin copper foil and modified resin film proposed by the present invention is to solve the problems mentioned in the above prior art.

[0006] To achieve the above object, the present invention adopts the following technical solution: An on-line composite coating system for ultra-thin copper foil and modified resin film, comprising: Unwinding Pretreatment Module: The ultra-thin copper foil unwinding unit adopts an adaptive constant tension control algorithm combined with fuzzy PID control technology, adjusts the tension through formulas, and is processed by variable-frequency ultrasonic technology and a plasma treatment device. The modified resin film unwinding unit adopts an intelligent speed compensation algorithm, and adjusts the unwinding speed in real time according to the film thickness change and stretching characteristics through formulas; Coating Solution Preparation and Supply Module: The coating solution is prepared in a closed stirring kettle, and a double planetary double-power stirrer is used. The stirring speed is dynamically adjusted by a neural network algorithm, and the viscosity and density of the coating solution are monitored in real time. When the threshold is exceeded, the adjustment amount is calculated by a formula and automatically added for adjustment. After the coating solution is filtered, it is transported to the coating head, and the pressure fluctuation compensation technology is used to stabilize the pressure during the transportation process; Precision Coating Module: A slot die coating head is adopted, and the internal flow channel is designed with a bionic micro-channel. The coating thickness is controlled by adjusting the gap between the coating head and the copper foil and combining with formulas. During the coating process, a multi-spectral interference thickness gauge is used to monitor the film thickness in real time. When the detected film thickness deviation exceeds the threshold, the coating solution flow rate and coating conditions are automatically feedback-adjusted; Lamination Module: After coating, the ultra-thin copper foil and the modified resin film are synchronously fed into the lamination roller group. The heating roller uses electromagnetic induction heating, and the cooling roller uses gradient three-stage cooling. The lamination pressure is monitored in real time by a piezoelectric pressure sensor, and the pressure of the hydraulic system is automatically adjusted using a formula; Online Detection and Feedback Control Module: A multi-modal detection device is set up, which integrates machine vision, infrared thermal imaging, and Raman spectroscopy technologies to detect surface defects, internal temperature distribution, and chemical composition of the composite film. The principal component analysis algorithm is combined with a deep learning model to analyze the data. When component deviation defects are detected, the adjustment amount is calculated by a formula and the parameters are feedback-corrected. According to the detection results, the parameters of each module are adjusted through the industrial Ethernet;

[0007] Furthermore, it also includes: Environment Adaptive Module: Temperature, humidity, air quality, and light sensors are set around the system to monitor environmental parameters in real time. When the environmental parameters exceed the set threshold, the adjustment amount is calculated by a formula E adjust is the environmental comprehensive adjustment value, and T, H, A, and L are the actual temperature, humidity, air quality, and light intensity respectively. T set 、H set 、A set 、L set are the set values respectively, and the environmental conditions are automatically adjusted through the air conditioning system, air purification system, and light-shielding device.

[0008] Furthermore, it also includes: Self-Repairing Coating Head Module: The coating head adopts a micro-channel structure. When blockage occurs, the pressure is detected by an internal pressure sensor, and using the formula P blockage =P normalJudge the degree of blockage by +φ×ΔQ, P blockage is the blockage pressure, P normal is the normal pressure, φ is the blockage coefficient, ΔQ is the flow rate change. The system automatically switches to the standby microchannel to continue coating and starts the cleaning program, and uses high-pressure pulse cleaning technology and chemical cleaning agents to clean the microchannel, and verifies the cleaning effect through flow detection.

[0009] Furthermore, in the unwind preprocessing module, the adaptive constant tension is adjusted by the formula T new =T old +K p ×e+K i ×∑e+K d × Adjust, T new is the new tension value, T old is the old tension value, K p 、K i 、K d are the proportional, integral, and differential coefficients of fuzzy PID adaptive adjustment, e is the tension deviation, ∑e is the deviation integral, is the deviation differential; the unwind speed is adjusted by the formula v compensated =v base ×(1+α×Δh+β×Δs), v compensated is the compensated speed, v base is the base speed, α and β are compensation coefficients, Δh is the thickness change, Δs is the stretching change; After ultrasonic cleaning of the copper foil, a plasma activation drying unit is set up. The radio frequency plasma technology is used to remove the residual moisture on the surface of the dried copper foil and activate the surface of the copper foil, and a contact angle measuring instrument is used to monitor the activation effect.

[0010] Furthermore, in the coating solution preparation and supply module, the viscosity and density of the coating solution are calculated for the adjustment amount by the formula V1 and D1 are the actual viscosity and density, V0 and D0 are the set viscosity value and density value, and ΔC is the comprehensive deviation value; the conveying process is calculated for the pressure by the formula P compensated =P base +γ×ΔP, P compensated is the compensated pressure, P base is the base pressure, γ is the compensation coefficient, and ΔP is the pressure fluctuation value; The stirring kettle is provided with an ultrasonic-assisted dispersion device. During the stirring process, the ultrasonic frequency is set to 25 kHz, and the particles in the coating solution are evenly dispersed through the cavitation effect.

[0011] Furthermore, in the precision coating module, the coating thickness is controlled by the formula Control, Let \(d\) be the coating thickness, \(Q\) be the flow rate of the coating solution, \(v\) be the coating speed, \(w\) be the coating width, \(\delta\) be the temperature influence coefficient, \(\Delta T\) be the difference between the actual temperature and the standard temperature, and \(T_0\) be the standard temperature; The coating head is equipped with an intelligent spray assist device. During the coating process, according to the coating speed and film thickness requirements, through the formula \(V\) spray =\(\mu\times v\times\) control the spray volume. \(V\) spray is the spray volume, \(\mu\) is the spray coefficient, \(v\) is the coating speed, is the coating thickness, and the spray liquid is a surfactant solution.

[0012] Furthermore, in the composite pressing module, through the formula \(T\) cooling = \(T\) initial −\(\theta\times t\) to control the cooling process. \(T\) cooling is the temperature after cooling, \(T\) initial is the initial temperature, \(\theta\) is the cooling rate coefficient, and \(t\) is the time; The hydraulic system uses the formula to adjust the pressure. \(F\) is the pressure, \(p\) is the pressure, \(S\) is the contact area, \(\eta\) is the speed influence coefficient, \(\Delta v\) is the speed change, and \(v_0\) is the set speed; The heating roller is internally provided with a microchannel structure, and liquid metal is used for heat transfer. Through the formula calculate the heat conduction efficiency. \(Q\) transfer is the heat transfer amount, \(k\) is the thermal conductivity of the liquid metal, \(A\) is the heat transfer area, \(\Delta T\) is the temperature difference, and \(d\) is the thickness of the microchannel.

[0013] Furthermore, in the on-line detection and feedback control module, through the formula calculate the adjustment amount. \(\Delta A\) is the adjustment parameter, \(a\) i is the weight coefficient, \(\Delta C\) i is the deviation of each detection index; Set up a fault warning and emergency handling unit. Use the Bayesian network algorithm to monitor and analyze the operating parameters of each module of the system. When a potential fault risk is detected, through the formula calculate the fault probability. \(P\) fault is the probability of the fault occurring, \(b\) i is the weight coefficient, \(P\) i is the probability of abnormality of each parameter. When the fault probability exceeds the set threshold, the system issues a warning signal and starts the emergency handling procedure.

[0014] Furthermore, the environment adaptation module adopts an intelligent energy management system, and automatically adjusts the operating parameters of the air conditioning system, air purification system, and shading device according to the environmental adjustment requirements and energy price fluctuations through an optimization algorithm.

[0015] Furthermore, in the self-repairing coating head module, the cleaning program adopts an adaptive cleaning strategy, and automatically selects appropriate cleaning pressure, cleaning time, and cleaning agent formula according to the degree of blockage and the composition of the blockage through a fuzzy decision-making algorithm.

[0016] Compared with the existing technologies, the beneficial effects of the present invention are as follows: In the unwind pre-treatment stage, the high-precision adaptive constant tension control and intelligent speed compensation algorithm effectively avoid the stretching deformation and wrinkling problems of the copper foil and the resin film. At the same time, the special cleaning and activation processes significantly enhance the surface activity of the copper foil, providing a good foundation for subsequent coating and ensuring stronger coating adhesion.

[0017] The coating solution preparation and supply module can accurately control the composition and performance of the coating solution through neural network algorithms and multi-parameter monitoring and adjustment. Combined with the pressure fluctuation compensation technology, it ensures the stability of the coating process. The bionic micro-channel coating head of the precision coating module and the film thickness control method considering temperature effects achieve high-precision adjustment of the coating thickness. With the intelligent spray assist device, coating defects are greatly reduced.

[0018] In the composite pressing module, the intelligent temperature-controlled heating roller, the gradient cooling roller, and the pressure adjustment considering the influence of speed ensure the tight and uniform bonding of the copper foil and the resin film, improving the composite quality. The online detection and feedback control module integrates multi-modal detection technologies, can comprehensively and quickly monitor the quality of the composite film, and combined with the high-speed linkage adjustment mechanism, can timely correct production parameters to avoid the generation of a large number of defective products.

[0019] In addition, innovative designs such as the environment adaptive module and the self-repairing coating head module enhance the adaptability of the system to complex environments and its own stability, reduce the equipment failure risk and maintenance costs, effectively improve the production efficiency and product qualification rate, and provide strong technical support for the development of related industries. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic block diagram of an on-line composite coating system for ultra-thin copper foil and modified resin film proposed by the present invention; Figure 2 It is a schematic diagram for comparing the coating thickness deviation of different systems; Figure 3 It is a schematic diagram showing the change of product qualification rate over time; Figure 4 It is a schematic diagram showing the relationship between production efficiency and energy consumption; Figure 5 It is a schematic diagram for monthly comparison of equipment failure rates. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0021] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0022] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus cannot be understood as a limitation to the present invention.

[0023] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of the described features. In the description of the present invention, "a plurality" means two or more, unless otherwise specifically defined. In addition, the terms "installation", "connection", and "connection" should be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or an integral connection; it may be a mechanical connection or an electrical connection; it may be directly connected or indirectly connected through an intermediate medium, and it may be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations. The present invention will be further described in detail below with reference to the accompanying drawings.

[0024] Refer to Figures 1 to 5 : An on-line composite coating system for ultra-thin copper foil and modified resin film, comprising: Unwinding and preprocessing module: The ultra-thin copper foil unwinding unit selects a magnetic powder brake as the tension control actuator, which forms a closed-loop control system with a tension sensor and a PLC controller. The tension sensor adopts a high-precision strain gauge sensor and is installed at the turning roller of the copper foil unwinding path to monitor the copper foil tension in real time. The PLC controller is built-in with an adaptive constant tension control algorithm, combined with fuzzy PID control technology, according to the formula T new =T old +K p ×e+K i ×∑e+K d × (where Tnew is the new tension value, T old is the old tension value, K p , K i , K d are the proportional, integral, and differential coefficients for fuzzy PID adaptive adjustment. e is the tension deviation, ∑e is the integral of the deviation, is the differential of the deviation). According to the deviation between the set tension value and the actual monitored value, the excitation current of the magnetic powder brake is dynamically adjusted to ensure that the tension fluctuation range is stable within ±0.3 N. After the copper foil is unrolled, it enters the ultrasonic cleaning tank. The cleaning tank is filled with an alkaline cleaning solution with a special formula, and its main components are sodium hydroxide, surfactant, and corrosion inhibitor, with concentrations of 10%, 5%, and 3% respectively. The temperature of the cleaning solution is maintained at 58 ± 1 °C by an electric heating tube in cooperation with a PID temperature controller. The output frequency of the ultrasonic generator changes dynamically between 35 - 45 kHz. The electrical signal is converted into mechanical vibration through an ultrasonic transducer to generate high-frequency ultrasonic waves, forming countless tiny cavitation bubbles in the cleaning solution. The cavitation effect is used to remove impurities such as oil stains and oxides on the surface of the copper foil. After cleaning, the copper foil enters the plasma treatment device. This device uses a radio frequency power supply, and the working gas is a mixture of argon and nitrogen in a volume ratio of 3:1. The treatment power is set at 180 W, and the copper foil passes through the treatment area at a speed of 2 m / min, with a treatment time of 12 s, forming a micro-nano dual-scale rough structure on the surface of the copper foil, significantly improving the surface activity. The unrolling unit of the modified resin film is driven by a servo motor, and a high-precision encoder is connected to the motor shaft end to provide real-time feedback on the change in the roll diameter. The PLC controller runs an intelligent speed compensation algorithm, according to the formula v compensated = v base ×(1 + α × Δh + β × Δs) (where v compensated is the compensated speed, v base is the basic speed, α and β are compensation coefficients, Δh is the thickness change, and Δs is the stretching change), combined with the real-time thickness and stretching characteristics of the film, automatically adjusts the rotational speed of the servo motor to control the unrolling speed error within ±0.1 m / min.

[0025] Coating Solution Preparation and Supply Module: The preparation of the coating solution is carried out in a closed stirring kettle. The stirring kettle adopts a double planetary and double power stirring structure. The inner stirring paddle and the outer stirring paddle are respectively driven by independent servo motors, and can rotate at different speeds and in different directions. Before the stirring starts, the operator inputs the coating solution formula through the touch screen. The system automatically calculates the dosage of each raw material. The operator inputs the coating solution formula (such as the mass ratio of resin to curing agent is 3:1) through the touch screen. The system calls the material ratio algorithm based on the formula database (storing more than 200 groups of historical formula data) and automatically calculates the dosage of each raw material. The metering pump selects a high-precision gear pump (accuracy ±0.5%). The PLC controller outputs a 4-20mA current signal to control the pump speed. For example, when the formula requires transporting 500 mL of epoxy resin, the system calculates the pulse frequency to be 200 Hz, and controls the metering pump to transport at a flow rate of 10 mL / s, with an error ≤ ±1 mL. And it controls the metering pump to accurately transport the raw materials to the stirring kettle. During the stirring process, the PLC controller dynamically adjusts the speeds of the inner and outer stirring paddles through the neural network algorithm according to the rheological characteristics of the coating solution. The speed range is 200 - 800 r / min. An on-line viscometer and a densitometer are installed in the stirring kettle to monitor the viscosity and density of the coating solution in real time. When the deviation between the actual viscosity V1, density D1 and the set values V0, D0 exceeds ±3%, the PLC controller calculates the comprehensive deviation value according to the formula (where V1, D1 are the measured viscosity / density, and V0, D0 are the set values). When ΔC > 5, start the adjustment logic: If the viscosity is too high, add a diluent (ethanol), and the addition amount Q = K × ΔC (unit K = 0.1 mL / unit deviation), and automatically control the metering pump to add diluent, thickener or additive for adjustment. After the stirring is completed, the coating solution is filtered through a three-stage precision filter (the filtration accuracies are 1μm, 0.3μm, 0.05μm in sequence) to remove impurity particles. The filtered coating solution is transported to the coating head by a peristaltic pump. A pressure sensor and a flow sensor are installed on the transport pipeline. The PLC controller adopts the pressure fluctuation compensation technology and calculates according to the formula P compensated = P base + γ × ΔP (where P compensated is the compensated pressure, P base is the basic pressure, γ is the compensation coefficient, and ΔP is the pressure fluctuation value), and adjusts the speed of the peristaltic pump in real time to ensure that the transport pressure is stable at 1.0 - 1.5 MPa.

[0026] Precision Coating Module: The coating head adopts a new microstructured slit design. Its internal flow channel imitates the branching structure of human blood vessels. The size and shape of the flow channel are optimized through CFD (Computational Fluid Dynamics) simulation to ensure the uniform distribution of the coating solution within the coating head. The gap between the coating head and the copper foil is adjusted by an electric lifting mechanism, with an adjustment range of 3 - 40 μm and an accuracy of 0.05 μm. The coating speed is controlled by a servo motor driving the coating roller, with a speed range of 8 - 40 m / min. During the coating process, the system combines the formula (where is the coating thickness, Q is the flow rate of the coating solution, v is the coating speed, w is the coating width, δ is the temperature influence coefficient, ΔT is the difference between the actual temperature and the standard temperature, and T0 is the standard temperature) to precisely control the coating thickness. The system installs a temperature sensor near the coating head to monitor the ambient temperature in real time, and automatically adjusts the rotation speed of the peristaltic pump according to the temperature change to control the flow rate of the coating solution. At the same time, a multi-spectral interference thickness gauge is used to monitor the film thickness in real time. This thickness gauge is installed 10 cm behind the coating head and measures the film thickness at a frequency of 100 Hz. When the detected film thickness deviation exceeds ±2%, the PLC controller automatically feedback-adjusts the rotation speed of the peristaltic pump and the gap of the coating head to achieve closed-loop control of the film thickness. In addition, the coating head is equipped with an intelligent spray assist device. According to the coating speed and film thickness requirements, through the formula V spray = μ × v × (where V spray is the spray volume, μ is the spray coefficient, v is the coating speed, is the coating thickness) to precisely control the ejection volume of the spray liquid (special surfactant solution), improve the leveling and wettability of the coating solution, and reduce coating streaks and orange peel phenomena.

[0027] Composite Laminating Module: The composite roller group consists of an intelligent temperature-controlled heating roller and a gradient cooling roller. The heating roller uses electromagnetic induction heating. An induction coil is set inside, and the current frequency and magnitude are adjusted through a frequency converter to achieve rapid heating. Temperature sensors are evenly distributed on the surface of the heating roller to monitor temperature data in real time. The PLC controller adopts a fuzzy adaptive control algorithm and automatically adjusts the temperature of the heating roller according to the characteristics of the composite material (such as the thickness of the copper foil, the type of modified resin film) and the running speed. The temperature range is 90 - 180 °C, with an accuracy of ±0.5 °C. The cooling roller adopts a three-stage gradient cooling structure, with independent cooling channels inside, through which cooling water at different temperatures is introduced. The temperature range of the first-stage cooling is 30 - 50 °C, the second stage is 20 - 30 °C, and the third stage is 10 - 20 °C. The flow rate of the cooling water is controlled by an electric control valve. The PLC controller is based on the formula T cooling = T initial − θ × t (where T cooling is the temperature after cooling, T initialis the initial temperature, θ is the cooling rate coefficient, and t is the time). According to the running speed and temperature requirements of the composite film, the cooling water flow rate of each section is dynamically adjusted. The cooling water flow rate is controlled by an electric control valve (accuracy ±1%). The three cooling zones correspond to different control logics: The first section (entrance zone): T cooling =T initial −0.5×t. When the running speed v > 20 m / min, the opening of the control valve automatically increases by 10%; The second section (constant temperature zone): It is adjusted by the PID algorithm to keep T cooling = 60°C. When the deviation exceeds ±2°C, the control valve is adjusted at a rate of 5% / s; The third section (exit zone): T cooling =T initial −0.3×t. Combining the real-time data of the infrared temperature sensor (accuracy ±0.5°C), the opening of the control valve is updated every 10 seconds; Gradient cooling is achieved. The composite pressure is provided by a hydraulic system. The pressure output by the hydraulic pump acts on the composite roller after being adjusted by a proportional pressure reducing valve. The system uses a piezoelectric pressure sensor to monitor the composite pressure. The sensor is installed at the bearing seat of the composite roller to feedback the pressure data in real time. When the pressure fluctuation exceeds ±5%, the PLC controller uses the formula F = p×S×(1 + η× ) (where F is the pressure, p is the pressure intensity, S is the contact area, η is the speed influence coefficient, Δv is the speed change amount, and v0 is the set speed), comprehensively considering the influence of speed on the composite pressure, and automatically adjusts the pressure of the hydraulic system to ensure the tight fit of the copper foil and the resin film.

[0028] Online detection and feedback control module: The online multi-modal detection device integrates a line array camera, an infrared thermal imager, and a Raman spectrometer. The resolution of the line array camera is 1200 dpi, and it is combined with a multi-spectral light source to detect defects such as bubbles, scratches, and missing plating on the surface of the composite film; The temperature measurement range of the infrared thermal imager is -20 - 500°C, with an accuracy of ±2°C, and it monitors the internal temperature distribution of the composite film in real time; The Raman spectrometer can analyze the chemical composition and molecular structure of the composite film. The three detection devices work synchronously, and the detection speed is consistent with the production line speed. The detection data is transmitted to an industrial computer, and the computer runs the principal component analysis algorithm combined with a deep learning model to process and analyze the data. When component deviation or defects are detected, the computer is based on the formula (where ΔA is the adjustment parameter, a i is the weight coefficient, ΔC iCalculate the adjustment amount based on the deviation of each detection index (e.g., detect a film thickness deviation of +5% (ΔC1 = 5, weight a1 = 0.5) and a temperature deviation of +3°C (ΔC2 = 3, weight a2 = 0.3), then the adjustment amount ΔA = 0.5×5 + 0.3×3 = 3.4, corresponding to adjusting the coating head gap by -3.4 μm. And send the instruction to the PLC controller through the industrial Ethernet to achieve high-speed linkage adjustment of the parameters of each module, with a response time ≤ 100 ms. At the same time, the system sets up a fault warning and emergency handling unit, which uses the Bayesian network algorithm to monitor and analyze the operating parameters of each module of the system in real time. When a potential fault risk is detected, through the formula (where P fault is the probability of failure, b i is the weight coefficient, P i is the probability of abnormality of each parameter) to calculate the probability of failure. When the probability of failure exceeds the set threshold, the system automatically issues a warning signal and starts an emergency handling procedure, such as automatic shutdown, switching to standby equipment, etc.

[0029] In the present invention, the following modules are further included: Environment adaptive module: Temperature, humidity, air quality and light sensors are set around the system to monitor environmental parameters. When the temperature, humidity, air quality and light intensity exceed the set range, use the formula (E adjust is the comprehensive environmental adjustment value, T, H, A, L are the actual temperature, humidity, air quality, light intensity respectively, T set , H set , A set , L set are the set values respectively) to calculate the adjustment amount. Automatically adjust the environmental conditions through the air conditioning system, air purification system and light shielding device to ensure that the system operates in a stable environment and reduce the influence of environmental factors on the quality of the composite coating.

[0030] In the present invention, the following modules are further included: Self-repairing coating head module: The coating head adopts a replaceable microchannel structure. When the microchannel is blocked, the abnormal increase in pressure is detected by the built-in pressure sensor. Use the formula P blockage = P normal + φ×ΔQ (P blockage is the blocking pressure, P normal is the normal pressure, φ is the blocking coefficient, ΔQ is the flow rate change) to judge the blocking degree. The system automatically switches to the standby microchannel to continue coating and starts the cleaning program. Use high-pressure pulse cleaning technology and chemical cleaning agents to clean the blocked microchannel. After cleaning, verify the cleaning effect through flow detection to ensure the continuous and stable operation of the coating head.

[0031] In the present invention, after the copper foil in the roll pre-treatment module is ultrasonically cleaned, a plasma activation drying unit is provided. Using radio frequency plasma technology, by applying a radio frequency electric field in a specific vacuum chamber, gas is ionized to form plasma. When the copper foil passes through the chamber, the high-energy particles in the plasma collide violently with the water molecules on the surface of the copper foil. The water molecules are quickly decomposed and discharged in gaseous form, thus efficiently drying the surface of the copper foil. By precisely controlling parameters such as radio frequency power, gas flow rate, and chamber pressure, it can be ensured that the residual moisture content on the surface of the dried copper foil is ≤0.05%. During the drying process, the active particles in the plasma react chemically with the atoms on the surface of the copper foil, introducing a large number of active functional groups such as hydroxyl groups and carboxyl groups on the surface. The functional groups significantly increase the surface energy of the copper foil surface, transforming the surface of the copper foil from a relatively inert state to a more active state, providing a more ideal adhesion basis for subsequent coating. To monitor the activation effect in real time and accurately, the system is equipped with a contact angle measuring instrument. The contact angle measuring instrument drops a specific test liquid droplet onto the surface of the copper foil and, using optical imaging and precise algorithms, measures the contact angle of the liquid droplet on the surface of the copper foil in real time. When the contact angle becomes smaller, it indicates that the hydrophilicity of the copper foil surface is enhanced, that is, the surface energy is increased and the activation effect is good; otherwise, it means that the activation degree is insufficient. When it is detected that the activation effect does not meet the expectation, the system automatically adjusts the relevant parameters of the plasma activation drying unit, such as radio frequency power, processing time, etc., to ensure that the surface of the copper foil is always in the best activation state, and thus provides a stable and reliable adhesion guarantee for the subsequent coating process.

[0032] In the present invention, the stirring kettle in the coating solution preparation and supply module is equipped with an ultrasonic-assisted dispersion device. When the stirring kettle is operating normally, it applies ultrasonic waves with a frequency of 25 kHz, generating a unique cavitation effect. When the sound pressure of the ultrasonic wave reaches a certain value, a large number of tiny bubble nuclei will form in the liquid. Under the periodic action of the ultrasonic wave, they will experience a process of rapid growth and sudden closure. At the moment when the bubble closes, an extremely high local pressure and temperature are generated, forming a strong shock wave and micro-jet. The particles in the coating solution are subjected to violent impact and shear forces, and the particles that might originally attract each other and aggregate to form agglomerates are forcibly dispersed by these forces. For example, for nanoparticles of coating materials, they are prone to agglomerate due to the action of van der Waals forces and other forces in the liquid, while the cavitation effect of ultrasonic waves can effectively overcome the acting forces and make the particles evenly distributed in the coating solution. In addition, the ultrasonic-assisted dispersion device is also equipped with intelligent control, which can monitor the dispersion state of the coating solution in real time. By analyzing parameters such as particle size distribution and concentration uniformity, it automatically adjusts the power and action time of the ultrasonic wave. The ultrasonic-assisted dispersion device is equipped with a laser particle size analyzer (detection range 0.1 - 100 μm) and a concentration sensor, and the real-time monitoring data is transmitted to the PLC: When the particle size distribution span > 1.5 μm, the power is automatically increased by 10% (e.g., from 200 W to 220 W); when the concentration uniformity < 95%, the action time is extended by 2 minutes (e.g., from 10 minutes to 12 minutes); the parameters are adjusted through the fuzzy PID algorithm (K p = 0.8, K i = 0.2, K d = 0.1) to achieve smooth adjustment; if it is detected that the particle agglomeration phenomenon has intensified, the system will automatically increase the ultrasonic power and extend the action time; on the contrary, the power is appropriately reduced to reduce energy consumption. Through the continuous action of the ultrasonic-assisted dispersion device, the particles in the coating solution can be more evenly dispersed, effectively preventing the occurrence of agglomeration, greatly improving the stability and uniformity of the coating solution, providing a high-quality coating solution for the subsequent online composite coating process of the ultra-thin copper foil and the modified resin film, and ensuring that the coating quality of the final product is more stable and reliable.

[0033] In the present invention, the coating head of the precision coating module is equipped with an intelligent spray assist device. During the coating process, according to the coating speed and the required set film thickness, the formula V spray = μ × v × is used to accurately control the spray volume. Among them, the spray coefficient μ is a key parameter determined through a large number of experiments and data analyses, comprehensively considering factors such as the type and characteristics of the coating solution and the structure of the coating head. Through advanced sensor technology, the system can real-time monitor the coating speed v, with an accuracy of up to ±0.1 m / min; at the same time, using a high-precision film thickness measuring instrument, the film thickness can be accurately obtained, and the measurement error is controlled within ±0.01 μm. These accurately measured data will be transmitted to the intelligent control system in real time, and after rapid calculation, the accurate spray volume V spray。The spray liquid is a special surfactant solution that has been screened and formulated, with a unique molecular structure and properties. The spray liquid is a compound solution of sodium dodecylbenzenesulfonate (SDBS) and polyethylene glycol (PEG-400) in a mass ratio of 2:1, with a concentration of 5%. The SDBS molecule contains a hydrophilic sulfonic acid group and a hydrophobic alkyl chain, and PEG-400 provides chain segment flexibility. The two work together to reduce the surface tension to 25-28 mN / m (45 mN / m without addition). Through real-time monitoring with a surface tension meter (accuracy ±0.1 mN / m), when the surface tension > 30 mN / m, a mixture of SDBS and PEG-400 is automatically supplemented (the addition amount is the deviation value × 10 mL); it can effectively reduce the surface tension of the coating solution, thereby significantly improving the leveling and wettability of the coating solution. When the spray liquid is evenly sprayed on the surface of the coating solution, it will guide the molecules of the coating solution to arrange and flow more orderly at the microscopic level. In actual coating, without the assistance of the spray liquid, the coating solution may have problems such as uneven surface tension, resulting in coating stripes and orange peel phenomena, seriously affecting the coating quality. When the intelligent spray assistance device works, by precisely controlling the spray amount, a uniform auxiliary layer is formed on the surface of the coating solution. The auxiliary layer can promote the rapid and uniform spreading of the coating solution on the surface of the ultra-thin copper foil and the modified resin film, effectively avoiding the generation of stripe and orange peel phenomena, ensuring that the finally formed coating surface is flat and smooth, and greatly improving the quality and performance of the product.

[0034] In the present invention, a microchannel structure is provided inside the heating roller of the composite pressing module to improve the heat conduction performance. The microchannels inside the heating roller are manufactured by precision machining processes. The dimensions of the channels are precisely designed and optimized, and parameters such as their width and depth are strictly controlled. The microchannels inside the heating roller are machined by electrical discharge machining (accuracy ±5 μm), with a trapezoidal cross-section and a channel spacing of 5 mm. The channel layout is optimized through ANSYS simulation to ensure that the heat transfer area is increased by 40% compared to traditional circular channels. The surface roughness Ra of the microchannels ≤ 0.8 μm, which is detected by a coordinate measuring machine (accuracy ±2 μm) to ensure the maximum contact area with the liquid metal (gallium-indium-tin alloy, thermal conductivity 32 W / (m·K)). Ensure that the liquid metal can flow smoothly. A liquid metal is selected as the heat transfer medium, which has an extremely high thermal conductivity, superior to traditional heat transfer fluids. The liquid metal circulates in the microchannels and can transfer heat quickly and efficiently. According to the heat conduction formula , where k is the thermal conductivity of the liquid metal, A is the heat transfer area, and the special structure of the microchannel increases the contact area with the inner wall of the heating roller, thus effectively enhancing the scale of heat transfer; ΔT is the temperature difference, and the system can monitor and regulate the temperature difference between the inside and outside of the heating roller in real time through a precise temperature control device to ensure continuous and stable heat transfer; d is the thickness of the microchannel, and a reasonable thickness design further optimizes the heat conduction efficiency. Through the precise control and coordinated action of the above parameters, the heating roller can achieve efficient heat conduction. During the actual operation process, the temperature monitoring system collects the temperature data at different positions on the surface of the heating roller in real time and feeds it back to the intelligent control system. The system dynamically adjusts parameters such as the flow rate, flow velocity of the liquid metal, and the power of the heating source according to the temperature deviation to ensure that the temperature uniformity on the surface of the heating roller reaches ±0.3°C. A high degree of temperature uniformity can make the two heat evenly during lamination, avoiding composite defects such as bubbles and delamination caused by local overheating or overcooling, thereby significantly improving the composite quality and ensuring the performance and quality of the product.

[0035] In the present invention, the on-line detection and feedback control module is provided with a fault warning and emergency handling unit. The Bayesian network algorithm is used to conduct all-round real-time monitoring and in-depth analysis on the operating parameters of each module of the system. A large number of high-precision sensors are distributed inside the system to collect key operating parameters such as temperature, pressure, rotational speed, and flow rate in real time, covering all links such as the coating liquid preparation and supply module, the precision coating module, and the composite lamination module, and thousands of data points can be generated per second. The Bayesian network algorithm processes the massive data through its probability reasoning ability, constructs a model based on prior knowledge and historical data, and assigns a reasonable weight coefficient b i to the abnormal probability P i of each parameter. The weight coefficient is continuously optimized and adjusted through machine learning and data analysis. When parameter fluctuations are detected, the algorithm will quickly calculate the probability P of a fault occurring according to the formula fault . If the temperature of the coating liquid rises abnormally and the flow rate becomes unstable at the same time, the algorithm will comprehensively consider the abnormal probabilities of the two parameters and their weights to evaluate the system fault risk. When the calculated fault probability exceeds the preset threshold, the system immediately triggers a response measure, automatically sends out an audible and visual warning message to inform the operator of the potential fault risk, and at the same time starts the emergency handling procedure. If there is a fault risk in the key equipment, the system automatically shuts down within milliseconds to avoid the expansion of the fault; for the module with standby equipment, it seamlessly switches to the standby equipment to ensure the uninterrupted coating production process.

[0036] In the present invention, the environment adaptation module adopts an intelligent energy management system. Through high-precision sensors, key parameters such as the temperature and humidity of the environment, air quality, and light intensity are monitored in real time. When the environmental parameters deviate from the appropriate range required by the ultra-thin copper foil and modified resin film coating process, the system will respond quickly. The system is also connected to the data interface of the energy supply end and can obtain the fluctuation information of energy prices in real time, accurately capturing both the differences in electricity prices during peak and valley periods and the dynamic changes in natural gas prices. In terms of data processing and decision-making, the optimization algorithm simulates the genetic, mutation, and natural selection mechanisms in biological evolution. The system regards the operating parameters such as the cooling and heating power and air volume of the air conditioning system, the filtration level and air volume of the air purification system, and the opening and closing degree of the shading device as "genes" in evolution. According to the environmental adjustment requirements and energy price fluctuations, through multiple rounds of "gene" crossover, mutation, and screening, these parameter combinations are continuously iteratively optimized. When the environmental temperature rises slightly but is still within the process allowable range and it is at the peak of electricity consumption with a high electricity price at this time, the genetic algorithm will first fine-tune the air volume and air outlet angle of the air conditioner rather than significantly increasing the cooling power, and at the same time moderately adjust the shading device to reduce the heat brought by direct sunlight. When the air quality deteriorates, the system will comprehensively consider the energy price and select the air purification system operation mode with the optimal energy consumption on the premise of ensuring the purification effect. Through intelligent control, on the premise of fully meeting the environmental requirements of the ultra-thin copper foil and modified resin film coating, the energy saving rate can reach 20-30%, effectively reducing the production cost and improving the comprehensive benefit of the system.

[0037] In the present invention, the cleaning procedure of the self-healing coating head module adopts an adaptive cleaning strategy, deeply integrating intelligent algorithms and precision control technologies. The cleaning procedure includes three levels of strategies: mild blockage (P blockage −P normal <0.2 MPa): High-pressure pulsed cleaning with deionized water at 50°C (pressure 3 MPa, pulse frequency 20 Hz, duration 1 minute); moderate blockage (0.2 MPa ≤ P blockage −P normal <0.5 MPa): Switch to acetone solution (concentration 99.5%) for cleaning, pressure 4 MPa, assisted by ultrasonic waves (frequency 40 kHz) for 2 minutes; severe blockage (P blockage −P normal≥0.5 MPa): Automatically switch to the standby channel and simultaneously initiate chemical immersion (the cleaning agent consists of 10% NaOH solution). After soaking for 30 minutes, rinse with deionized water. Verify the effect through flow detection after cleaning (standard flow rate: 10 mL / s, allowable error ±5%). The system monitors the clogging situation of the coating head in real-time. With the help of high-precision sensors, it can accurately sense the degree of clogging and conduct a detailed classification from mild clogging to severe clogging. Meanwhile, through the component analysis device, it can accurately identify whether the clogging substance is metal particles, resin residue, or other impurities. The fuzzy decision-making algorithm constructs a large database model based on a large amount of experimental data and actual application cases. When obtaining the information on the degree of clogging and the composition of the clogging substance, it quickly retrieves and matches in the model, and through complex fuzzy logic operations, automatically selects the most appropriate combination of cleaning parameters. The cleaning pressure can be continuously adjusted from low-pressure gentle rinsing to high-pressure strong dredging, and the pressure adjustment accuracy can reach ±0.1 MPa. The cleaning time is accurately set according to the clogging situation, ranging from several minutes to dozens of minutes, with a control accuracy of ±5 seconds. For different clogging substance compositions, it can quickly switch among multiple preset formulations. For example, for metal particle clogging, select a cleaning agent containing a specific chelating agent; for resin residue, use an organic solvent formulation with strong dissolving ability. The adaptive cleaning strategy not only significantly improves the cleaning efficiency and effect, enables the coating head to return to the normal working state in a shorter time, but also minimizes the damage to the coating head during the cleaning process, extends its service life, and provides a solid guarantee for the stable operation of the online composite coating system for ultra-thin copper foil and modified resin film.

[0038] The above is only a preferred specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution of the present invention and its inventive concept, makes equivalent substitutions or changes, and all should be covered by the protection scope of the present invention.

Claims

1. An on-line composite coating system for an ultra-thin copper foil and a modified resin film, characterized in that Includes the following modules: Unwinding pretreatment module: The ultra-thin copper foil unwinding unit adopts an adaptive constant tension control algorithm combined with fuzzy PID control technology, adjusts the tension through a formula, and uses variable frequency ultrasonic technology and plasma treatment device for processing. The modified resin film unwinding unit adopts an intelligent speed compensation algorithm, and adjusts the unwinding speed in real time through a formula according to the film thickness change and tensile characteristics; Coating liquid preparation and supply module: The coating liquid is prepared in a closed stirring kettle, using a dual planetary dual-power agitator. The stirring speed is dynamically adjusted through a neural network algorithm, and the viscosity and density of the coating liquid are monitored in real time. When the threshold is exceeded, the adjustment amount is calculated using a formula and automatically added and adjusted. The coating liquid is filtered and then transported to the coating head. During the transportation process, pressure fluctuation compensation technology is used to stabilize the pressure; Precision coating module: It adopts a slit coating head and a bionic microchannel design for the internal flow channel. The coating thickness is controlled by adjusting the gap between the coating head and the copper foil in combination with a formula. During the coating process, a multi-spectral interferometer thickness gauge is used to monitor the film thickness in real time. When the film thickness deviation exceeds the threshold, the coating liquid flow rate and coating conditions are automatically adjusted based on feedback. Composite pressing module: After coating, the ultra-thin copper foil and the modified resin film are simultaneously fed into the composite roller group. The heating roller adopts electromagnetic induction heating, and the cooling roller adopts gradient three-stage cooling. The composite pressure is monitored in real time by a piezoelectric pressure sensor, and the hydraulic system pressure is automatically adjusted by a public; Online detection and feedback control module: A multimodal detection device is set up to integrate machine vision, infrared thermal imaging and Raman spectroscopy technology to detect surface defects, internal temperature distribution and chemical composition of the composite film. The principal component analysis algorithm is combined with a deep learning model to analyze the data. When a component deviation defect is detected, the adjustment amount is calculated through a formula to feedback the correction parameters. The parameters of each module are adjusted through Industrial Ethernet according to the detection results.

2. The online composite coating system for ultra-thin copper foil and modified resin film according to claim 1, wherein Also includes: Environmental Adaptation Module: Temperature, humidity, air quality, and light sensors are set around the system to monitor environmental parameters in real-time. When the environmental parameters exceed the set thresholds, the adjustment amount is calculated using the formula to calculate the adjustment amount, where E adjust is the comprehensive environmental adjustment value, T, H, A, and L are the actual temperature, humidity, air quality, and light intensity respectively, and T set , H set , A set , and L set are the set values respectively. The environmental conditions are automatically adjusted through the air conditioning system, air purification system, and light shielding device.

3. The online composite coating system for ultra-thin copper foil and modified resin film according to claim 1, characterized in that, Also includes: Self-healing coating head module: The coating head adopts a microchannel structure. When blockage occurs, the pressure is detected by an in-built pressure sensor, and the blockage degree is judged using the formula P blockage =P normal +φ×ΔQ. P blockage is the blockage pressure, P normal is the normal pressure, φ is the blockage coefficient, and ΔQ is the flow rate change. The system automatically switches to the standby microchannel to continue coating and starts the cleaning program. The high-pressure pulse cleaning technology and chemical cleaning agents are used to clean the microchannel, and the cleaning effect is verified by flow rate detection.

4. The on-line composite coating system for ultra-thin copper foil and modified resin film according to claim 1, characterized in that In the unwinding preprocessing module, the adaptive constant tension is adjusted by the formula T new =T old +K p ×e+K i ×∑e+K d × where T new is the new tension value, T old is the old tension value, and K p , K i , and K d are the proportional, integral, and differential coefficients of the fuzzy PID adaptive adjustment. e is the tension deviation, ∑e is the deviation integral, and compensated is the differential of the deviation. The unwinding speed is adjusted by the formula v base =v compensated ×(1 + α×Δh + β×Δs), where v base is the compensated speed, v base is the base speed, α and β are the compensation coefficients, Δh is the thickness change, and Δs is the stretching change; After the copper foil is ultrasonically cleaned, a plasma activation drying unit is set up. Radio frequency plasma technology is used to dry the residual moisture on the surface of the copper foil and activate the surface of the copper foil. A contact angle meter is used to monitor the activation effect.

5. The online composite coating system for ultra-thin copper foil and modified resin film according to claim 1, wherein In the coating solution preparation and supply module, the viscosity and density of the coating solution are adjusted by the formula to calculate the adjustment amount, where V1 and D1 are the actual viscosity and density, V0 and D0 are the set viscosity value and density value, and ΔC is the comprehensive deviation value; The conveying process calculates the pressure through the formula P compensated =P base +γ×ΔP, where P compensated is the compensated pressure, P base is the base pressure, γ is the compensation coefficient, and ΔP is the pressure fluctuation value; The stirring tank is equipped with an ultrasonic assisted dispersion device. During the stirring process, the ultrasonic frequency is set to 25kHz to evenly disperse the particles in the coating solution through the cavitation effect.

6. The online composite coating system for ultra-thin copper foil and modified resin film according to claim 1, wherein The coating thickness in the precision coating module is controlled by the formula where is the coating thickness, Q is the flow rate of the coating solution, v is the coating speed, w is the coating width, δ is the temperature influence coefficient, ΔT is the difference between the actual temperature and the standard temperature, and T0 is the standard temperature; The coating head is equipped with an intelligent spray assist device, and during the coating process, the spray volume is controlled according to the coating speed and film thickness requirements through the formula V spray =μ×v× where V spray is the spray volume, μ is the spray coefficient, v is the coating speed, is the coating thickness, and the spray liquid is a surfactant solution.

7. The on-line composite coating system for ultra-thin copper foil and modified resin film according to claim 1, wherein In the composite pressing module, the cooling process is controlled by the formula T cooling =T initial −θ×t, where T cooling is the temperature after cooling, T initial is the initial temperature, θ is the cooling rate coefficient, and t is the time; The hydraulic system uses the formula to adjust the pressure. F is the pressure, p is the pressure intensity, S is the contact area, η is the velocity influence coefficient, Δv is the velocity change, and v0 is the set velocity; A microchannel structure is provided inside the heating roller, and liquid metal is used for heat transfer. Through the formula the heat conduction efficiency is calculated, where Q transfer is the heat transfer amount, k is the thermal conductivity of the liquid metal, A is the heat transfer area, ΔT is the temperature difference, and d is the microchannel thickness.

8. The on-line composite coating system for ultra-thin copper foil and modified resin film according to claim 1, characterized in that In the on-line detection and feedback control module, the adjustment amount is calculated through the formula where ΔA is the adjustment parameter, a i is the weight coefficient, and ΔC i is the deviation of each detection index; A fault warning and emergency handling unit is set up, which uses the Bayesian network algorithm to monitor and analyze the operating parameters of each module of the system. When potential fault risks are detected, the fault probability is calculated through the formula where P fault is the probability of fault occurrence, b i is the weight coefficient, and P i is the probability of abnormality of each parameter. When the fault probability exceeds the set threshold, the system issues a warning signal and starts the emergency handling procedure.

9. The online composite coating system for ultra-thin copper foil and modified resin film according to claim 2, characterized in that, The environmental adaptive module adopts an intelligent energy management system, which automatically adjusts the operating parameters of the air conditioning system, air purification system and shading device through optimization algorithms according to environmental regulation needs and energy price fluctuations.

10. The online composite coating system for ultra-thin copper foil and modified resin film according to claim 3, wherein, The cleaning program in the self-repairing coating head module adopts an adaptive cleaning strategy, which automatically selects the appropriate cleaning pressure, cleaning time and cleaning agent formula through a fuzzy decision algorithm based on the degree of blockage and the composition of the blockage.

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