Coated copper foil production line and process

Abstract

The invention discloses a copper foil cladding production line and process, and relates to the technical field of LED flexible flat cable production, and the production line is composed of an uncoiler, a slitting machine, a transition carrier roller, an aluminum foil copper foil pasting mechanism, a shaping and cladding mechanism and a discharging carrier roller in sequence in the aluminum foil flowing direction. A plurality of groups of upper and lower roll shafts which synchronously rotate are arranged in the shaping and coating mechanism; and each pair of upper and lower roll shafts are correspondingly arranged and are in meshing transmission through gears. In the process, an aluminum foil and copper foil fitting body sequentially penetrates through each group of roll shafts and a feeding roll shaft to enable the copper foil to be centered; a leveling roller shaft is used for pressing and leveling; subsequent multiple sets of shaping roll shafts conduct progressive shaping on the two ends of the copper foil through ring protrusions and ring grooves of different shapes and shaping faces of specific angles, the two ends of the copper foil are bent downwards to be vertical and then bent inwards step by step by different angles, and finally the two ends of the copper foil are wrapped outside the aluminum foil through the effect of the plane roll shafts. According to the invention, automatic and high-precision coating of the copper foil on the surface of the aluminum foil is realized, the production efficiency and the product quality are improved, and the cost is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of LED flexible flat cable production, and in particular to a copper foil coated production line and process. Background Art

[0002] A key process in the production of flexible LED cables is the coating of aluminum foil with copper foil. This process has a crucial impact on the electrical performance, mechanical strength, and service life of the flexible LED cable. Aluminum foil offers excellent electrical conductivity and heat dissipation, while copper foil offers excellent electrical conductivity and flexibility. Coating copper foil with aluminum foil leverages the advantages of both, improving the overall performance of the flexible LED cable.

[0003] However, the industry currently relies on manual labor to wrap copper foil around aluminum foil. This manual process presents numerous drawbacks: First, it is inefficient. Production speed is limited by the operator's skill level and physical strength, making it difficult to meet the demands of large-scale production, resulting in extended production cycles and unreliable delivery times. Second, manual labor suffers from poor quality consistency. Operators vary in their skill levels and work habits, and even the same operator, at different times or under different conditions, cannot guarantee consistent wrapping quality from one session to the next. This can easily lead to problems such as loose wrapping, inconsistent copper foil lengths, and inaccurate wrapping angles in LED flexible cables, compromising the product's electrical performance and mechanical strength, reducing product yields, and increasing production costs. Furthermore, manual labor poses safety risks. Operators easily become fatigued during long, repetitive tasks, which can lead to workplace accidents due to operator errors. Summary of the Invention

[0004] In view of the deficiencies in the prior art, the present invention provides a copper foil cladding production line and process, which solves the problems raised by the above background technology.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: In a first aspect, the present invention provides a clad copper foil production line, comprising: Uncoiler, used to release the rolled aluminum foil to the slitting machine; Slitting machine, used to cut aluminum foil into multiple strips; Transition rollers are used to support the aluminum foil after slitting; Aluminum foil laminating copper foil mechanism, used to laminarly laminate copper foil onto the aluminum foil surface at equal intervals to form a laminated body; The shaping and wrapping mechanism is used to progressively shape the two ends of the copper foil in the laminate, and finally wrap the copper foil around the outside of the aluminum foil; The discharge roller is used to transport the aluminum foil and copper foil composite after coating.

[0006] Furthermore, the shaping and coating mechanism includes multiple groups of synchronously rotating upper and lower rollers, each group of rollers consists of a lower roller and an upper roller, which in turn include a feeding lower roller, a feeding upper roller, a leveling lower roller, a leveling upper roller, No. 1 to No. 5 shaping lower rollers and corresponding No. 1 to No. 5 shaping upper rollers, and each roller end is driven by a motor through gear meshing.

[0007] Furthermore, the lower feed roller is set as a flat roller, and the surface of the upper feed roller is provided with symmetrical limiting rings, and the spacing between the limiting rings matches the width of the copper foil to achieve the centering of the copper foil.

[0008] Furthermore, the lower leveling roller, the upper leveling roller, the No. 5 shaping lower roller, and the No. 5 shaping upper roller are all flat rollers. The lower leveling roller and the upper leveling roller are used to eliminate the surface unevenness of the aluminum foil and the copper foil, and the No. 5 shaping lower roller and the No. 5 shaping upper roller are used to finally bend the two ends of the copper foil to be parallel to the copper foil itself.

[0009] Furthermore, a No. 1 shaping ring convex is provided on the surface of the No. 1 shaping lower roller, a No. 1 shaping ring groove is provided on the surface of the No. 1 shaping upper roller, and a No. 1 shaping surface is provided on both sides of the No. 1 shaping ring groove, which is at an angle of 45° to the vertical line.

[0010] Furthermore, a No. 2 shaping ring convex is provided on the surface of the No. 2 shaping lower roller, a No. 2 shaping ring groove is opened on the surface of the No. 2 shaping upper roller, and No. 2 shaping surfaces with right-angle surface structures are provided on both sides of the No. 2 shaping ring groove, and the distance between the two No. 2 shaping surfaces is adapted to the thickness of the copper foil.

[0011] Furthermore, a No. 3 shaping ring groove is opened on the surface of the No. 3 shaping lower roller, and a No. 3 shaping surface is provided on both sides of the No. 3 shaping ring groove, which is at an angle of 30° to the vertical line, and the No. 3 shaping upper roller is set as a flat roller.

[0012] Furthermore, a No. 4 shaping ring groove is opened on the surface of the No. 4 shaping lower roller, and No. 4 shaping surfaces are provided on both sides of the No. 4 shaping ring groove, which are at an angle of 60° to the vertical line, and the No. 4 shaping upper roller is set as a flat roller.

[0013] In a second aspect, the present invention further provides a shaping and coating process for a coated copper foil production line, comprising the following steps: S1. Use the limiting ring of the upper feed roller to center the copper foil on the aluminum foil, ensuring that the protruding lengths at both ends are symmetrical; S2, pressing and flattening the aluminum foil and the copper foil by the lower and upper leveling rollers; S3, bend the two ends of the copper foil downward by 45 degrees through the No. 1 shaping lower roller, No. 1 shaping ring convex, No. 1 shaping upper roller, No. 1 shaping ring groove, and No. 1 shaping surface; S4, bend the two ends of the copper foil to a vertical state through the No. 2 shaping lower roller, the No. 2 shaping ring convex, the No. 2 shaping upper roller, and the No. 2 shaping surface; S5, bend the two ends of the copper foil inward 30 degrees through the No. 3 shaping lower roller, No. 3 shaping ring groove, No. 3 shaping surface, and No. 3 shaping upper roller; S6. Bend the two ends of the copper foil inwards by 30° to form a 60° angle through the No. 4 shaping lower roller, the No. 4 shaping ring groove, the No. 4 shaping surface, and the No. 4 shaping upper roller. S7. Bend the two ends of the copper foil to be parallel to the aluminum foil by the No. 5 shaping lower roller and the No. 5 shaping upper roller to complete the coating.

[0014] The present invention provides a copper foil cladding production line and process. Compared with the existing technology, it has the following advantages: This copper foil-wrapped production line and its shaping and coating process achieves high-precision and consistent automated coating of copper foil on the surface of aluminum foil through a series of automated and carefully designed roller structures and shaping steps. It effectively solves the problems of low efficiency and unstable quality of manual coating, greatly improves production efficiency and product yield, reduces production costs, and meets the market demand for large-scale production of high-quality LED flexible cables. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a structural schematic diagram of the copper foil cladding production line of the present invention; Figure 2 This is a schematic diagram of the disassembly of the shaping and coating mechanism of the present invention; Figure 3 This is a simplified diagram illustrating the assembly of the shaping and coating mechanism of the present invention; Figure 4 Schematic diagram of the shape change of the copper foil inside the shaping and coating mechanism in the present invention; Figure 5 This is a cross-sectional view of the aluminum and copper foils between the upper and lower feed rollers in the present invention; Figure 6 This is a cross-sectional view of the aluminum and copper foils between the upper and lower leveling rollers in the present invention; Figure 7 This is a cross-sectional view of the aluminum and copper foils between the No. 1 shaping upper and lower rollers in the present invention; Figure 8 This is a cross-sectional view of the aluminum and copper foils between the No. 2 shaping upper and lower rollers in the present invention; Figure 9 This is a cross-sectional view of the aluminum and copper foils between the No. 3 shaping upper and lower rollers in the present invention; Figure 10 This is a cross-sectional view of the aluminum and copper foils between the No. 4 shaping upper and lower rollers in the present invention; Figure 11This is a cross-sectional view of the aluminum and copper foils between the No. 5 shaping upper and lower rollers in the present invention.

[0016] Figure: 100, uncoiler; 200, slitting machine; 300, transition roller; 400, aluminum foil laminating mechanism; 500, shaping and wrapping mechanism; 600, discharge roller; 1, lower feed roller; 2, upper feed roller; 21, limiting ring; 3, lower leveling roller; 4, upper leveling roller; 5, lower shaping roller No. 1; 51, shaping ring convex No. 1; 6, upper shaping roller No. 1; 61, ring groove No. 1; 62, shaping surface No. 1; 7, lower shaping roller No. 2 Shaft; 71, No. 2 shaping ring convex; 8, No. 2 shaping upper roller; 81, No. 2 shaping ring groove; 82, No. 2 shaping surface; 9, No. 3 shaping lower roller; 91, No. 3 shaping ring groove; 92, No. 3 shaping surface; 10, No. 3 shaping upper roller; 11, No. 4 shaping lower roller; 111, No. 4 shaping ring groove; 112, No. 4 shaping surface; 12, No. 4 shaping upper roller; 13, No. 5 shaping lower roller; 14, No. 5 shaping upper roller; 15, aluminum foil; 16, copper foil. DETAILED DESCRIPTION

[0017] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0018] See also Figure 1 The present invention provides a technical solution: a copper foil coated production line, which is composed of an unwinder 100, a longitudinal slitting machine 200, a transition roller 300, an aluminum foil 15-coated copper foil 16 mechanism 400, a shaping and coating mechanism 500, and a discharge roller 600 according to the flow direction of the aluminum foil 15. The unwinder 100 is used to release the rolled aluminum foil 15 to the longitudinal slitting machine 200, and the longitudinal slitting machine 200 is used to cut a whole sheet of aluminum foil 15 into several Aluminum foil strips 15, transition rollers 300 are used to support the slit aluminum foil strips 15, aluminum foil 15-copper foil 16 laminating mechanism 400 is used to laminarly laminate several copper foils 16 on the surface of the aluminum foil 15 at equal distances to form a laminated body, shaping and wrapping mechanism 500 is used to progressively shape the two ends of the copper foil 16 in the laminated body, and finally wrap the copper foil 16 around the outside of the aluminum foil 15, and discharge rollers 600 are used to support the laminated body of aluminum foil 15 and copper foil 16 and transport it outward; It should be noted that the uncoiler 100, the longitudinal slitting machine 200, the transition roller 300 and the discharge roller 600 all adopt existing technologies, and their specific structures and working principles are not described in detail here. According to the flow direction of the aluminum foil 15, the interior of the shaping and coating mechanism 500 is connected in sequence with the feeding lower roller 1, the feeding upper roller 2, the leveling lower roller 3, the leveling upper roller 4, the No. 1 shaping lower roller 5, the No. 1 shaping upper roller 6, the No. 2 shaping lower roller 7, the No. 2 shaping upper roller 8, the No. 3 shaping lower roller 9, the No. 3 shaping upper roller 10, the No. 4 shaping lower roller 11, the No. 4 shaping upper roller 12, the No. 5 shaping lower roller 13 and the No. 5 shaping upper roller 14, which can rotate synchronously. Among them, the feeding upper roller 2, the leveling upper roller 4, the No. 1 shaping upper roller 6, The second shaping upper roller 8, the third shaping upper roller 10, the fourth shaping upper roller 12, and the fifth shaping upper roller 14 are correspondingly located directly above the feeding lower roller 1, the leveling lower roller 3, the first shaping lower roller 5, the second shaping lower roller 7, the third shaping lower roller 9, the fourth shaping lower roller 11, and the fifth shaping lower roller 13. The bonding body of the aluminum foil 15 and the copper foil 16 will pass between the above rollers. Gears are installed on the same side end of each roller. The gears at the ends of the two rollers located on the same vertical line are meshed, and the total power input end is driven by a motor. Specific to each set of rollers: The lower feed roller 1 is set as a flat roller, and the surface of the upper feed roller 2 is symmetrically connected to the limit ring 21, and the spacing of the limit ring 21 is adapted to the width of the copper foil 1616; The lower leveling roller 3 and the upper leveling roller 4 are both configured as flat rollers; The surface of the No. 1 shaping lower roller 5 is connected to the No. 1 shaping annular protrusion 51, and the surface of the No. 1 shaping upper roller 6 is provided with a No. 1 shaping annular groove 61. Both sides of the No. 1 shaping annular groove 61 are provided with No. 1 shaping surfaces 62. The No. 1 shaping surface 62 is provided as an inclined surface with an angle of 45° with the vertical line. The surface of the second shaping lower roller 7 is connected to the second shaping ring protrusion 71, and the surface of the second shaping upper roller 8 is provided with a second shaping ring groove 81. Both sides of the second shaping ring protrusion 71 and the second shaping ring groove 81 are provided with second shaping surfaces 82. A spacing adapted to the thickness of the copper foil 16 is reserved between the two second shaping surfaces 82. The second shaping surface 82 is set to a right angle surface with an angle of 0° with the vertical line. The surface of the third shaping lower roller 9 is provided with a third shaping annular groove 91, and the third shaping upper roller 10 is set as a flat roller. Both sides of the third shaping annular groove 91 are provided with third shaping surfaces 92, and the third shaping surface 92 is set as an inclined surface with an angle of 30 degrees with the vertical line; The surface of the fourth shaping lower roller 11 is provided with a fourth shaping annular groove 111, the fourth shaping upper roller 12 is set as a flat roller, and both sides of the fourth shaping annular groove 111 are provided with fourth shaping surfaces 112, and the fourth shaping surface 112 is set as an inclined surface with an angle of 60° with the vertical line; The fifth shaping lower roller shaft 13 and the fifth shaping upper roller shaft 14 are both set as flat roller shafts.

[0019] Please refer to Figure 2-11 , the shaping and coating process of the above production line includes the following steps: S1. When the aluminum foil 15 and the copper foil 16 pass through between the feeding lower roller shaft 1 and the feeding upper roller shaft 2, the symmetrically arranged limiting rings 21 will make the copper foil 16 centered on the aluminum foil 15, that is, the lengths of the two ends of the copper foil 16 protruding from the two ends of the aluminum foil 15 are the same, ensuring that the lengths of the two ends of the copper foil 16 coated on the surface of the aluminum foil 15 are the same during the subsequent shaping process, as shown in the appendix Figure 5 shown; S2. When the aluminum foil 15 and the copper foil 16 pass through between the leveling lower roller shaft 3 and the leveling upper roller shaft 4, the leveling lower roller shaft 3 and the leveling upper roller shaft 4 can jointly press and level the aluminum foil 15 and the copper foil 16, preparing for the subsequent shaping and reducing the coating error caused by the unevenness of the aluminum foil 15 and the copper foil 16, as shown in the appendix Figure 6 shown; S3. When the aluminum foil 携带铜箔16穿过一号整形下辊轴5、一号整形上辊轴6之间时,因为一号整形面62的设置,会让铜箔16的两端向下弯折45°,如附 Figure 7 shown; S4. When the aluminum foil 15 carries the copper foil 16 through between the second shaping lower roller shaft 7 and the second shaping upper roller shaft 8, the two ends of the copper foil 16 that were originally bent at 45° will continue to bend inward until they are vertical, that is, the copper foil 16 is in a "U" - shaped state at this time, as shown in the appendix Figure 8 shown; S5. When the aluminum foil 15 carries the copper foil 16 through between the third shaping lower roller shaft 9 and the third shaping upper roller shaft 10, due to the setting of the third shaping surface 92, the two ends of the copper foil 16 that were originally in a vertical state will continue to bend inward by 30° at this time, as shown in the appendix Figure 9 shown; S6. When the aluminum foil 15 carries the copper foil 16 through between the fourth shaping lower roller shaft 11 and the fourth shaping upper roller shaft 12, due to the setting of the fourth shaping surface 112, the two ends of the copper foil 16 that were originally bent inward by 30° will continue to bend inward by 30° here, forming a state where the included angle between the two ends and the copper foil 16 itself is 60°, as shown in the appendix Figure 10 shown; S7. When the aluminum foil 15 carries the copper foil 16 through the fifth shaping lower roller shaft 13 and the fifth shaping upper roller shaft 14, the two ends of the copper foil 16 that were originally bent at 60° will, under the action of the plane of the fifth shaping lower roller shaft 13, bend to be parallel to the copper foil 16 itself, that is, from the beginning where the two ends of the copper foil 16 were on the upper surface of the aluminum foil 15, now they are bent to the lower surface of the aluminum foil 15, so that the two ends of the copper foil 16 wrap the two sides of the aluminum foil 15, as shown in the appendix Figure 11 It should be noted that there seems to be an incorrect expression "铝箔1携带铜箔16" in the original text, which should be "铝箔15携带铜箔16", and this has been translated according to the corrected content.As shown, the entire molding and covering process is completed.

Claims

1. A copper foil clad production line, characterized in that: include: An unwinder (100) for releasing the rolled aluminum foil to a longitudinal slitting machine (200); A longitudinal slitting machine (200) for slitting the aluminum foil into a plurality of aluminum foil strips; A transition roller (300) is used to support the aluminum foil after slitting; An aluminum foil-copper foil laminating mechanism (400) is used to laminarly laminate the copper foil onto the surface of the aluminum foil at equal intervals to form a laminated body; A shaping and covering mechanism (500) is used to progressively shape the two ends of the copper foil in the laminate, and finally allow the copper foil to be covered on the outside of the aluminum foil; The discharge roller (600) is used to convey the coated aluminum foil and copper foil composite.

2. A copper foil clad production line according to claim 1, characterized in that: The shaping and coating mechanism (500) includes multiple groups of synchronously rotating upper and lower rollers, each group of rollers consisting of a lower roller and an upper roller, which sequentially include a feeding lower roller (1), a feeding upper roller (2), a leveling lower roller (3), a leveling upper roller (4), No. 1 to No. 5 shaping lower rollers (5, 7, 9, 11, 13) and corresponding No. 1 to No. 5 shaping upper rollers (6, 8, 10, 12, 14), and each roller end is driven by a motor through gear meshing transmission.

3. A copper foil clad production line according to claim 2, characterized in that: The lower feed roller (1) is configured as a flat roller, and the surface of the upper feed roller (2) is provided with symmetrical limiting rings (21), the spacing between the limiting rings (21) matches the width of the copper foil, and is used to achieve centering of the copper foil.

4. A copper foil clad production line according to claim 2, characterized in that: The lower leveling roller (3), the upper leveling roller (4), the No. 5 shaping lower roller (13), and the No. 5 shaping upper roller (14) are all plane rollers. The lower leveling roller (3) and the upper leveling roller (4) are used to eliminate the unevenness of the surfaces of the aluminum foil and the copper foil. The No. 5 shaping lower roller (13) and the No. 5 shaping upper roller (14) are used to finally bend the two ends of the copper foil to be parallel to the copper foil itself.

5. The copper foil cladding production line according to claim 2, characterized in that: A No. 1 shaping ring convex (51) is provided on the surface of the No. 1 shaping lower roller (5), a No. 1 shaping ring groove (61) is provided on the surface of the No. 1 shaping upper roller (6), and No. 1 shaping surfaces (62) are provided on both sides of the No. 1 shaping ring groove (61) at an angle of 45° to the vertical straight line.

6. The copper foil cladding production line according to claim 2, characterized in that: The surface of the No. 2 shaping lower roller (7) is provided with a No. 2 shaping ring convex (71), the surface of the No. 2 shaping upper roller (8) is provided with a No. 2 shaping ring groove (81), and No. 2 shaping surfaces (82) with a right-angle surface structure are provided on both sides of the No. 2 shaping ring groove (81), and the distance between the two No. 2 shaping surfaces (82) is adapted to the thickness of the copper foil.

7. The copper foil cladding production line according to claim 2, characterized in that: A No. 3 shaping ring groove (91) is provided on the surface of the No. 3 shaping lower roller (9), and No. 3 shaping surfaces (92) are provided on both sides of the No. 3 shaping ring groove (91) at an angle of 30° to the vertical line. The No. 3 shaping upper roller (10) is configured as a flat roller.

8. The copper foil cladding production line according to claim 2, characterized in that: A No. 4 shaping ring groove (111) is provided on the surface of the No. 4 shaping lower roller (11), and No. 4 shaping surfaces (112) are provided on both sides of the No. 4 shaping ring groove (111) at an angle of 60° to the vertical line. The No. 4 shaping upper roller (12) is configured as a flat roller.

9. A shaping and coating process for a coated copper foil production line, characterized in that: The following steps are involved: S1. Use the limiting ring (21) of the upper feed roller (2) to center the copper foil on the aluminum foil, ensuring that the protruding lengths at both ends are symmetrical; S2, pressing and flattening the aluminum foil and the copper foil by means of a flattening lower roller (3) and a flattening upper roller (4); S3, bend the two ends of the copper foil downward by 45° through the No. 1 shaping lower roller (5), the No. 1 shaping ring convex (51), the No. 1 shaping upper roller (6), the No. 1 shaping ring groove (61), and the No. 1 shaping surface (62); S4, bending the two ends of the copper foil to a vertical state through the second shaping lower roller (7), the second shaping ring convex (71), the second shaping upper roller (8), and the second shaping surface (82); S5, bend the two ends of the copper foil inward by 30° through the No. 3 shaping lower roller (9), the No. 3 shaping ring groove (91), the No. 3 shaping surface (92), and the No. 3 shaping upper roller (10); S6, through the No. 4 shaping lower roller (11), the No. 4 shaping ring groove (111), the No. 4 shaping surface (112), and the No. 4 shaping upper roller (12), the two ends of the copper foil are further bent inward by 30° to form a 60° angle; S7, bend the two ends of the copper foil to be parallel to the aluminum foil by the No. 5 shaping lower roller (13) and the No. 5 shaping upper roller (14), and complete the coating.

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