Lightweight large-diameter cathode roller for production of electrolytic copper foil

Abstract

A lightweight large-diameter cathode roller for the production of an electrolytic copper foil. A titanium cylinder is connected to a support cylinder by means of threads, and silver plating is performed on surfaces of the threads, so as to increase a conductive contact area between the titanium cylinder and the support cylinder, reduce the energy consumption and local hot spots due to contact resistance, and facilitate uniform distribution of currents on a surface of the titanium cylinder. Grid-shaped conductive paths composed of side conductive aluminum plates, a central conductive aluminum plate, circumferential ribs and axial ribs are uniformly distributed on the inner wall of the support cylinder. The currents on the surface of the titanium cylinder of the cathode roller are conducted to a shaft of aluminum alloy through the support cylinder, and are then conducted from the cathode roller through the shaft of aluminum alloy, thereby ensuring the current uniformity on the surface of the titanium cylinder of the cathode roller and an operating current density of 9000A / m2 or more. In the present invention, an aluminum alloy is used as a conductive material and a structural strength material, the structure is simple, the weight is reduced by 35% or more, the problems caused by turning, lifting, flipping, transferring, transportation and driving during production, manufacturing and use are reduced, the smooth surface quality of a copper foil produced by a large-diameter cathode roller is improved, and the surface density index is ensured.

Description

A lightweight, large-diameter cathode roller for electrolytic copper foil production Technical Field

[0001] This invention relates to the field of electrolytic copper foil equipment manufacturing, specifically a cathode roller with a diameter greater than 3000mm for electrolytic copper foil production. Background Technology

[0002] Electrolytic copper foil, as one of the basic materials in the electronics industry, is mainly used in the manufacture of printed circuit boards (PCBs), copper-clad laminates (CCLs), lithium-ion batteries, and energy storage batteries. Electrolytic copper foil is produced by electrolysis. Under the action of an applied DC electric field, copper ions in the electrolyte in the anode tank of the foil-making machine are continuously electrodeposited onto the surface of a uniformly rotating cathode roller. After deposition to a certain thickness, the foil is peeled, surface-treated, and wound up to continuously produce electrolytic copper foil.

[0003] The cathode roller, serving as the carrier for electrolytic copper foil production, is a rotating structure with shafts at both ends and a cylinder in the middle. It is primarily composed of internally supporting steel for strength, conductive copper, and externally corrosion-resistant titanium for foil production. The larger its diameter and the longer its width, the greater the area involved in electrolytic foil production, resulting in higher production efficiency. As a core piece of equipment in electrolytic copper foil production, the cathode roller's specifications, conductivity, and grain size all affect the production efficiency, economic benefits, and product quality of the copper foil, and have always been a core focus for copper foil companies. After more than 30 years of development, the diameter of the cathode roller has increased from 1500mm to the current 3600mm, significantly improving its foil production efficiency. However, as the diameter of the cathode roller increases, its weight doubles, leading to various problems in its manufacturing and use: lifting, turning, transferring, and transporting the cathode roller between different processes during manufacturing becomes more difficult; higher rotational speeds cannot be used during surface turning and polishing, affecting surface finish and efficiency, and reducing the smoothness of the produced copper foil; a higher-power motor is needed to drive the cathode roller during electrolytic foil production, causing the cathode roller drive system to occupy too much space, affecting the uniform rotation of the cathode roller and resulting in out-of-tolerance surface density, a key indicator of the produced copper foil; and stricter requirements are placed on the cathode roller support structure, foundation, and storage floor load-bearing capacity of the foil production machine, increasing unnecessary copper foil production costs. These significant weight increases caused by the larger cathode roller diameter have brought considerable trouble to both electrolytic copper foil equipment manufacturers and electrolytic copper foil producers.

[0004] The invention patent CN 101928978 B discloses a rotating cathode roller for electrolysis, comprising an outer cylinder and an inner cylinder. The inner cylinder is made of aluminum alloy, and a mesh of conductive plates is distributed on its inner surface. This prevents the inner cylinder from overheating under high current flow, suppresses the generation of hot spots, and improves the contact normal stress, overall rigidity, and heat dissipation performance of the rotating cathode roller for electrolysis. This patent mainly utilizes the high thermal expansion coefficient and good electrical conductivity of aluminum alloy to increase the normal pressure at the joint between the inner and outer cylinders during operation, thus suppressing the generation of hot spots. However, it does not address the issue of lightweighting large-diameter cathode rollers, nor does it solve the problem of ensuring that the overall structure and conductivity of the aluminum alloy cathode roller meet the requirements for foil production. Summary of the Invention

[0005] To address the issue that the increasing diameter of cathode rollers leads to greater weight, which negatively impacts surface finish and processing efficiency during lifting, turning, transferring, and transporting in the manufacturing and electrolytic copper foil production processes, this invention proposes a lightweight, large-diameter cathode roller for electrolytic copper foil production.

[0006] This invention includes an aluminum alloy shaft, two titanium sleeves, two titanium sheaths, two titanium plates, two side conductive aluminum plates, a support cylinder made of aluminum alloy, and a central conductive aluminum plate. The support cylinder is mounted on the aluminum alloy shaft; the two side conductive aluminum plates are respectively mounted on the aluminum alloy shaft, with the outer circumferential surface of each side conductive aluminum plate respectively abutting the inner circumferential surface at both ends of the support cylinder. The two titanium sleeves are respectively mounted on the surface of the aluminum alloy shaft and located outside the two side conductive aluminum plates, with the end face of each side conductive aluminum plate abutting the end face of the side conductive aluminum plate at its respective location. The two titanium plates are respectively mounted on the outer circumferential surface of the titanium sleeves and located on one side of the outer end face of each side conductive aluminum plate; each titanium plate is fixed to the side conductive aluminum plate at its respective location by titanium bolts and counterweights. The two titanium sheaths are respectively mounted on the outer circumferential surface of the titanium sleeves, located outside the titanium plates, with the inner end face of the titanium sheath abutting the outer end face of the titanium plate at its respective location. The outer end of the titanium sheath is welded to the outer circular surface of the titanium sheath, and the inner ends of the titanium sheath and the titanium sheath are welded to the titanium plate respectively.

[0007] The central conductive aluminum plate is located inside the support cylinder and is fitted onto the outer circumferential surface of the aluminum alloy shaft 1; the central conductive aluminum plate is located at the axial symmetry plane of the support cylinder.

[0008] The inner wall surface of the support cylinder is uniformly distributed with conductive paths. Each conductive path consists of two side conductive aluminum plates, a central conductive aluminum plate, multiple annular ribs, and multiple axial ribs. The annular ribs are arranged axially along the inner circumference of the support cylinder, with a center-to-center distance of 600 mm between adjacent annular ribs. The axial ribs are arranged circumferentially along the inner circumference of the support cylinder, with an included angle of 15° between adjacent axial ribs. A grid of conductive paths is formed by the perpendicular intersections of the annular and axial ribs. Both ends of each axial rib are fixedly connected to the side conductive aluminum plate 5 at their respective ends.

[0009] The aluminum alloy materials that make up the conductive path have a conductivity > 40% IACS and a resistivity < 0.04Ω·mm2 / m at a temperature of 20℃ to 70℃.

[0010] The central conductive aluminum plate has cylindrical bosses on both ends to increase its conductive area. The axial height of each boss is 10mm, and its outer diameter is 1300mm. The central conductive aluminum plate is located inside the support cylinder and at its axial symmetry plane. The distance between the central conductive aluminum plate and the side conductive aluminum plates at both ends of the support cylinder is 600mm. The inner circumferential surface of the central conductive aluminum plate is fixedly connected to the circumferential surface of the aluminum alloy shaft; the outer circumferential surface of the central conductive aluminum plate is fixedly connected to the inner surface of the support cylinder.

[0011] The cross-sectional area of ​​the small-diameter segment of the aluminum alloy shaft is greater than the minimum cross-sectional area S1 required for the aluminum alloy shaft to conduct electricity. The minimum cross-sectional area S1 is determined by (2): S1 = I / 2(K1·J) (2)

[0012] In the formula: S1 is the minimum conductive cross-sectional area required for the aluminum alloy shaft to conduct electricity, in mm. 2 I is the design total current of the cathode roller, in A; K1 is the cross-sectional conductivity correction factor, with a value of 1 to 1.5; J is the current density of the aluminum alloy, in A / mm². 2 .

[0013] The total design current I is calculated using formula (1): I = 1 / 2·k·s·j (1)

[0014] In the formula: I is the total design current of the cathode roller, in A; k is the correction factor for the total design current of the cathode roller, with a value of 1 to 2; s is the outer circumference area of ​​the designed cathode roller titanium cylinder, in mm. 2 j represents the current density of the titanium cylinder material, in A / mm². 2 .

[0015] The minimum contact conductive area S′ between the side conductive aluminum plate and the support cylinder is determined by formula (3-1). n S′ n =I / [(n+m)·K2·J] (3-1)

[0016] The minimum contact conductive area S″ between the side conductive aluminum plate and the aluminum alloy shaft is determined using formula (3-2). n S″ n =I / [(n+m)·K2·J] (3-2)

[0017] In the formula: S′ n It is the minimum contact conductive area between the side conductive aluminum plate and the support cylinder, in mm. 2 ;S″ n It is the minimum conductive contact area between the side-conductive aluminum plate and the aluminum alloy shaft, in mm. 2 I is the total design current of the cathode roller, in A; n is the total number of side conductive aluminum plates included in the cathode roller; m is the total number of center conductive aluminum plates included in the cathode roller; K2 is the contact conductivity correction factor, with a value of 0.5 to 1; J is the current density of the aluminum alloy, in A / mm². 2 .

[0018] The minimum conductive cross-sectional area S of the side conductive aluminum plate included in the cathode roller is determined by formula (4). n S n ＝ I / [(n+m)·K1·J] (4)

[0019] In the formula: S n It is the minimum conductive cross-sectional area of ​​the side-conductive aluminum plate, in mm. 2 I is the total design current of the cathode roller, in A; n is the total number of side conductive aluminum plates included in the cathode roller; m is the total number of center conductive aluminum plates included in the cathode roller; K1 is the cross-sectional conductivity correction factor, with a value of 1 to 1.5; J is the current density of the aluminum alloy, in A / mm². 2 .

[0020] The minimum conductive cross-sectional area S2 of the support cylinder included in the cathode roller is determined by formula (5): S2=I / (K1·J) (5)

[0021] In the formula: S2 is the minimum conductive cross-sectional area required for the support cylinder to conduct electricity, in mm. 2 I is the design total current of the cathode roller, in A; K1 is the cross-sectional conductivity correction factor, with a value of 1 to 1.5; J is the current density of the aluminum alloy, in A / mm². 2 .

[0022] The minimum contact conductive area S′ between the central conductive aluminum plate and the support cylinder is determined using formula (6-1). m S′ m =I / [(n+m)·K2·J] (6-1)

[0023] The minimum contact conductive area S″ between the central conductive aluminum plate and the aluminum alloy shaft is determined using formula (6-2). m S″ m =I / [(n+m)·K2·J] (6-2)

[0024] In the formula: S′ m It is the minimum conductive contact area between the central conductive aluminum plate and the support cylinder, in mm. 2 ;S″ m It is the minimum contact conductive area between the central conductive aluminum plate and the aluminum alloy shaft, in mm. 2 I is the total design current of the cathode roller, in A; n is the total number of side conductive aluminum plates included in the cathode roller; m is the total number of center conductive aluminum plates included in the cathode roller; K2 is the contact conductivity correction factor, with a value of 0.5 to 1; J is the current density of the aluminum alloy, in A / mm². 2 .

[0025] The minimum conductive cross-sectional area S of the central conductive aluminum plate of the cathode roller is determined by formula (7). m S m =I / [(n+m)·K1·J] (7)

[0026] In the formula: S m It is the minimum conductive cross-sectional area of ​​the central conductive aluminum plate, in mm. 2 I is the total design current of the cathode roller, in A; n is the total number of side conductive aluminum plates included in the cathode roller; m is the total number of center conductive aluminum plates included in the cathode roller; K1 is the cross-sectional conductivity correction factor, with a value of 1 to 1.5; J is the current density of the aluminum alloy, in A / mm².2 .

[0027] This invention proposes a lightweight, large-diameter cathode roller for electrolytic copper foil production. The titanium cylinder and support cylinder are assembled via a threaded connection, and the threaded surfaces are silver-plated, increasing the contact conductive area and reducing energy consumption and localized hot spots in the cathode roller's contact resistance. This promotes uniform current distribution on the titanium cylinder surface. The inner wall of the support cylinder is uniformly distributed with a grid-like conductive path composed of side conductive aluminum plates, a central conductive aluminum plate, circumferential ribs, and axial ribs. This path uniformly conducts the current on the titanium cylinder surface through the support cylinder, from the side and central conductive aluminum plates to the aluminum alloy shaft, and then from the aluminum alloy shaft out of the cathode roller, ensuring current uniformity on the titanium cylinder surface and a current of 9000 A / m. 2 The above operating current density; the cathode roller of the present invention uses a central conductive aluminum plate and a side conductive aluminum plate that have structural support, current conduction and weight reduction functions. Its structure is simple, and the conductive material and structural strength material are both aluminum alloys with relatively low density. Compared with the traditional cathode roller of the same model, the weight can be reduced by more than 35%, which helps to reduce various problems caused by turning, lifting, flipping, transfer, transportation and driving in the production and application of large-diameter cathode rollers. It improves the surface quality of copper foil produced by large-diameter cathode rollers and ensures the areal density index of copper foil produced by large-diameter cathode rollers. Attached Figure Description

[0028] Figure 1 is a front view of the cathode roller.

[0029] Figure 2 is a left view of the cathode roller.

[0030] Figure 3 is a front view of the internal structure of the cathode roller.

[0031] Figure 4 is a front view and cross-sectional view (AA) of the internal structure of the cathode roller.

[0032] Figure 5 is a front view and sectional view of the internal structure of the cathode roller.

[0033] Figure 6 is a partial EE sectional view of the main view AA of the internal structure of the cathode roller.

[0034] Figure 7 shows the central conductive aluminum plate.

[0035] Figure 8 shows the side conductive aluminum plate.

[0036] In the diagram: 1. Aluminum alloy shaft; 2. Titanium sleeve; 3. Titanium sheath; 4. Titanium plate; 5. Side conductive aluminum plate; 6. Titanium cap; 7. Titanium bolt counterweight; 8. Titanium cylinder; 9. Support cylinder; 10. Central conductive aluminum plate; 11. Circumferential rib; 12. Titanium ring; 13. Triangular reinforcing rib; 14. Axial rib; 15. Reinforcing rib; 16. Titanium bolt. Detailed Implementation

[0037] This embodiment uses a cathode roller with a diameter of 3600mm and a width of 1380mm. The total design current I is calculated using formula (1) as follows: I=1 / 2·k·s·j (1)

[0038] k is the total current correction factor for the embodiment, with a value of 1; based on the diameter and width of the cathode roller in the embodiment, the outer circumference S of the titanium cylinder is calculated to be 15599520 mm². 2 The current density j of the titanium material is 0.009 A / mm². 2 Substituting the data into formula (1), we obtain the total design current I of the cathode roller in the embodiment as 7000A.

[0039] The cathode roller comprises an aluminum alloy shaft 1, two titanium sleeves 2, two titanium sheaths 3, two titanium plates 4, two side conductive aluminum plates 5, a support cylinder 9, and a central conductive aluminum plate 10. The support cylinder 9 is mounted on the aluminum alloy shaft 1; the two side conductive aluminum plates 5 are respectively mounted on the aluminum alloy shaft 1, with the outer circumferential surface of each side conductive aluminum plate in contact with the inner circumferential surface at both ends of the support cylinder 9. The two titanium sleeves 2 are respectively mounted on the surface of the aluminum alloy shaft 1 and are located outside the two side conductive aluminum plates 5, with the end face of each side conductive aluminum plate in contact with the end face of the side conductive aluminum plate at its respective location. The two titanium plates 4 are respectively mounted on the outer circumferential surface of the titanium sleeves and are located on one side of the outer end face of each side conductive aluminum plate 5; each titanium plate 4 is fixed to the side conductive aluminum plate 5 at its respective location by titanium bolts and counterweights 7. Two titanium sleeves 3 are respectively fitted onto the outer circumferential surface of the titanium sleeve 2, positioned on the outer side of the titanium plate 4, with the inner end face of the titanium sleeve 3 fitting against the outer end face of the titanium plate 4 at its location. The outer end of the titanium sleeve 3 is welded to the outer circumferential surface of the titanium sleeve, and the inner ends of the titanium sleeve and the titanium plate are respectively welded to the titanium plate.

[0040] The central conductive aluminum plate 10 is located inside the support cylinder 9 and is fitted onto the outer circumferential surface of the aluminum alloy shaft 1; the central conductive aluminum plate 10 is located at the axial symmetry plane of the support cylinder.

[0041] The aluminum alloy shaft 1, two titanium sleeves 2, two titanium sheaths 3, two titanium plates 4, two side conductive aluminum plates 5, support cylinder 9, and central conductive aluminum plate 10 are coaxial.

[0042] In this embodiment, the aluminum alloy shaft is a stepped shaft formed by rolling, with the diameter of the small diameter section at both ends being 420mm and the diameter of the large diameter section in the middle being 450mm; the end faces formed by the diameter difference at both ends of the stepped shaft are the positioning surfaces of the two side conductive aluminum plates 5.

[0043] To ensure the conductivity of the cathode roller, the cross-sectional area of ​​the small-diameter section of the aluminum alloy shaft is greater than the minimum cross-sectional area S1 required for the aluminum alloy shaft to conduct electricity; the minimum cross-sectional area S1 is determined by (2) S1=I / 2(K1·J) (2)

[0044] S1 is the minimum conductive cross-sectional area required for the aluminum alloy shaft to conduct electricity, in mm. 2 I is the design total current of the cathode roller, in A; K1 is the cross-sectional conductivity correction factor, with a value of 1 to 1.5; J is the current density of the aluminum alloy, in A / mm². 2 .

[0045] In this embodiment, the total design current I of the cathode roller is 70000A; the cross-sectional conductivity correction factor K1 is set to 1; and the current density J of the aluminum alloy is 1.5A / mm². 2 Substituting the data into formula (2), the minimum conductive cross-sectional area S1 of the aluminum alloy shaft of the cathode roller in the embodiment is obtained as 23333 mm. 2 The cross-sectional area of ​​the aluminum alloy shaft must be greater than its minimum conductive cross-sectional area.

[0046] The titanium sleeve 2 is cylindrical, with a stepped outer circumferential surface. The outer diameter of the smaller outer diameter section is 430 mm, and the outer diameter of the larger outer diameter section is 440 mm. The inner diameter of the titanium sleeve is the same as the diameter of the smaller diameter section of the aluminum alloy shaft, ensuring a tight fit between the two after assembly.

[0047] The titanium sheath 3 is an annular plate, and its inner circumferential surface is tightly fitted with the outer circumferential surface of the large outer diameter section of the titanium sheath 2. In this embodiment, the titanium sheath is an annular plate with a diameter of Φ440×Φ540mm×10mm.

[0048] The titanium plate 4 is an annular plate, with its inner circumferential surface welded to the outer circumferential surface of the large outer diameter section of the titanium sleeve 2, and its outer circumferential surface welded to the inner circumferential surface of the titanium cylinder 8. Two rings of through holes are evenly distributed on the titanium plate 4 for mounting titanium bolt counterweights; the diameter of each through hole is 40 mm.

[0049] The titanium cap 6 is a Φ70mm×6mm annular plate used to seal the two through holes on the titanium plate and is welded to the titanium plate.

[0050] The two titanium rings 12 are respectively fixed at the outer edges of the outer end faces 4 of the two plates, with each titanium ring's outer end face 5mm lower than the outer end face of the titanium cylinder 8. Threaded holes are evenly distributed on each titanium ring for installing an insulating ring between the foil-making machine and the cathode roller. The inner circle of the titanium ring is welded to the outer end face of the titanium plate, and the outer circle of the titanium ring and the shaft surface are welded to the inner circumferential surface of the titanium cylinder 8. In this embodiment, the titanium ring is a circular ring with a diameter of Φ3580mm × Φ3460mm × 30mm.

[0051] The side conductive aluminum plate 5 is a Φ3550mm×Φ420mm×15mm annular plate with a cylindrical boss concentric with the inner circle at its inner end. The boss is 20mm thick and has an outer diameter of Φ1200mm. The inner surface of the boss is welded to the outer surface of the aluminum alloy shaft and has triangular reinforcing ribs between them. The outer surface of the boss is welded to the inner wall of the support cylinder and has triangular reinforcing ribs between them.

[0052] To ensure the conductivity of the cathode roller, the area of ​​the outer circumferential surface of the side conductive aluminum plate is greater than the minimum contact conductive area S′. n The area of ​​the inner circumferential surface of the side conductive aluminum plate is greater than the minimum contact conductive area S″. n；

[0053] The minimum contact conductive area S′ between the side conductive aluminum plate and the support cylinder is determined by formula (3-1). n S′ n =I / [(n+m)·K2·J] (3-1)

[0054] The minimum contact conductive area S″ between the side conductive aluminum plate and the aluminum alloy shaft is determined using formula (3-2). n S″ n =I / [(n+m)·K2·J] (3-2)

[0055] In the formula:

[0056] S′ n —Minimum conductive contact area between the side conductive aluminum plate and the support cylinder, in mm 2 ;

[0057] S″ n —Minimum conductive contact area between the side conductive aluminum plate and the aluminum alloy shaft, in mm 2 ;

[0058] I—Total design current of the cathode roller, in amperes (A);

[0059] n — the total number of side conductive aluminum plates included in the cathode roller;

[0060] m — the total number of central conductive aluminum plates contained in the cathode roller;

[0061] K2—Contact conductivity correction factor, with a value ranging from 0.5 to 1;

[0062] J – Current density of aluminum alloy, unit: A / mm² 2 .

[0063] In this embodiment, the total design current I of the cathode roller is 70000A; the total number of side conductive aluminum plates n of the cathode roller is 2; the total number of center conductive aluminum plates m of the cathode roller is 1; the contact conductivity correction factor K2 is 0.6; and the current density J of the aluminum alloy is 1.5A / mm². 2 .

[0064] Substituting the data into formula (3-1), we obtain the minimum contact conductive area S′ between the side conductive aluminum plate and the support cylinder. n 25925mm 2 The area of ​​the outer circumferential surface of the side conductive aluminum plate is greater than the minimum contact conductive area S′. n .

[0065] Substituting the data into formula (3-2), we obtain the minimum contact conductive area S″ between the side conductive aluminum plate and the aluminum alloy shaft. n 25925mm 2 The area of ​​the inner circumferential surface of the side conductive aluminum plate is greater than the minimum contact conductive area S″. n .

[0066] The side conductive aluminum plate has 12 evenly distributed weight-reducing fan-shaped holes. The side with the longer arc length of the fan-shaped hole is close to the outer circle surface of the side conductive aluminum plate and is 400mm away, while the side with the shorter arc length of the fan-shaped hole is close to the outer circle surface of the boss of the side conductive aluminum plate and is 260mm away.

[0067] To ensure the conductivity of the cathode roller, the number and position of the weight-reducing fan-shaped holes on the side conductive aluminum plate must not have a cross-sectional area smaller than its minimum conductive cross-sectional area S. n The minimum conductive cross-sectional area S of the side conductive aluminum plate n The following calculation is performed using formula (4): S n =I / [(n+m)·K1·J] (4)

[0068] The total design current I of the cathode roller in this embodiment is 70000A; the total number n of the side conductive aluminum plates included in the cathode roller in this embodiment is 2; the total number m of the center conductive aluminum plates included in the cathode roller in this embodiment is 1; the cross-sectional conductivity correction coefficient K1 is set to 1; and the current density J of the aluminum alloy is 1.5A / mm². 2 Substituting the data into formula (4) yields the minimum conductive cross-sectional area S of the side conductive aluminum plate of the cathode roller in the embodiment. n 15556mm 2 The cross-sectional area of ​​the side conductive aluminum plate is greater than its minimum conductive cross-sectional area S. n .

[0069] The side conductive aluminum plate has two rings of threaded through holes that mate with the titanium plate. The outer ring of threaded through holes is the mounting hole for the titanium bolt counterweight, and the inner ring is the connecting hole for connecting the titanium plate and the side conductive aluminum plate.

[0070] In this embodiment: the titanium cylinder is fitted onto the support cylinder; the specifications of the titanium cylinder are Φ3600mm×Φ3580mm×1380mm. The titanium cylinder is made of pure titanium, and the microstructure of the pure titanium is a single-phase equiaxed α structure with an average grain size grade of 11. The inner surface of the titanium cylinder has a threaded surface that mates with the support cylinder, and the inner circumferential surface of the titanium cylinder is silver-plated to a depth of 3-5 μm. The straightness and circular runout of the outer circumference of the titanium cylinder are ≤0.05mm, and the roughness Ra value is less than 0.2μm.

[0071] The support cylinder is mounted on an aluminum alloy shaft. The dimensions of the support cylinder are Φ3580mm×Φ3550mm×1358mm. The outer circumferential surface of the support cylinder is threaded, and the outer circumferential surface of the support cylinder is silver-plated to a thickness of 3-5μm.

[0072] The inner wall surface of the cathode roller support cylinder is evenly distributed with conductive paths. These conductive paths consist of two side conductive aluminum plates 5, a central conductive aluminum plate 10, multiple annular ribs 11, and multiple axial ribs 14. Each annular rib is arranged axially along the inner circumference of the support cylinder, with a center-to-center distance of 600 mm between adjacent annular ribs. Each axial rib is arranged circumferentially along the inner circumference of the support cylinder, with an included angle of 15° between adjacent axial ribs. The perpendicular intersections of the annular and axial ribs form a grid of conductive paths. Both ends of each axial rib are fixedly connected to the side conductive aluminum plate 5 at their respective ends.

[0073] To ensure the conductivity of the cathode roller, the cross-sectional area of ​​the support cylinder is greater than its minimum conductive cross-sectional area S2. The minimum conductive cross-sectional area S2 of the aluminum alloy shaft is calculated according to formula (5) as follows: S2=I / (K1·J) (5)

[0074] In this embodiment, the total design current I of the cathode roller is 70000A; the cross-sectional conductivity correction factor K1 is set to 1; and the current density J of the aluminum alloy is 1.5A / mm². 2 Substituting the data into formula (5), the minimum conductive cross-sectional area S2 of the support cylinder for the cathode roller in the embodiment is obtained as 46666 mm. 2 The cross-sectional area of ​​the support cylinder must be greater than its minimum conductive cross-sectional area S2.

[0075] The circumferential rib 11 has dimensions of Φ3550mm×Φ3310mm×15mm, and the axial rib 14 has dimensions of 300mm×100mm×15mm. To facilitate uniform current distribution on the titanium cylinder surface of the cathode roller, the inner wall of the cathode roller's support cylinder is uniformly distributed with a grid-like conductive path composed of side conductive aluminum plates, a central conductive aluminum plate, circumferential ribs, and axial ribs. The outer axial ribs connect adjacent side conductive aluminum plates 5 and circumferential ribs 11, respectively, while the middle axial ribs connect adjacent circumferential ribs 11 and the central conductive aluminum plate 10, thereby uniformly conducting the current on the titanium cylinder surface of the cathode roller through the support cylinder from the side conductive aluminum plates and the central conductive aluminum plate to the aluminum alloy shaft. The distance between the circumferential rib and an adjacent side conductive aluminum plate, central conductive aluminum plate, or circumferential rib is 300mm, and the angle between adjacent axial ribs is 15°.

[0076] The central conductive aluminum plate is a circular plate with a diameter of Φ3550mm × Φ450mm × 20mm. Each end of the central conductive aluminum plate has a cylindrical boss to increase its conductive area; the axial height of the boss is 10mm and its outer diameter is 1300mm. The central conductive aluminum plate is located inside the support cylinder and at its axial symmetry plane. The distance between the central conductive aluminum plate and the side conductive aluminum plates located at both ends of the support cylinder is 600mm. The inner circumferential surface of the central conductive aluminum plate is fixedly connected to the circumferential surface of the aluminum alloy shaft; the outer circumferential surface of the central conductive aluminum plate is fixedly connected to the inner surface of the support cylinder.

[0077] To ensure the conductivity of the cathode roller, the area of ​​the outer circumferential surface of the central conductive aluminum plate is greater than the minimum contact conductive area S′. m The area of ​​the inner circumferential surface of the central conductive aluminum plate is greater than the minimum contact conductive area S″. m；

[0078] The minimum contact conductive area S′ between the central conductive aluminum plate and the support cylinder is determined using formula (6-1). m S′ m =I / [(n+m)·K2·J] (6-1)

[0079] The minimum contact conductive area S″ between the central conductive aluminum plate and the aluminum alloy shaft is determined using formula (6-2). m S″ m =I / [(n+m)·K2·J] (6-2)

[0080] In the formula:

[0081] S′ m —Minimum conductive contact area between the central conductive aluminum plate and the support cylinder, in mm 2 ;

[0082] S″ m —Minimum conductive contact area between the central conductive aluminum plate and the aluminum alloy shaft, in mm 2 ;

[0083] I—Total design current of the cathode roller, in amperes (A);

[0084] n — the total number of side conductive aluminum plates included in the cathode roller;

[0085] m — the total number of central conductive aluminum plates contained in the cathode roller;

[0086] K2—Contact conductivity correction factor, with a value ranging from 0.5 to 1;

[0087] J – Current density of aluminum alloy, unit: A / mm² 2 .

[0088] In this embodiment, the total design current I of the cathode roller is 70000A; the total number n of the side conductive aluminum plates included in the cathode roller of this embodiment is 2; the total number m of the center conductive aluminum plates included in the cathode roller of this embodiment is 1; the contact conductivity correction factor K2 is 0.6; and the current density J of the aluminum alloy is 1.5A / mm². 2 Substituting the data into formula (6-1), we obtain the minimum contact conductive area S′ between the central conductive aluminum plate and the support cylinder. m 25925mm 2 The area of ​​the outer circumferential surface of the central conductive aluminum plate is greater than its minimum contact conductive area S′. m .

[0089] Substituting the data into formula (6-2), we obtain the minimum contact conductive area S″ between the central conductive aluminum plate and the aluminum alloy shaft. m 25925mm 2 The area of ​​the inner circumferential surface of the central conductive aluminum plate is greater than its minimum contact conductive area S″m.

[0090] The central conductive aluminum plate has 12 evenly distributed weight-reducing fan-shaped holes. The side with the longer arc length of the fan-shaped hole is close to the outer circle of the central conductive aluminum plate and is 400mm away. The side with the shorter arc length of the fan-shaped hole is close to the outer circle of the boss of the central conductive aluminum plate and is 260mm away.

[0091] To ensure the conductivity of the cathode roller, the number and position of the weight-reducing fan-shaped holes on the central conductive aluminum plate must not have a cross-sectional area smaller than its minimum conductive cross-sectional area S. m The minimum conductive cross-sectional area S of the central conductive aluminum plate m The following calculation is performed using formula (7): S m =I / [(n+m)·K1·J] (7)

[0092] The total design current I of the cathode roller in this embodiment is 70000A; the total number n of the side conductive aluminum plates included in the cathode roller in this embodiment is 2; the total number m of the center conductive aluminum plates included in the cathode roller in this embodiment is 1; the cross-sectional conductivity correction coefficient K1 is set to 1; and the current density J of the aluminum alloy is 1.5A / mm². 2 Substituting the data into formula (7) yields the minimum conductive cross-sectional area S of the central conductive aluminum plate of the cathode roller in the embodiment. m 15556mm 2 The cross-sectional area of ​​the central conductive aluminum plate is greater than its minimum conductive cross-sectional area S. m .

[0093] The aluminum alloy shaft, support cylinder, side conductive aluminum plate, central conductive aluminum plate, circumferential ribs, and axial ribs constitute the conductive path of the cathode roller. The aluminum alloy materials constituting the conductive path have a conductivity of 40% IACS and a resistivity of 0.04 Ω·mm² / m at temperatures ranging from 20℃ to 70℃.

Claims

1. A large-diameter cathode roller for electrolytic copper foil production, characterized in that, The device includes an aluminum alloy shaft (1), two titanium sleeves (2), two titanium sheaths (3), two titanium plates (4), two side conductive aluminum plates (5), an aluminum alloy support cylinder (9), and a central conductive aluminum plate (10). The support cylinder (9) is mounted on the aluminum alloy shaft (1). The two side conductive aluminum plates (5) are respectively mounted on the aluminum alloy shaft (1), such that the outer circumferential surface of each side conductive aluminum plate is in contact with the inner circumferential surface at both ends of the support cylinder (9). The two titanium sleeves (2) are respectively mounted on the surface of the aluminum alloy shaft (1) and are located on the outer side of the two side conductive aluminum plates (5), ensuring that each side is conductive. The end faces of the aluminum plates are respectively attached to the end faces of the side conductive aluminum plates at their respective positions; two titanium plates (4) are respectively fitted on the outer circumferential surface of the titanium sleeve and located on one side of the outer end face of each side conductive aluminum plate (5); each titanium plate (4) is fixedly connected to the side conductive aluminum plate (5) at its respective position by titanium bolt counterweight 7; two titanium sleeves (3) are respectively fitted on the outer circumferential surface of the titanium sleeve (2), located on the outside of the titanium plate (4), and the inner end face of the titanium sleeve (3) is attached to the outer end face of the titanium plate (4) at its respective position; the outer end of the titanium sleeve (3) is welded to the outer circumferential surface of the titanium sleeve, and the inner end of the titanium sleeve and the titanium sleeve are respectively welded to the titanium plate; The central conductive aluminum plate (10) is located inside the support cylinder (9) and is fitted onto the outer circumferential surface of the aluminum alloy shaft (1); the central conductive aluminum plate is located at the axial symmetry plane of the support cylinder.

2. The large-diameter cathode roller for electrolytic copper foil production as described in claim 1, characterized in that, The inner wall surface of the cathode roller support cylinder is uniformly distributed with conductive paths; the conductive paths consist of two side conductive aluminum plates (5), a central conductive aluminum plate (10), multiple annular ribs (11), and multiple axial ribs (14); each annular rib is arranged axially on the inner circumferential surface of the support cylinder, and the center distance between each two adjacent annular ribs is 600mm; each axial rib is arranged circumferentially on the inner circumferential surface of the support cylinder, and the included angle between each adjacent axial rib is 15°; the perpendicular intersection between the annular ribs and the axial ribs forms a grid of conductive paths; the two ends of each axial rib are respectively fixedly connected to the side conductive aluminum plate (5) at the end. The aluminum alloy material constituting the conductive path has an electrical conductivity > 40% IACS and an electrical resistivity < 0.04 Ω mm at a temperature of 20°C to 70°C 2 / m.

3. The large-diameter cathode roller for electrolytic copper foil production as described in claim 1, characterized in that, The central conductive aluminum plate has cylindrical bosses on both ends to increase its conductive area; the axial height of the boss is 10mm and the outer diameter is 1300mm; the central conductive aluminum plate is located inside the support cylinder and at its axial symmetry plane; the distance between the central conductive aluminum plate and the side conductive aluminum plates located at both ends of the support cylinder is 600mm; the inner circumferential surface of the central conductive aluminum plate is fixedly connected to the circumferential surface of the aluminum alloy shaft; the outer circumferential surface of the central conductive aluminum plate is fixedly connected to the inner surface of the support cylinder.

4. The large-diameter cathode roller for electrolytic copper foil production as described in claim 1, characterized in that, The cross-sectional area of ​​the small-diameter segment of the aluminum alloy shaft is greater than the minimum cross-sectional area S1 required for the aluminum alloy shaft to conduct electricity. The minimum cross-sectional area S1 is determined by (2): S1 = I / 2(K1·J) (2) In the formula: S1 is the minimum conductive cross-sectional area required for the aluminum alloy shaft to conduct electricity, with units of mm 2 ; I is the design total current of the cathode roller, with units of A; K1 is the cross-sectional conductive correction coefficient, with a value of 1-1.5; J is the current density of the aluminum alloy, with units of A / mm 2 .

5. The large-diameter cathode roller for electrolytic copper foil production as described in claim 4, characterized in that, The total design current I is calculated using formula (1): I = 1 / 2·k·s·j (1) In the formula, I is the designed total current of the cathode roller, in A; k is the correction coefficient of the designed total current of the cathode roller, and is 1-2; and s is the outer circle area of the designed cathode roller titanium cylinder, in mm 2 ; j is the current density of the titanium cylinder material in A / mm 2 .

6. The large-diameter cathode roller for electrolytic copper foil production as described in claim 1, characterized in that, The minimum contact conductive area S' of the side conductive aluminum plate and the support cylinder is determined by formula (3-1) n : S' n = I / [(n+m)·K2·J] (3-1) The minimum contact conductive area S" of the side conductive aluminum plate and the aluminum alloy shaft is determined by formula (3-2) n : S" n = I / [(n + m) - K2- J] (3-2) wherein S' is the minimum contact conductive area between the side conductive aluminum plate and the support cylinder, in mm n wherein S' is the minimum contact conductive area between the side conductive aluminum plate and the support cylinder, in mm 2 ; S" n is the minimum contact conductive area of the side conductive aluminum plate and the aluminum alloy shaft, in mm 2 ; I is the designed total current of the cathode roller, in A; n is the total number of side conductive aluminum plates contained by the cathode roller; m is the total number of central conductive aluminum plates contained in the cathode roller; K2 is a contact conductive correction coefficient, and the value is 0.5-1; J is the current density of the aluminum alloy, unit A / mm 2 .

7. The large-diameter cathode roller for electrolytic copper foil production as described in claim 1, characterized in that, The minimum conductive cross-sectional area S of the side conductive aluminum plate included in the cathode roller is determined by Equation (4) n : S n = I / [(n + m) · K1 · J] (4) In the formula: S n is the minimum conductive cross-sectional area of the side conductive aluminum plate, unit: mm 2 ; I is the design total current of the cathode roller, unit: A; n is the total number of side conductive aluminum plates contained by the cathode roller; m is the total number of center conductive aluminum plates contained by the cathode roller; K1 is the cross-sectional conductive correction coefficient, the cross-sectional conductive value is 1~1.5; J is the current density of aluminum alloy, unit: A / mm 2 .

8. The large-diameter cathode roller for electrolytic copper foil production as described in claim 1, characterized in that, The minimum conductive cross-sectional area S2 of the support cylinder included in the cathode roller is determined by formula (5): S2=I / (K1·J) (5) wherein: S2 is the minimum conductive cross-sectional area required for the support cylinder to conduct electricity, in mm 2 ; I is the designed total current of the cathode roller, in A; K1 is the cross-section conductive correction coefficient, with a value of 1-1.5; J is the current density of the aluminum alloy, in A / mm 2 .

9. The large-diameter cathode roller for electrolytic copper foil production as described in claim 1, characterized in that, The minimum contact conductive area S' of the center conductive aluminum plate and the support cylinder is determined by formula (6-1) m : S' m = I / [(n+m)·K2·J] (6-1) The minimum contact conductive area S″ between the central conductive aluminum plate and the aluminum alloy shaft is determined using formula (6-2). m : S″ m =I / [(n+m)·K2·J] (6-2) In the formula: S′ m It is the minimum conductive contact area between the central conductive aluminum plate and the support cylinder, in mm. 2 ;S″ m It is the minimum contact conductive area between the central conductive aluminum plate and the aluminum alloy shaft, in mm. 2 I is the design total current of the cathode roller, in A; n is the total number of side conductive aluminum plates included in the cathode roller. m is the total number of centrally conductive aluminum plates included in the cathode roller; K2 is the contact conductivity correction factor, ranging from 0.5 to 1; J is the current density of the aluminum alloy, in A / mm². 2 .

10. The large-diameter cathode roller for electrolytic copper foil production as described in claim 1, characterized in that, The minimum conductive cross-sectional area S of the central conductive aluminum plate of the cathode roller is determined by formula (7). m S m =I / [(n+m)·K1·J] (7) In the formula: S m It is the minimum conductive cross-sectional area of ​​the central conductive aluminum plate, in mm. 2 I is the total design current of the cathode roller, in A; n is the total number of side conductive aluminum plates included in the cathode roller; m is the total number of center conductive aluminum plates included in the cathode roller; K1 is the cross-sectional conductivity correction factor, with a value of 1 to 1.5; J is the current density of the aluminum alloy, in A / mm². 2 .

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