Ceramic roller for cooling, manufacturing method therefor, and film coating system

Abstract

The present application relates to the technical field of film material manufacturing. Provided are a ceramic roller for cooling, a manufacturing method therefor, and a film coating system. The preparation method for the ceramic roller for cooling comprises the following steps: providing a metal roller blank, the surface of the metal roller blank having a metal layer made of Al and / or an Al alloy; with the metal roller blank as an anode, forming an aluminum oxide ceramic layer having a thickness of ≤100 μm on the surface of the metal layer by means of anodic oxidation, so as to obtain a ceramic roller intermediate; and sequentially performing organic hole sealing treatment and grinding and polishing treatment on the surface of the aluminum oxide ceramic layer of the ceramic roller intermediate, so as to obtain the ceramic roller for cooling. After being energized, the ceramic roller for cooling can generate a large electrostatic attraction force between the ceramic layer and a film material, so that the film material and the ceramic layer are closely and fully fitted to each other; in addition, since the ceramic layer is dense, a better cooling effect can be provided for the film material, thereby improving product yield and production capacity.

Description

A ceramic roller for cooling, its preparation method, and a coating system thereof.

[0001] Cross-references to related applications

[0002] This disclosure claims priority to Chinese Patent Application No. 2024118792691, filed on December 19, 2024, entitled "A Ceramic Roller for Cooling and its Preparation Method and Coating System", the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to the field of membrane manufacturing technology, and more specifically, to a cooling ceramic roller and its preparation method, and a coating system. Background Technology

[0004] With the rapid development of the new energy industry, the demand for novel composite materials based on polymer thin film materials is becoming increasingly apparent, such as the development of composite current collectors and their widespread application in secondary batteries. The preparation of composite current collectors typically involves using a thin-film polymer film as the base film, and then forming a conductive metal layer on the base film using coating equipment (such as roll-to-roll evaporation coating or magnetron sputtering coating). However, the high temperatures generated during the coating process can easily lead to problems such as scorching, wrinkling, or even breakage of the film material during preparation. To ensure the preparation of high-quality composite current collectors, cooling ceramic rollers are usually required. Specifically, a ceramic roller (with a channel for heat exchange medium transport inside the roller body, the roller body being a conductive material, and the roller body surface being an insulating ceramic layer) is connected to either a positive or negative electrode, while the conductive metal layer on the membrane material is connected to the opposite negative or positive electrode voltage. This creates a bias voltage between the ceramic roller and the conductive metal layer of the membrane material, resulting in a polar charge on the ceramic layer side and a corresponding opposite charge on the membrane material side. This electrostatic adsorption of the two polarities allows the membrane material to adhere tightly to the ceramic layer surface during the manufacturing process, enabling rapid cooling of the membrane material through heat exchange. However, the ceramic layer in the cooling ceramic roller is typically formed using a plasma spraying process, which suffers from weak electrostatic adsorption forces. This makes it difficult for the membrane material and the ceramic layer to adhere tightly and fully. Furthermore, the ceramic layer prepared by this process has poor density (weak thermal conductivity), resulting in poor cooling of the membrane material, which in turn affects product yield and production capacity. Summary of the Invention

[0005] The purpose of this application is to provide a cooling ceramic roller and its preparation method and coating system. After being energized, the cooling ceramic roller can generate a large electrostatic adsorption force between the ceramic layer and the film material, so that the film material and the ceramic layer are tightly and fully bonded. In addition, the relatively dense ceramic layer can provide a better cooling effect for the film material, thereby improving the product yield and production capacity.

[0006] The embodiments of this application are implemented as follows:

[0007] In a first aspect, embodiments of this application provide a method for preparing a ceramic roller for cooling, comprising the following steps:

[0008] A metal roller blank is provided, the interior of which has channels configured to transport coolant, and the surface of the metal roller blank has a metal layer made of Al and / or Al alloy; using the metal roller blank as an anode, an alumina ceramic layer with a thickness ≤100 μm is formed on the surface of the metal layer by anodizing to obtain a ceramic roller intermediate; the surface of the alumina ceramic layer of the ceramic roller intermediate is subjected to organic sealing treatment and grinding and polishing treatment in sequence to obtain a ceramic roller for cooling.

[0009] In the aforementioned technical solutions, during the preparation of the cooling ceramic roller, the ceramic layer is typically formed using plasma spraying. The thickness of the ceramic layer is usually over 100 μm (too thick a ceramic layer results in weak electrostatic adsorption between it and the membrane material after energization), and it suffers from poor density (poor thermal conductivity), making it difficult to quickly and effectively cool the membrane material. This application innovatively applies anodizing technology to the preparation of the cooling ceramic roller. The ceramic layer formed by this method has a smaller and controllable thickness (a smaller ceramic layer results in stronger electrostatic adsorption between it and the membrane material after energization), and the resulting ceramic layer has high density (good thermal conductivity), allowing the cooling ceramic roller to adhere tightly and fully to the membrane material after energization (better adhesion leads to more efficient heat transfer and better cooling). Furthermore, the ceramic layer's superior thermal conductivity provides a better cooling effect for the membrane material, thereby improving product yield and production capacity.

[0010] In some alternative implementations, the thickness of the alumina ceramic layer is 30–70 μm.

[0011] In the above technical solution, the lower limit of the thickness of the alumina ceramic layer is to enable it to have a suitable voltage resistance, thereby improving the problem that the alumina ceramic layer may be broken down by voltage after being energized; the upper limit of the thickness of the alumina ceramic layer is to enable it to form a large electrostatic adsorption force with the membrane material after being energized and also to have a relatively good thermal conductivity, thereby improving the cooling effect of the membrane material.

[0012] In some alternative embodiments, in the step of forming an alumina ceramic layer on the surface of the metal layer by anodizing, the processing temperature is 22~24°C, the processing time is 25~35 min, and the current density is 0.5~2 A / mm. 2 The molar concentration of hydrogen ions in the electrolyte is 3~4.1 mol / L.

[0013] In the above technical solution, during the anodizing process, the processing temperature, processing time, current density, and molar concentration of hydrogen ions in the electrolyte are all limited to specific ranges. This allows for the convenient and efficient formation of a ceramic layer with uniform thickness, high density, and a thickness in the range of 30~70 μm on the surface of the metal layer. This enables the ceramic layer to form a large electrostatic adsorption force with the film material after energization and also has excellent thermal conductivity.

[0014] In some alternative implementations, the grinding and polishing step satisfies at least one of the following conditions A to C:

[0015] A until the roughness Ra of the alumina ceramic layer is ≤0.2 μm.

[0016] B. Until the thickness uniformity deviation of the alumina ceramic layer is <±15%.

[0017] C until the surface flatness deviation of the alumina ceramic layer is < ±20 μm.

[0018] In the above technical solution, during the grinding and polishing process, the roughness, thickness uniformity deviation, and surface flatness deviation of the alumina ceramic layer are limited to the above ranges, which enables the ceramic layer and the membrane material to adhere more tightly and fully after being energized, thereby improving the cooling effect on the membrane material. At the same time, it also makes the cooling rate of each area of ​​the membrane material more consistent, thereby improving the quality of the product.

[0019] Secondly, embodiments of this application provide a cooling ceramic roller, which is prepared using the method for preparing a cooling ceramic roller as provided in the first aspect embodiment.

[0020] In the above technical solution, the cooling ceramic roller is prepared by the method for preparing the cooling ceramic roller provided in the first aspect embodiment. The cooling ceramic roller has the advantages of small thickness and high density. After being energized, it can be tightly and fully bonded to the film material (the better the bonding effect, the more sufficient the heat transfer, and the better the cooling effect). In addition, the ceramic layer has excellent thermal conductivity, which can provide a better cooling effect for the film material, thereby improving the product yield and production capacity.

[0021] In some alternative embodiments, the cooling ceramic roller comprises a metal roller blank and an alumina ceramic layer on its surface.

[0022] In some alternative embodiments, the metal roll blank has a channel configured to convey coolant, and the outlet channel is located between the inlet channel and the alumina ceramic layer.

[0023] In some alternative embodiments, the cooling ceramic roller includes a metal roller blank and an alumina ceramic layer on its surface, wherein the metal roller blank includes a substrate and an Al metal layer located on the surface of the substrate, and the alumina ceramic is located on the surface of the Al metal layer.

[0024] In some alternative embodiments, a channel configured to deliver coolant is formed within the substrate, and the outlet channel is located between the inlet channel and the alumina ceramic layer.

[0025] Thirdly, embodiments of this application provide a coating system including a cooling ceramic roller as provided in the second aspect embodiment.

[0026] In the above technical solution, the coating system includes a cooling ceramic roller as provided in the second aspect embodiment. Since the ceramic layer on the ceramic roller is prepared by anodizing, it has the advantages of small thickness and high density. After being energized, it can be tightly and fully bonded to the film material (the better the bonding effect, the more sufficient the heat transfer, and the better the cooling effect). In addition, the ceramic layer has excellent thermal conductivity, which can provide a better cooling effect for the film material, thereby improving the product yield and the production capacity of the coating system.

[0027] In some alternative embodiments, the coating system includes a coating source, a plurality of cooling ceramic rollers, and a plurality of passing rollers. The plurality of cooling ceramic rollers are all located above the coating source and are distributed in sequence at intervals. The plurality of cooling ceramic rollers extend from one side of the coating area of ​​the coating source to the opposite side to cover the entire coating area. A passing roller is provided between two adjacent cooling ceramic rollers and is located on the side of the cooling ceramic rollers away from the coating source.

[0028] In the above-mentioned technical solutions, current coating systems typically use a single large-diameter cooling ceramic roller. This type of coating system usually cannot cover the entire coating area of ​​the coating source, resulting in a large amount of material waste. In addition, during the conveying process of the film material, under the same film roll tension, since the radial pressure applied to the surface of the ceramic roller by the film roll is inversely proportional to its diameter, when using a single large-diameter cooling ceramic roller, the radial force exerted by the film material on the large-diameter cooling ceramic roller is relatively small, resulting in poor adhesion between the two, which in turn affects the cooling effect of the film material. In this application, multiple small-diameter cooling ceramic rollers are used and arranged to extend from one side of the coating area of ​​the coating source to the opposite side to cover the entire coating area. This improves the utilization rate of the coating source material, thereby reducing coating costs. Furthermore, compared to a large-diameter single roller, using multiple small-diameter rollers helps improve coating uniformity and facilitates precise control of coating thickness. Moreover, by using multiple small-diameter cooling ceramic rollers relative to a single large-diameter cooling ceramic roller, the radial force exerted by the film material on the cooling ceramic rollers is increased under the same film roll tension, allowing for better adhesion and improved cooling effect on the film material. Additionally, the overpass roller between adjacent cooling ceramic rollers is located on the side of the cooling ceramic roller facing away from the coating source, enabling the material to reach the base film conveniently and quickly, thereby improving coating efficiency and reducing material waste.

[0029] In some alternative implementations, the diameter of each cooling ceramic roller is 100 to 300 mm.

[0030] In some alternative implementations, the coating system is a roll-to-roll evaporation coating system, with one coating source and the distance from the geometric center of the plurality of cooling ceramic rollers to the geometric center of the coating source is 50 to 150 cm.

[0031] In the above technical solution, when the coating system is a roll-to-roll evaporation coating system, the distance from the geometric center of each cooling ceramic roller to the geometric center of the coating source is limited to a specific range, which can better receive atomic particles from the coating source, thereby facilitating the formation of a conductive metal layer; at the same time, the appropriate distance also helps to reduce some of the heat of the atomic particles during the transport process, thereby reducing the temperature of the atomic particles when they reach the surface of the film material, that is, reducing the source temperature, thereby preparing a high-quality composite current collector.

[0032] In some alternative implementations, the geometric centers of the multiple cooling ceramic rollers are all equidistant from the geometric center of the coating source.

[0033] In the above technical solution, the distance from the geometric center of the multiple cooling ceramic rollers to the geometric center of the coating source is set to the same form, that is, the multiple cooling ceramic rollers are distributed in an arc shape with equal spacing around the coating source. This has the advantage of a more regular structural design. At the same time, the film material on the multiple cooling ceramic rollers can also receive atomic particles from the coating source at equal intervals, thereby improving the coating uniformity of atomic particles and preparing a conductive metal layer with a more uniform thickness.

[0034] In some alternative implementations, the coating system is a magnetron sputtering coating system, with multiple coating sources, and multiple cooling ceramic rollers are located above the coating sources and distributed sequentially at intervals along the horizontal direction.

[0035] In the above technical solution, when the coating system is a magnetron sputtering coating system, multiple cooling ceramic rollers are located above the coating source and are arranged in a horizontally spaced manner, that is, multiple cooling ceramic rollers are arranged horizontally side by side, which can make the shape of the cavity rectangular, with advantages such as small space occupation, easy preparation and low manufacturing cost.

[0036] In some alternative implementations, multiple baffles are also included, with a baffle configured to block atomic particles disposed between two adjacent cooling ceramic rollers. The baffles are located on the side of the cooling ceramic roller away from the coating source and are located between the passing roller and the cooling ceramic roller. Attached Figure Description

[0037] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0038] Figure 1 is a process flow diagram of a method for preparing a cooling ceramic roller according to an embodiment of this application;

[0039] Figure 2 is a schematic diagram of the structure of the first type of cooling ceramic roller provided in the embodiment of this application;

[0040] Figure 3 is a schematic diagram of the structure of the second type of cooling ceramic roller provided in the embodiment of this application;

[0041] Figure 4 is a schematic diagram of the structure of the first coating system provided in the embodiment of this application;

[0042] Figure 5 is a schematic diagram of the structure of the second coating system provided in the embodiment of this application.

[0043] Icons: 100-Ceramic roller for cooling; 110-Metal roller blank; 110a-Substrate; 110b-Al metal layer; 111-Outlet channel; 112-Inlet channel; 120-Alumina ceramic layer; 10-Coating system; 200-Coating source; 300-Roller; 400-Baffle. Embodiments of the present invention

[0044] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0045] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0046] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0047] In the description of this application, it should be noted that the terms "center", "upper", "lower", "vertical", "horizontal", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this application is in use. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0048] Furthermore, terms such as "horizontal," "vertical," and "sag" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0049] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set up," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0050] The following provides a detailed description of a cooling ceramic roller, its preparation method, and its coating system.

[0051] In a first aspect, embodiments of this application provide a method for preparing a ceramic roller for cooling, comprising the following steps:

[0052] A metal roller blank is provided, the interior of which has channels configured to transport coolant, and the surface of the metal roller blank has a metal layer made of Al and / or Al alloy; using the metal roller blank as an anode, an alumina ceramic layer with a thickness ≤100 μm is formed on the surface of the metal layer by anodizing to obtain a ceramic roller intermediate; the surface of the alumina ceramic layer of the ceramic roller intermediate is subjected to organic sealing treatment and grinding and polishing treatment in sequence to obtain a ceramic roller for cooling.

[0053] In related technologies, the preparation process of cooling ceramic rollers mainly employs plasma spraying technology. Specifically, on a leveled and cleaned metal roller blank, a metal bonding layer is first sprayed onto the clean roller blank surface using plasma spraying. Then, a ceramic layer is sprayed onto the bonding layer using plasma spraying. The surface of the ceramic layer is then subjected to organic sealing and polishing treatments to form a ceramic layer with a thickness of over 100 μm. The ceramic layer of the cooling ceramic roller prepared by this process is too thick, resulting in weak electrostatic adsorption between the roller and the membrane material after energization. Furthermore, it suffers from poor density and thermal conductivity, making it difficult to quickly and effectively cool the membrane material.

[0054] This application innovatively applies anodizing technology to the fabrication process of a cooling ceramic roller. It is understood that, comparatively, the ceramic layer formed by this method has a smaller and more controllable thickness, which facilitates stronger electrostatic adsorption between the roller and the membrane material when energized. Furthermore, the ceramic layer formed by this method has high density and excellent thermal conductivity. This allows the cooling ceramic roller to adhere tightly and fully to the membrane material after energization. The tighter the adhesion, the more efficient the heat transfer and the more significant the cooling effect. Combined with the excellent thermal conductivity of the ceramic layer itself, the overall cooling efficiency of the membrane material is significantly improved, thereby increasing product yield and production capacity.

[0055] It should be noted that although anodizing is a commonly used technique for preparing ceramic layers, its primary purpose is usually to modify the substrate itself, such as improving its wear resistance, corrosion resistance, impact resistance, or hardness. To date, the inventors have not found any reports of applying this technique to coating systems for preparing cooling ceramic rollers. Therefore, in this application, the inventors innovatively apply anodizing technology to the preparation process of cooling ceramic rollers, thereby solving the problem that existing cooling ceramic rollers cannot achieve rapid and effective cooling of the film material, representing a significant innovation in this field.

[0056] It should be noted that the configuration of the metal roll blank is not limited and can be adapted to actual needs. For example, the metal roll blank can be made entirely of Al material, that is, the metal roll blank is a one-piece structure; or the metal roll blank can be set as a combination of different materials, such as the base material is stainless steel, the outer peripheral wall of the stainless steel is provided with a layer of Al metal, and the interior of the base has channels configured to transport coolant.

[0057] As an example, the thickness of the alumina ceramic layer is 30 to 70 μm, for example, but not limited to any one of the values ​​of 30 μm, 40 μm, 50 μm, 60 μm and 70 μm or any range between the two.

[0058] In this embodiment, the lower limit of the thickness of the alumina ceramic layer is set to enable it to have a more suitable voltage resistance, thereby improving the problem that the alumina ceramic layer may be broken down by voltage after being energized; the upper limit of the thickness of the alumina ceramic layer is set to enable it to form a larger electrostatic adsorption force with the membrane material after being energized, thereby improving the thermal conductivity and thus improving the cooling effect on the membrane material.

[0059] As an example, in the step of forming an alumina ceramic layer on the surface of a metal layer by anodizing, the processing temperature is 22~24℃, for example, but not limited to any one of 22℃, 22.5℃, 23℃, 23.5℃, and 24℃, or any range between the two; the processing time is 25~35 min, for example, but not limited to any one of 25 min, 26 min, 27 min, 28 min, 29 min, 30 min, 31 min, 32 min, 33 min, 34 min, and 35 min, or any range between the two; and the current density is 0.5~2 A / mm. 2 For example, but not limited to, a current density of 0.5 A / mm 2 1 A / mm 2 1.5 A / mm 2 and 2 A / mm2 The value can be any point in the range or any range between the two; the molar concentration of hydrogen ions in the electrolyte is 3 to 4.1 mol / L, for example, but not limited to any point in the range of 3 mol / L, 3.1 mol / L, 3.2 mol / L, 3.3 mol / L, 3.4 mol / L, 3.5 mol / L, 3.6 mol / L, 3.7 mol / L, 3.8 mol / L, 3.9 mol / L, 4.0 mol / L and 4.1 mol / L or any range between the two.

[0060] In this embodiment, during the anodizing process, the processing temperature, processing time, current density, and molar concentration of hydrogen ions in the electrolyte are all limited to specific ranges. This allows for the convenient and efficient formation of a ceramic layer with uniform thickness, high density, and a thickness in the range of 30-70 μm on the surface of the metal layer. This enables the ceramic layer to form a large electrostatic adsorption force with the membrane material after energization, while maintaining excellent thermal conductivity, thereby improving the cooling effect on the membrane material.

[0061] As an example, in the grinding and polishing process, at least one of the following conditions A to C must be met:

[0062] A until the roughness Ra of the alumina ceramic layer is ≤0.2 μm.

[0063] B. Until the thickness uniformity deviation of the alumina ceramic layer is <±15%.

[0064] C until the surface flatness deviation of the alumina ceramic layer is < ±20 μm.

[0065] In other words, when any of the above conditions are met during the grinding and polishing process, the process is considered complete and processing is stopped. For example, when the surface roughness first reaches Ra ≤ 0.2 μm, the polishing operation can be terminated; or when the thickness uniformity deviation is improved to less than ±15%, or the surface flatness deviation is controlled within ±20 μm, the process can also be ended.

[0066] In this embodiment, during the grinding and polishing process, the roughness, thickness uniformity deviation, and surface flatness deviation of the alumina ceramic layer are limited to the above-mentioned ranges, which also enables the ceramic layer and the membrane material to adhere more tightly and fully after being energized, thereby improving the cooling effect on the membrane material; at the same time, the above conditions also make the cooling rate of each area of ​​the membrane material more consistent, thereby improving the quality of the composite current collector.

[0067] It should be noted that for processes or steps in the preparation of ceramic rollers for cooling that are not specifically described or limited, they can be set according to conventional methods in the field.

[0068] As an example, the process flow diagram of the method for preparing a ceramic roller for cooling is exemplarily shown in Figure 1.

[0069] Furthermore, this application provides a cooling ceramic roller, which is prepared using the method for preparing a cooling ceramic roller provided in the foregoing embodiments.

[0070] In this application, the cooling ceramic roller is manufactured using the method for preparing a cooling ceramic roller as provided in the first aspect embodiment. This cooling ceramic roller has the advantages of small thickness and high density, and can adhere tightly and fully to the film material after being energized. The tighter the adhesion, the more sufficient the heat transfer, and the more ideal the cooling effect. Combined with the excellent thermal conductivity of the ceramic layer, the overall cooling efficiency of the film material is significantly improved, thereby effectively ensuring the stability of the coating process and improving product yield and production capacity.

[0071] To better understand the technical solution, two specific structural diagrams of the cooling ceramic roller 100 are provided for illustration. See Figures 2 and 3 for details. Figure 2 shows the metal roller blank 110, which is entirely made of Al metal. Specifically, the cooling ceramic roller 100 includes a metal roller blank 110 and an alumina ceramic layer 120 on its surface. The metal roller blank 110 has channels configured to transport coolant, with the outlet channel 111 located between the inlet channel 112 and the alumina ceramic layer 120. Figure 3 shows the metal roller blank 110... The cooling ceramic roller 100 is formed by combining a stainless steel base 110a and an Al metal layer 110b. Specifically, the cooling ceramic roller 100 includes a metal roller blank 110 and an alumina ceramic layer 120 on the surface. The metal roller blank 110 includes a base 110a and an Al metal layer 110b on the surface of the base 110a. The alumina ceramic layer 120 is located on the surface of the Al metal layer 110b. The base 110a has a channel configured to transport coolant, and the outlet channel 111 is located between the inlet channel 112 and the alumina ceramic layer 120.

[0072] Furthermore, embodiments of this application provide a coating system including a cooling ceramic roller provided in the foregoing embodiments.

[0073] In this embodiment, the coating system includes a cooling ceramic roller as provided in the second aspect embodiment. Since the ceramic layer on the roller is prepared by anodizing, it has the advantages of small thickness and high density. After being energized, it can adhere tightly and fully to the film material. The tighter the adhesion, the more efficient the heat transfer, and the more ideal the cooling effect. Furthermore, the ceramic layer has excellent thermal conductivity, significantly improving the overall cooling efficiency of the film material, thereby effectively ensuring the stability of the coating process and improving product yield and production capacity.

[0074] Furthermore, the inventors discovered that current coating systems typically employ large-diameter single cooling ceramic rollers. This type of coating system often struggles to cover the entire coating area of ​​the coating source, resulting in significant material waste. Additionally, during film transport, under the same roll tension, the radial pressure exerted on the ceramic roller surface is inversely proportional to its diameter. This means that when using a large-diameter single cooling ceramic roller, the radial force exerted by the film on the roller is relatively small, leading to poor adhesion and consequently affecting the cooling effect on the film. Consequently, the coating system struggles to meet the coating requirements of composite current collectors. Therefore, considering manufacturing costs and product yield, the inventors further optimized the structure of the coating system.

[0075] Referring to Figures 4 and 5, as an example, the coating system 10 includes a coating source 200, a plurality of cooling ceramic rollers 100, and a plurality of guide rollers 300. Each cooling ceramic roller 100 has a diameter of 100-300 mm, including but not limited to any value among 100 mm, 150 mm, 200 mm, 250 mm, and 300 mm, or any range between both. The plurality of cooling ceramic rollers 100 are located above the coating source 200 and are distributed sequentially at intervals. The plurality of cooling ceramic rollers 100 extend from one side of the coating area of ​​the coating source 200 to the opposite side to cover the entire coating area. A guide roller 300 is disposed between two adjacent cooling ceramic rollers 100, and this guide roller 300 is located on the side of the cooling ceramic roller 100 opposite to the coating source 200.

[0076] In this embodiment, multiple small-diameter cooling ceramic rollers 100 are used, and these rollers are positioned to extend from one side of the coating area of ​​the coating source 200 to the opposite side to cover the entire coating area. This improves the utilization rate of the raw materials in the coating source 200, thereby reducing coating costs. Furthermore, compared to a single large-diameter roller, using multiple small-diameter rollers helps improve coating uniformity and facilitates precise control of coating thickness. Moreover, by using multiple small-diameter cooling ceramic rollers 100 relative to a single large-diameter roller 100, the radial force exerted by the film material on the cooling ceramic rollers 100 under the same film roll tension is increased, allowing for better adhesion and improved cooling effect on the film material, thus contributing to higher product yield. Additionally, the guide roller 300 between adjacent cooling ceramic rollers 100 is located on the side of the cooling ceramic roller 100 away from the coating source 200, allowing the raw material to reach the base film conveniently and quickly, thereby improving coating efficiency and reducing material waste.

[0077] It should be noted that there is no limitation on the specific type of coating system. Any coating system that requires the use of a ceramic roller for auxiliary cooling can be applied, such as the commonly used roll-to-roll evaporation coating system and magnetron sputtering coating system. The specific system can be adapted to meet the actual needs.

[0078] Referring to Figure 4, as an example, the coating system 10 is a roll-to-roll evaporation coating system, and there is one coating source 200. The distance from the geometric center of the plurality of cooling ceramic rollers 100 to the geometric center of the coating source 200 is 50-150 cm, for example, but not limited to, any point value or any range between 50 cm, 60 cm, 70 cm, 80 cm, 90 cm, 100 cm, 110 cm, 120 cm, 130 cm, 140 cm, and 150 cm.

[0079] In this embodiment, when the coating system 10 is a roll-to-roll evaporation coating system, the distance from the geometric center of each cooling ceramic roller 100 to the geometric center of the coating source 200 is limited to a specific range, which can better receive atomic particles from the coating source 200, thereby facilitating the formation of a conductive metal layer; at the same time, the appropriate distance also helps to reduce some of the heat of the atomic particles during the transport process, thereby reducing the temperature of the atomic particles when they reach the surface of the film material, that is, reducing the source temperature, thereby preparing a high-quality composite current collector.

[0080] It should be noted that in other possible implementations, there may be multiple coating sources 200.

[0081] Referring to Figure 4, as an example, the distances from the geometric center of the plurality of cooling ceramic rollers 100 to the geometric center of the coating source 200 are all equal.

[0082] In this embodiment, the distance from the geometric center of the multiple cooling ceramic rollers 100 to the geometric center of the coating source 200 is set to the same form, that is, the multiple cooling ceramic rollers 100 are arranged in an arc shape with equal spacing around the coating source 200. This has the advantage of a more regular structural design. At the same time, the film material on the multiple cooling ceramic rollers 100 can also receive atomic particles from the coating source 200 at equal intervals, thereby improving the coating uniformity of atomic particles and preparing a conductive metal layer with a more uniform thickness.

[0083] Referring to Figure 5, as an example, the coating system 10 is a magnetron sputtering coating system, with multiple coating sources 200, and multiple cooling ceramic rollers 100 are located above the coating sources 200 and are distributed sequentially at intervals along the horizontal direction.

[0084] In this embodiment, when the coating system 10 is a magnetron sputtering coating system, multiple cooling ceramic rollers 100 are located above the coating source 200 and are arranged in a horizontally spaced manner, that is, multiple cooling ceramic rollers 100 are arranged in a horizontally parallel manner, which can make the shape of the cavity rectangular, and has the advantages of small space occupation, easy preparation and low manufacturing cost.

[0085] It should be noted that in other possible implementations, the coating source 200 may also be a single source.

[0086] Furthermore, it should be noted that any structural or functional units in each coating system 10 that are not specifically described or limited can be configured in accordance with conventional choices in the art.

[0087] As an example, a baffle 400 configured to block atomic particles is also provided between two adjacent cooling ceramic rollers 100. The baffle 400 is located on the side of the cooling ceramic roller 100 away from the coating source 200, and the baffle 400 is located between the passing roller 300 and the cooling ceramic roller 100.

[0088] The features and performance of this application will be further described in detail below with reference to the embodiments.

[0089] Example 1

[0090] This application provides a method for preparing a ceramic roller for cooling, comprising the following steps:

[0091] A metal roll blank made of Al metal with a diameter of 250 mm is provided. The interior of the metal roll blank has channels configured for conveying coolant, as shown in Figure 2. Using the metal roll blank as the anode, an alumina ceramic layer is formed on the surface of the metal layer by anodizing. The anodizing step is performed at a temperature of 23°C, a processing time of 30 min, and a current density of 1 A / mm². 2 The molar concentration of hydrogen ions in the electrolyte is 3.5 mol / L, resulting in a ceramic roller intermediate with an alumina ceramic layer of 60 μm thickness. The surface of the alumina ceramic layer of the ceramic roller intermediate is subjected to organic sealing treatment and grinding and polishing treatment in sequence. In the grinding and polishing treatment step, the roughness Ra of the alumina ceramic layer is 0.2 μm, the thickness uniformity deviation of the alumina ceramic layer is ±5%, and / or the surface flatness deviation of the alumina ceramic layer is ±5 μm, to obtain a ceramic roller for cooling.

[0092] Comparative Example 1

[0093] This application provides a comparative example of a method for preparing a ceramic roller for cooling, comprising the following steps:

[0094] A metal roll blank with a diameter of 250 mm is provided. The interior of the metal roll blank has channels configured for conveying coolant. A nickel-based alloy bonding layer and an alumina ceramic layer are sequentially formed on the surface of the metal roll blank using plasma spraying deposition technology to obtain a ceramic roll intermediate with an alumina ceramic layer with a thickness of 150 μm. The surface of the alumina ceramic layer of the ceramic roll intermediate is subjected to organic sealing treatment and grinding and polishing treatment. In the grinding and polishing treatment step, the roughness Ra of the alumina ceramic layer is 0.2 μm, the thickness uniformity deviation of the alumina ceramic layer is ±5%, and the surface flatness deviation of the alumina ceramic layer is ±5 μm to obtain a cooling ceramic roll.

[0095] Test case

[0096] Electrostatic adsorption force test

[0097] Test method:

[0098] A 4.5 μm thick polyethylene terephthalate (PET) film was used as the base film, and a 1 μm thick conductive metal layer was coated on the base film as the composite current collector. The cooling ceramic rollers prepared in Example 1 and Comparative Example 1 were used as test objects. The conductive metal layer was attached to the ceramic layer of the cooling ceramic roller. A bias voltage of 250 V was applied between the metal roller blank of the ceramic roller and the conductive metal layer, so that the film material was tightly adsorbed on the ceramic roller. Then, the film material was pulled tangentially from the ceramic roller, with the force gradually increasing until the film material slid relative to the ceramic layer. The pulling force during sliding was recorded, which is the magnitude of the electrostatic adsorption force. The results are recorded in Table 1.

[0099] Table 1

[0100]

[0101] Referring to Table 1, the test results of Example 1 and Comparative Example 1 show that, according to the preparation process provided in the embodiments of this application, that is, the ceramic layer on the cooling ceramic roller is prepared by anodizing. Compared with the conventional plasma spraying process for preparing the ceramic layer on the cooling ceramic roller, the ceramic layer in the former is thinner. Under the same voltage, the ceramic layer and the film material can adhere more tightly and fully after being energized. In addition, the ceramic layer in the former is denser, which can transfer heat more quickly and effectively, thereby providing a better cooling effect for the film material, so as to improve the yield and production capacity of the corresponding products.

[0102] The above description is merely a preferred embodiment of this application and is not intended to limit the application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application. Industrial applicability

[0103] In summary, this application provides a cooling ceramic roller and its preparation method, as well as a coating system. After being energized, the cooling ceramic roller can generate a large electrostatic adsorption force between the ceramic layer and the film material, so that the film material and the ceramic layer are tightly and fully bonded. In addition, the relatively dense ceramic layer can provide a better cooling effect for the film material, thereby improving the product yield and production capacity.

Claims

1. A method for preparing a ceramic roller for cooling, characterized in that, Includes the following steps: A metal roll blank is provided, the interior of which has channels configured for conveying coolant, and the surface of which has a metal layer made of Al and / or an Al alloy. Using the metal roll blank as the anode, an alumina ceramic layer with a thickness of ≤100 μm is formed on the surface of the metal layer by anodizing to obtain a ceramic roll intermediate; The surface of the alumina ceramic layer of the ceramic roller intermediate is subjected to organic sealing and polishing treatments in sequence to obtain the cooling ceramic roller.

2. The method for preparing a ceramic roller for cooling according to claim 1, characterized in that, The thickness of the alumina ceramic layer is 30~70 μm.

3. The method for preparing a ceramic roller for cooling according to claim 2, characterized in that, In the step of forming an alumina ceramic layer on the surface of the metal layer by anodizing, the processing temperature is 22~24℃, the processing time is 25~35 min, and the current density is 0.5~2 A / mm. 2 The molar concentration of hydrogen ions in the electrolyte is 3~4.1 mol / L.

4. The method for preparing a ceramic roller for cooling according to any one of claims 1 to 3, characterized in that, During the grinding and polishing process, at least one of the following conditions A to C must be met: A. Until the roughness Ra of the alumina ceramic layer is ≤0.2 μm; B. Until the thickness uniformity deviation of the alumina ceramic layer is < ±15%; C until the surface flatness deviation of the alumina ceramic layer is < ±20 μm.

5. A ceramic roller for cooling, characterized in that, It is prepared by the method for preparing a cooling ceramic roller as described in any one of claims 1 to 4.

6. The coating system according to claim 5, characterized in that, The cooling ceramic roller includes a metal roller blank and an alumina ceramic layer on its surface.

7. The coating system according to claim 6, characterized in that, The metal roll blank has a channel configured to transport coolant, and the outlet channel is located between the inlet channel and the alumina ceramic layer.

8. The coating system according to claim 5, characterized in that, The cooling ceramic roller includes a metal roller blank and an alumina ceramic layer on its surface, wherein the metal roller blank includes a substrate and an Al metal layer located on the surface of the substrate, and the alumina ceramic is located on the surface of the Al metal layer.

9. The coating system according to claim 8, characterized in that, The substrate has a channel configured to transport coolant, and the outlet channel is located between the inlet channel and the alumina ceramic layer.

10. A coating system, characterized in that, It includes a cooling ceramic roller as described in any one of claims 5 to 9.

11. The coating system according to claim 10, characterized in that, The system includes a coating source, multiple cooling ceramic rollers, and multiple guide rollers. The multiple cooling ceramic rollers are all located above the coating source and are distributed sequentially at intervals. The multiple cooling ceramic rollers extend from one side of the coating area of ​​the coating source to the opposite side to cover the entire coating area. A guide roller is provided between two adjacent cooling ceramic rollers, and the guide roller is located on the side of the cooling ceramic rollers away from the coating source.

12. The coating system according to claim 11, characterized in that, Each of the aforementioned cooling ceramic rollers has a diameter of 100~300 mm.

13. The coating system according to claim 11, characterized in that, The coating system is a roll-to-roll evaporation coating system, and there is one coating source. The distance from the geometric center of the plurality of cooling ceramic rollers to the geometric center of the coating source is 50~150 cm.

14. The coating system according to claim 13, characterized in that, The distance from the geometric center of each of the plurality of cooling ceramic rollers to the geometric center of the coating source is equal.

15. The coating system according to claim 11, characterized in that, The coating system is a magnetron sputtering coating system, and there are multiple coating sources. The multiple cooling ceramic rollers are located above the multiple coating sources and are distributed sequentially at intervals along the horizontal direction.

16. The coating system according to any one of claims 11 to 15, characterized in that, It also includes multiple baffles, and a baffle configured to block atomic particles is provided between two adjacent cooling ceramic rollers. The baffle is located on the side of the cooling ceramic roller away from the coating source, and the baffle is located between the through roller and the cooling ceramic roller.

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