High-Tensile Electrolytic Copper Foil for RTR Process Stability
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Solution Overview
Problem
The roll-to-roll (RTR) process for manufacturing electrolytic copper foils is hindered by the occurrence of folds, wrinkles, and pleats, leading to repeated equipment stoppages and reduced productivity due to the inability to maintain continuous production.
Innovation Solution
An electrolytic copper foil with a copper film containing 99% copper and a protective layer, having a tensile strength of 45 to 65 kgf/mm², is developed, along with a manufacturing method involving a specific electrolyte composition and process conditions to prevent folds, wrinkles, and breaks during the RTR process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the RTR process is used for mass production of electrolytic copper foil, then continuous production capability is improved, but folds, wrinkles and pleats occur causing equipment stoppages and reduced productivity
Solution Approach 1:
The patent applies parameter changes by optimizing the electrolyte composition (specific ratios of sulfuric acid, copper sulfate, and additives like gelatin or starch) and controlling deposition parameters (current density, temperature, speed ratio between cathode and anode) to produce copper foil with enhanced mechanical properties including higher tensile strength and elongation, thereby preventing folds and wrinkles during RTR processing
Solution Approach 2:
The patent creates a composite structure by forming a copper foil with a specific grain structure and mechanical property profile through controlled electrolytic deposition. The copper foil essentially becomes a composite material with optimized crystalline structure and mechanical characteristics that resist folding and wrinkling during continuous production
2Manufacturing precision
If equipment is stopped and restarted to solve folds and wrinkles, then defect resolution is achieved, but productivity is lowered due to repeated stoppages
Solution Approach 1:
The patent applies preliminary action by pre-optimizing the electrolyte composition and deposition parameters before production begins, and by incorporating protective measures (such as using gelatin or starch in the electrolyte to control grain growth and improve foil uniformity) that prevent folds and wrinkles from forming in the first place, thereby eliminating the need for equipment stoppages
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The high-tensile-strength electrolytic copper foil ensures continuous production in the RTR process, enhancing productivity and preventing defects in products like secondary battery electrodes and flexible printed circuit boards.
Implementation Method 1
forming a copper film on the cathode in an electrolyte including 50 to 100 g/L of copper ions, 50 to 150 g/L of sulfuric acid, 0.5 to 6.5 ppm of imidazolidine-2-thione, and 0.2 to 5.5 ppm of silver (Ag)
Data Source
AI summary
A high strength electrolytic copper foil preventing generation of folds, wrinkles, pleats, and breaks during a roll-to-roll (RTR) process, a method of manufacturing the same, and an electrode and a secondary battery which allow high productivity to be secured by being manufactured with such an electrolytic copper foil. The electrolytic copper foil includes a copper film including 99 weight % or more of copper and a protective layer on the copper film, wherein the electrolytic copper foil has a tensile strength of 45 to 65 kgf/mm.sup.2.