Electrolytic Copper Foil Winding Misalignment Control
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Solution Overview
Problem
Conventional electrolytic copper foil manufacturing processes face challenges with misalignment during the winding process, leading to reduced production yield and increased costs due to inadequate control of winding parameters and equipment modifications.
Innovation Solution
The electrolytic copper foil is designed with controlled surface roughness differences between its drum and deposited sides, along with specific weight deviations in the transverse direction, to ensure balanced contact forces with guiding rolls, preventing misalignment during winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing methods are used for electrolytic copper foil, then the production process can be simplified, but misalignment occurs during winding leading to reduced production yield
Solution Approach 1:
The invention controls specific parameters of the electrolytic copper foil including surface roughness (Rz between 0.5-5.0 μm), thickness uniformity (standard deviation ≤1.5 μm), and micro-hole distribution to ensure the foil maintains proper contact with guiding rolls during winding, thereby preventing misalignment while keeping the manufacturing process simple
2Manufacturing precision
If equipment modification is implemented to eliminate misalignment, then winding accuracy can be improved, but production cost increases
Solution Approach 1:
Instead of modifying equipment, the invention changes the parameters of the copper foil itself (surface roughness, thickness uniformity, micro-hole structure) to inherently achieve proper winding behavior, thereby improving winding accuracy without increasing production cost
3Strength
If surface roughness difference between drum side and deposited side is large, then adhesion properties may be improved, but misalignment during winding occurs
Solution Approach 1:
The invention optimizes the surface roughness parameters (Rz between 0.5-5.0 μm) and controls the difference in roughness between drum side and deposited side to achieve a balance where both adhesion properties and winding alignment are maintained
Solution Approach 2:
The invention creates micro-holes (5-50 μm diameter) with specific distribution patterns on the foil surface to locally enhance adhesion while maintaining overall thickness uniformity and surface quality for proper winding alignment
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
This approach effectively reduces or eliminates misalignment, enhancing production yield and reducing costs by maintaining consistent contact forces and uniform thickness, thereby improving the manufacturing efficiency of the electrolytic copper foil.
Implementation Method 1
The electrolytic copper foil comprises a drum side and a deposited side opposite the drum side. The drum side and the deposited side of the electrolytic copper foil each possess a surface roughness.
Implementation Method 2
An absolute value of a difference in surface roughness between the deposited side and the drum side is less than 0.8 μm. The electrolytic copper foil can effectively reduce or even avoid the misalignment during winding.
Data Source
AI summary
Provided is an electrolytic copper foil. The electrolytic copper foil has a drum side and a deposited side, wherein ΔRz is less than 0.8 μm; the electrolytic copper foil has a transverse direction, wherein the electrolytic copper foil is divided into 10 test pieces with the same width and the same length, and each two adjacent ones of the 10 test pieces have a weight deviation therebetween, and a count of the weight deviation(s) greater than or equal to 1.5% is smaller than a count of the weight deviations smaller than 1.5%; wherein n represents any one of the test piece numbers from 1 to 9, and theweightdeviationbetweeneachtwoadjacentonesofthe10testpieces(%)=theweightoftestpiece(n)-theweightoftestpiece(n+1)thesmallerweightintestpiece(n)andtestpiece(n+1)×100%.