Electrolytic Copper Foil Surface Control for Roll-to-Roll Wrinkle Prevention
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Solution Overview
Problem
The roll-to-roll process for producing electrolytic copper foil often results in folds and wrinkles, leading to interruptions and low productivity due to the need to stop and reoperate equipment, which hampers continuous production and product quality.
Innovation Solution
An electrolytic copper foil with a copper film sandwiched between first and second protective layers, where the copper film has a longitudinal rising of 30 mm or less and transverse rising of 25 mm or less, and the transverse rising is 8.5 times the longitudinal rising or less, minimizing folds and wrinkles during the roll-to-roll process. This is achieved through a method involving anodic plates with different current densities and an anticorrosion solution to ensure uniform surface properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a roll-to-roll process is used for mass production of electrolytic copper foil, then productivity is improved through continuous production, but folds and wrinkles occur during the process causing equipment stoppages and reducing actual productivity
Solution Approach 1:
The patent applies preliminary action by pre-treating the copper foil surface before the roll-to-roll process. Specifically, a conversion coating layer is formed on the copper foil surface in advance, and a lubricant composition is applied to control surface properties. This preliminary preparation prevents folds and wrinkles from forming during subsequent rolling operations, allowing continuous production without equipment stoppages.
2Productivity
If the roll-to-roll process is continuously operated without interruptions, then productivity is maximized, but folds and wrinkles of the copper foil cannot be prevented without stopping the equipment
Solution Approach 1:
The patent introduces an intermediary substance - a lubricant composition containing specific additives - that mediates between the rolling process and the copper foil surface. This lubricant composition, applied in advance, acts as a protective layer that prevents direct contact and friction between the foil and rolling surfaces, thereby preventing folds and wrinkles while allowing high-speed continuous operation.
Solution Approach 2:
The patent changes surface parameters of the copper foil by forming a conversion coating layer and applying a lubricant composition with specific chemical composition. These parameter changes - including surface chemistry, roughness, and lubricity - are optimized to prevent folding and wrinkling during high-speed rolling, maintaining both productivity and surface flatness.
3Manufacturing precision
If equipment is stopped to solve folds and wrinkles, then surface quality is improved, but productivity deteriorates due to repeated stoppages and reoperations
Solution Approach 1:
The patent applies preliminary action by pre-treating the copper foil surface before the roll-to-roll process. Specifically, a conversion coating layer is formed on the copper foil surface in advance, and a lubricant composition is applied to control surface properties. This preliminary preparation prevents folds and wrinkles from forming during subsequent rolling operations, allowing continuous production without 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 solution prevents folds and wrinkles, ensuring high productivity and quality by maintaining uniform surface properties and reducing the need for equipment stoppages during the roll-to-roll process, thereby enhancing the production of secondary batteries and flexible printed circuit boards.
Implementation Method 1
allowing a current to flow between an anode plate and a rotational cathode drum to form a copper film on the rotational cathode drum, the anode plate and rotational cathode drum spaced apart from each other in an electrolytic solution contained in an electrolytic bath
Implementation Method 2
a method for manufacturing an electrolytic copper foil, the method comprising: allowing a current to flow between an anode plate and a rotational cathode drum to form a copper film on the rotational cathode drum
Data Source
AI summary
Disclosed are an electrolytic copper foil the fold and/or wrinkle of which can be avoided or minimized during a roll-to-roll process, a method for manufacturing the same, and an electrode and a secondary battery which are produced with such electrolytic copper foil so that high productivity can be guaranteed. An electrolytic copper foil of the disclosure has a longitudinal rising of 30 mm or less and a transverse rising of 25 mm or less, and the transverse rising is 8.5 times the longitudinal rising or less.