Four-High Roll Structure for Microtextured Foil Wear Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for preparing ultra-thin metal foils with surface microtexture are complex and difficult to scale up for mass production, leading to issues such as roll wear and reduced production efficiency.
Innovation Solution
A roll structure for a four-high rolling mill with a concave-convex design and reinforced textured microtexture on the concave working roll groove surface, preventing direct contact with supporting guide rolls, combined with a groove structure on the supporting guide roll to stabilize force distribution and reduce stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional rolling methods are used to prepare ultra-thin metal foils with surface microtexture, then production complexity is high and scaling is difficult, but the roll structure is simpler without specialized reinforcement
Solution Approach 1:
The patent applies local quality by providing surface reinforcement treatment (such as carburizing or nitrogen treatment) specifically on the groove surface of the concave working roll where the microtexture is located. This creates a localized hard layer with different properties than the base roll material, enhancing wear resistance precisely where contact and friction occur during rolling, while maintaining the overall roll structure design.
Solution Approach 2:
The patent employs composite materials by creating a layered structure in the roll groove surface through surface reinforcement treatment. The reinforced surface layer (with enhanced hardness and wear resistance) is combined with the base roll material, forming a composite structure that provides both the durability needed for mass production and the functional microtexture for foil surface quality.
2Device complexity
If the microtextured surface of working rolls contacts supporting guide rolls, then the structure is simpler, but wear of the microtexture increases rapidly
Solution Approach 1:
The patent introduces grooves on the supporting guide rolls that match the convex working roll profile, creating an intermediary structural arrangement. This groove design ensures that the supporting guide rolls contact the convex working roll at specific points rather than directly contacting the microtextured groove surface of the concave working roll, thereby preventing direct contact between microtextured surfaces and reducing wear while maintaining structural simplicity.
3Productivity
If conventional rolling processes are used, then energy consumption is high and production efficiency is low, but the process requires less specialized equipment modification
Solution Approach 1:
The patent replaces complex conventional surface treatment processes (such as machining, screen printing, laser-assisted processing, photolithography electroplating injection molding, and chemical etching) with a mechanical rolling process. By forming the microtexture directly on the roll surface and using the roll structure to imprint the pattern during rolling, the method achieves microtexture formation with lower energy consumption and higher production efficiency suitable for mass production.
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 enables high-precision, high-quality mass production of ultra-thin metal foils with extended roll life and improved production efficiency, while reducing energy consumption.
Implementation Method 1
the textured microtexture of the groove surface are reinforced by carburizing or nitrogen treatment
Implementation Method 2
the textured microtexture of the groove surface are reinforced by carburizing or nitrogen treatment
Data Source
AI summary
A roll structure of a four-high rolling mill for preparing ultra-thin metal foils with surface microtexture and a rolling method thereof, the roll structure of the four-high rolling mill includes: an upper supporting guide roll, a convex working roll, a concave working roll, and a lower supporting guide roll arranged in sequence from top to bottom; diameters of the upper and lower supporting guide roll are the same; diameters of the convex and concave working roll are the same; and the upper supporting guide roll and the concave working roll is provided with grooves that match the convex working roll; a textured microtexture is provided on a groove surface, the roll structure of the four-high rolling mill prevents direct contact between the microtextured surface of the concave work roll grooves and the supporting guide rolls, directly addressing the issue of roll wear in traditional microtexture rolling processes.