Low-Pressure Roll Texturing for Uniform Metal Substrate Patterns
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing coil-to-coil process for metal substrates often distorts the substrate and pattern due to the force applied during texturing, leading to thickness reduction and uneven pressure distribution.
Innovation Solution
A method and system that use a coil-to-coil processing system with vertically aligned upper and lower work rolls supported by intermediate rolls, where bearings impart bearing loads to maintain contact pressure below the yield strength of the substrate, allowing localized texture creation without overall thickness reduction, and a control system to adjust pressure parameters for uniform texture distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high force is applied during the texturing process, then the texture pattern is clearly defined, but the characteristics of the metal substrate are distorted
Solution Approach 1:
The patent applies low pressure rolling with work roll pressure controlled below the yield strength of the substrate, changing the pressure parameter to achieve texture transfer without substrate distortion. This maintains the stability of substrate characteristics while still producing a well-defined texture pattern through optimized low-pressure contact.
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 method achieves texture application on metal substrates with enhanced characteristics like increased lubricant retention, improved de-stacking, and reduced galling, while maintaining the substrate's original thickness and ensuring consistent texture across the width.
Implementation Method 1
the work rolls impart a work roll pressure on the metal substrate that is below the yield strength of the metal substrate
Implementation Method 2
measuring a contact pressure distribution of at least one of the first work roll pressure and the second work roll pressure across a width of the metal substrate
Data Source
Figure 1
Figure 2
Figure 3
AI summary
System and method of applying a texture on a substrate (108) include applying a texture to the substrate (108) with a work stand (102) of a coil-to-coil process (100). The work stand (102) includes an upper work roll (104A) and a lower work roll (104B) vertically aligned with the upper work roll. At least one of the upper work roll (104A) and the lower work roll (104B) includes the texture. Applying the texture includes applying, by the upper work roll (104A) and a lower work roll (104B), a work roll pressure on an upper surface (110) and a lower surface (112) of the substrate (108). The method further includes adjusting a contact pressure parameter of the work stand (102) such that the work stand provides a desired contact pressure distribution across the width of the substrate (108) and a desired thickness profile of the edges of the substrate while an overall thickness of the substrate remains substantially constant.