1. Overall installation accuracy is low, as the centerlines of individual components deviate from the machine’s designed centerline or are angled relative to it, causing severe wrinkling of the foil strip. The installation center must be adjusted accordingly.
2. Excessive parallelism deviation between the rollers can cause wrinkling of the foil strip. Therefore, carefully inspect whether the issue lies in the vertical or horizontal projection planes being non-parallel, and then make the necessary adjustments.
3. If the surface roughness of the nip rolls exceeds the specified tolerance—resulting in an uneven, non-smooth roll surface with noticeable machining marks—it can also cause wrinkling of the foil strip. In such cases, it’s necessary to request the manufacturer to provide a replacement.
4. The back roller and all idler rollers have foreign objects adhering to them or are being used with excessive water. Wipe them down with isopropyl alcohol, and ensure regular inspections to promptly identify and remove any contaminants. Take care not to damage the roller surfaces during this process.
5. If the foil tape connector is faulty and the tension on both sides of the foil tape is uneven, the electrode sheet will wrinkle. First, adjust the tension roller located beneath the coating head. Once the foil tape gradually stabilizes, return the adjustment roller to its original position.
6. When the gaps at both ends of the backing roller and coating roller are inconsistent as they approach contact, the electrode sheet will wrinkle. According to online coating operations, whether applying coating to the first or second side, this gap must be carefully adjusted—first by slightly widening it, then gradually narrowing it—while closely monitoring the dial gauge reading precisely at the moment when the coating roller just makes contact with the foil strip. Finally, reduce the gap by an additional 0.03 mm.
7. Misalignment system abnormalities can also cause electrode sheets to wrinkle. Check all three alignment systems—front, middle, and rear—to ensure they are set to automatic mode. According to real-time coating monitoring, wrinkles in the electrode sheets may also occur if the lengths of the foil strip on both sides are inconsistent, indicating excessive "sickle bend" that exceeds the system's correction capability. In such cases, the only solution is to replace the foil material.
8. When the electrode sheet tension is too high, the sheet may wrinkle. Check whether the tension setting is appropriate. Also, inspect each drive roller to ensure the winding and unwinding rollers rotate smoothly, and address any sluggish or inflexible rollers promptly.
9. If the back rollers fail to open to an inconsistent stroke, the electrode sheets will wrinkle. In this case, maintenance personnel need to inspect, confirm, and adjust the system. Begin trial coating only after both sides of the gap between the back roller and the coating roller measure exactly 1 mm (using a dial indicator). Once the trailing edge meets the required specifications, securely tighten the lock nuts.
10. During use, the rubber surface of the back roll undergoes periodic elastic deformation. If a certain level of deformation remains, wrinkling may occur, at which point the roll must be replaced with a new one.
11. According to Tubo Online, loose fastening screws on a coating roller can disrupt the parallel alignment of the rollers, leading to wrinkling. However, this issue can be easily resolved by promptly identifying and properly tightening the screws.
