Conductive structure and aluminum electrolytic cell

Abstract

This invention belongs to the field of aluminum electrolysis technology, specifically relating to a conductive structure and an aluminum electrolysis cell. The conductive structure includes: an input busbar; a flexible connector electrically connected to the input busbar; and an output busbar electrically connected to the flexible connector. Each of the input busbar, the flexible connector, and the output busbar includes at least one aluminum layer and at least one copper layer, with the aluminum layer and the copper layer connected together. This conductive structure and aluminum electrolysis cell can reduce energy consumption.

Description

Technical Field

[0001] This application belongs to the field of aluminum electrolysis technology, specifically relating to a conductive structure and an aluminum electrolysis cell. Background Technology

[0002] According to theoretical calculations, the key to improving the energy utilization rate of aluminum electrolytic cells lies in reducing the total voltage drop of the cell. The total voltage drop of an aluminum electrolytic cell mainly consists of the anode voltage drop, electrolyte voltage drop, cathode voltage drop, and bus system voltage drop. Among them, the bus system, as a key component for transmitting and distributing huge amounts of DC power, has a voltage drop of approximately 200mV, accounting for about 5% of the cell's operating voltage.

[0003] In related technologies, the uneven current distribution in the busbar system of traditional aluminum electrolysis cells leads to an unsatisfactory magnetic field distribution generated by the busbar system. The uneven magnetic field further causes uneven current distribution in the molten aluminum and electrolyte melt within the electrolysis cell, resulting in melt flow instability and aluminum melt interface fluctuations, ultimately leading to deterioration of electrolysis conditions, reduced current efficiency, and increased energy consumption. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides a conductive structure and an aluminum electrolytic cell, aiming to at least partially solve the technical problems of deteriorating electrolysis conditions, reduced current efficiency, and increased energy consumption in the bus system of the aluminum electrolytic cell.

[0005] The technical solution of this invention is as follows: A conductive structure includes: an input busbar; a flexible connector electrically connected to the input busbar; and an output busbar electrically connected to the flexible connector; wherein the input busbar, the flexible connector, and the output busbar each include at least one aluminum layer and at least one copper layer, and the aluminum layer is connected to the copper layer.

[0006] In some embodiments, when there are multiple aluminum layers and multiple copper layers, a copper layer is provided between two adjacent aluminum layers, and an aluminum layer is provided between two adjacent copper layers.

[0007] In some implementations, the total cross-sectional area of ​​the copper layer accounts for 5% to 20% of the cross-sectional area of ​​the incoming busbar, 5% to 20% of the cross-sectional area of ​​the flexible connector, and 5% to 20% of the cross-sectional area of ​​the outgoing busbar.

[0008] In some implementations, the power supply busbar includes: a column busbar; and a slant busbar electrically connected to the column busbar and the flexible connector.

[0009] In some implementations, the column busbar has heat dissipation grooves.

[0010] In some implementations, the aluminum layer and the copper layer are metallurgically bonded by rolling composite, heat treatment, explosive welding or brazing.

[0011] In some implementations, the power output bus has multiple parallel branches, each with the same resistance.

[0012] In some implementations, the two ends of the flexible connector are connected to the power inlet bus and the power outlet bus by welding or high-strength bolts.

[0013] In some embodiments, the conductive structure further includes: an aluminum anode rod electrically connected to the flexible connector; a carbon anode electrically connected to the aluminum anode rod; and a carbon cathode block electrically connected to the carbon anode and the power output busbar.

[0014] Based on the same inventive concept, this application also provides an aluminum electrolytic cell, including the aforementioned conductive structure.

[0015] The beneficial effects of the present invention include at least the following: Since the flexible connector is electrically connected to the incoming busbar and the outgoing busbar is electrically connected to the flexible connector, the incoming busbar can transmit electricity to the incoming busbar through the flexible connector.

[0016] Since the incoming busbar, flexible connector, and outgoing busbar all include at least one aluminum layer and at least one copper layer, with the aluminum and copper layers connected, the high conductivity of the copper layer (approximately 1.6 times that of the aluminum layer) can be used to directly reduce DC resistance. Furthermore, the different conductivity of the copper and aluminum layers allows for a layered design that guides the current distribution across the cross-sections of the incoming busbar, flexible connector, and outgoing busbar. According to electromagnetic field theory, the current density distribution along the cross-section of a conductor is related to the conductivity and permeability of the material. By setting copper layers with different conductivity levels within the cross-sections of the incoming busbar, flexible connector, and outgoing busbar, the current can be rationally distributed. The aluminum layer can automatically regulate the current path, forcing the current that would otherwise be concentrated on the surface due to the skin effect to redistribute to the interior of the cross-section. This effectively alleviates the "skin effect" under high-current direct current, avoids the problem of increased additional resistance and excessive local temperature rise caused by excessive current concentration on the surface, reduces resistance, thereby reducing heat generation and improving conductivity from the source. It also helps to ensure the uniformity of the magnetic field, ensuring that the current distribution in the aluminum liquid and electrolyte melt in the aluminum electrolysis cell is uniform, and will not cause melt flow instability and aluminum liquid interface fluctuations. This ensures the electrolysis conditions, improves current efficiency, reduces energy consumption, and ensures the service life of the aluminum electrolysis cell.

[0017] Moreover, the copper layer, as the main current-carrying channel, bears most of the current and heat dissipation area, while the aluminum layer provides structural support and reduces weight. Together, they enable the incoming busbar, flexible connectors, and outgoing busbar to have smaller cross-sectional areas and lighter weights under the same current carrying capacity. At the same time, the high-temperature strength of the copper layer is better than that of pure aluminum, and it has stronger resistance to softening in the high-temperature environment of the electrolytic cell. This effectively suppresses the strength decay and creep deformation caused by temperature rise, avoids deformation, and ensures long-term operational reliability.

[0018] Meanwhile, when the current flows through the power supply bus, the generated magnetic field vector produces components in both the direction perpendicular to and parallel to the surface of the aluminum electrolysis cell. These components are opposite to the magnetic field direction of the harmful horizontal current in the aluminum electrolysis cell and can actively cancel it out, thereby weakening the horizontal electromagnetic force on the aluminum liquid, stabilizing the aluminum liquid interface, and contributing to the uniformity of the magnetic field. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 These are schematic diagrams of the conductive structures in some embodiments; Figure 2 for Figure 1 A schematic diagram of the first arrangement of the aluminum and copper layers in the conductive structure; Figure 3 for Figure 1 Schematic diagram of the second arrangement of aluminum and copper layers in the conductive structure; Figure 4 for Figure 1 A schematic diagram of the third arrangement of the aluminum and copper layers in the conductive structure.

[0021] In the attached image: 10 power inlet busbar, 11 column busbar, 12 inclined busbar; 20 flexible connector; 30 power outlet busbar; 40 aluminum layer; 50 copper layer; 60 aluminum anode guide rod; 70 carbon anode; 80 carbon cathode block. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0023] It should be noted that all directional indications in the embodiments of the present invention are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0024] In this invention, unless otherwise explicitly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0025] Furthermore, in this invention, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed by this invention.

[0026] Specific technical solutions will now be described in detail with reference to the accompanying drawings, which are not necessarily drawn to scale. Similar or identical reference numerals may be used to designate the same or similar parts in different figures. The use of similar or identical reference numerals in different figures does not mean that all figures including similar or identical reference numerals constitute a single or the same embodiment. The accompanying drawings illustrate the various embodiments discussed in this application in a generalized, illustrative, and not restrictive manner.

[0027] Combination Figure 1 , Figure 2 , Figure 3 and Figure 4 The conductive structure in this embodiment includes: an input busbar 10, a flexible connector 20, and an output busbar 30. The flexible connector 20 is electrically connected to the input busbar 10. The output busbar 30 is electrically connected to the flexible connector 20. Each of the input busbar 10, the flexible connector 20, and the output busbar 30 includes at least one aluminum layer 40 and at least one copper layer 50, with the aluminum layer 40 and the copper layer 50 connected.

[0028] Since the flexible connector 20 is electrically connected to the power inlet bus 10 and the power outlet bus 30 is electrically connected to the flexible connector 20, the power inlet bus 10 can transmit electricity to the power inlet bus 10 through the flexible connector 20.

[0029] Since the incoming busbar 10, the flexible connector 20, and the outgoing busbar 30 all include at least one aluminum layer 40 and at least one copper layer 50, with the aluminum layer 40 connected to the copper layer 50, the high conductivity of the copper layer 50 (approximately 1.6 times that of the aluminum layer 40) can be utilized to directly reduce the DC resistance. Simultaneously, the copper layer 50 and the aluminum layer 40 have different conductivity levels. The stacked design of the copper layer 50 and the aluminum layer 40 can guide the current to be rationally distributed across the cross-sections of the incoming busbar 10, the flexible connector 20, and the outgoing busbar 30. According to electromagnetic field theory, the current density distribution along the cross-section in a conductor is related to the conductivity and permeability of the material. By utilizing the high conductivity of the copper layer 50 and the copper layer 40, the DC resistance can be directly reduced. Within the 30mm cross-section, copper layers 50 and aluminum layers 40 with different conductivity can be set to automatically regulate the current path. This forces the current, which would otherwise be concentrated on the surface due to the skin effect, to redistribute to the interior of the cross-section, effectively mitigating the "skin effect" under high-current direct current. This avoids the problems of increased additional resistance and excessive local temperature rise caused by excessive current concentration on the surface, thus reducing resistance. Consequently, it reduces heat generation and improves conductivity efficiency from the source. It also promotes magnetic field uniformity, ensuring uniform current distribution in the aluminum liquid and electrolyte melt within the aluminum electrolysis cell. This prevents melt flow instability and aluminum liquid interface fluctuations, ensuring electrolysis conditions, improving current efficiency, reducing energy consumption, and guaranteeing the service life of the aluminum electrolysis cell.

[0030] Moreover, the copper layer 50 serves as the main current-carrying channel, bearing most of the current and heat dissipation area, while the aluminum layer 40 provides structural support and reduces weight. Together, they enable the power inlet bus 10, flexible connector 20, and power outlet bus 30 to have smaller cross-sectional areas and lighter weights under the same current carrying capacity. At the same time, the high-temperature strength of the copper layer 50 is superior to that of pure aluminum, and it has stronger resistance to softening in the high-temperature environment of the electrolytic cell. This effectively suppresses the strength decay and creep deformation caused by temperature rise, avoids deformation, and ensures long-term operational reliability.

[0031] Meanwhile, when the current flows through the power inlet bus 10, the generated magnetic field vector produces components in both the direction perpendicular to and parallel to the surface of the aluminum electrolysis cell. These components are opposite to the magnetic field direction of the harmful horizontal current in the aluminum electrolysis cell and can actively cancel them out, thereby weakening the horizontal electromagnetic force on the aluminum liquid, stabilizing the aluminum liquid interface, and promoting magnetic field uniformity.

[0032] The combination of copper layer 50 and aluminum layer 40 increases the overall conductivity of the incoming busbar 10, flexible connector 20 and outgoing busbar 30 by 15% to 30%, directly reducing the voltage drop of the busbar system and resulting in significant energy savings.

[0033] The aluminum layer 40 and copper layer 50 form a layered layout with different electrical conductivity in the cross-section. Utilizing the characteristic that current concentrates in areas of high conductivity, the current is guided from the surface to the interior of the cross-section, achieving uniform current density. This effectively suppresses the skin effect, reduces local Joule heating, and results in a more balanced operating temperature for the power inlet bus 10, flexible connector 20, and power outlet bus 30, enhancing long-term creep resistance. The uniform current distribution and lower operating temperature reduce local overheating and thermal creep in the power inlet bus 10, flexible connector 20, and power outlet bus 30, indirectly extending the service life of the aluminum electrolysis cell lining, power inlet bus 10, flexible connector 20, and power outlet bus 30, and improving overall process stability.

[0034] The suppression of the skin effect and the uniform distribution of cross-sectional current density optimize the magnetic field distribution around the inlet bus 10, the flexible connector 20 and the outlet bus 30, weaken the harmful magnetic field components that cause fluctuations in the aluminum liquid, and thus make the aluminum liquid-electrolyte interface in the aluminum electrolysis cell more stable, which helps to reduce secondary reactions and aluminum loss caused by interface fluctuations and improve current efficiency.

[0035] Compared to pure aluminum (melting point 660℃), the copper layer 50 has a higher melting point (1083℃) and softens more slowly at high temperatures. Furthermore, the aluminum layer 40 provides ample heat dissipation channels, resulting in lower overall operating temperatures for the power input bus 10, flexible connector 20, and power output bus 30. This suppresses thermal creep and contact resistance degradation, improving the service life of the power input bus 10, flexible connector 20, and power output bus 30, as well as the operational stability of the aluminum electrolytic cell. This approach reduces the amount of copper used, balancing economic efficiency with lightweight design requirements.

[0036] Combination Figure 3 In some embodiments, when there are multiple aluminum layers 40 and multiple copper layers 50, a copper layer 50 is provided between two adjacent aluminum layers 40, and an aluminum layer 40 is provided between two adjacent copper layers 50, so as to form a layered layout with different electrical conductivity.

[0037] Combination Figure 2 In some embodiments, when there is one copper layer 50 and two aluminum layers 40, the copper layer 50 is located between the two aluminum layers 40.

[0038] In some embodiments, when there are two copper layers 50 and one aluminum layer 40, the aluminum layer 40 is located between the two copper layers 50.

[0039] In some embodiments, the total cross-sectional area of ​​the copper layer 50 accounts for 5% to 20% of the cross-sectional area of ​​the incoming busbar 10, 5% to 20% of the cross-sectional area of ​​the flexible connector 20, and 5% to 20% of the cross-sectional area of ​​the outgoing busbar 30, thereby reducing costs while ensuring high conductivity.

[0040] Combination Figure 1 In some embodiments, to achieve conductivity, the power supply bus 10 includes a column bus 11 and a diagonal bus 12. The diagonal bus 12 is electrically connected to the column bus 11 and the flexible connector 20, and the diagonal bus 12 conducts the electricity from the column bus 11 to the flexible connector 20.

[0041] In some embodiments, the column busbar 11 has heat dissipation grooves to facilitate heat dissipation and mechanical support. For example, the cross-sectional shape of the column busbar 11 can be I-shaped.

[0042] In some embodiments, the aluminum layer 40 and the copper layer 50 are metallurgically bonded by rolling composite, heat treatment, explosive welding or brazing to reduce the interfacial resistivity between the aluminum layer 40 and the copper layer 50.

[0043] In some embodiments, the power output bus 30 has multiple parallel branches, each with the same resistance. Matching the resistances of the parallel branches ensures that the current density drawn from each region of the aluminum electrolysis cell cathode is substantially consistent, thereby making the current flowing out from each region of the bottom of the aluminum electrolysis cell as uniform as possible and avoiding local overheating and current concentration that could corrode the cathode.

[0044] In some embodiments, the two ends of the flexible connector 20 are connected to the power input bus 10 and the power output bus 30 by welding or high-strength bolts, so as to realize the connection between the flexible connector 20 and the power input bus 10 and the power output bus 30.

[0045] For example, the two ends of the flexible connector 20 can be connected to the power input bus 10 and the power output bus 30 by low-temperature silver-based brazing, which not only ensures flexible connection and low contact resistance, but also makes full use of the low resistance characteristics of the structure combining aluminum layer 40 and copper layer 50.

[0046] Combination Figure 1 In some embodiments, to achieve conductivity, the conductive structure further includes: an aluminum anode rod 60, a carbon anode 70, and a carbon cathode block 80. The aluminum anode rod 60 is electrically connected to the flexible connector 20. The carbon anode 70 is electrically connected to the aluminum anode rod 60. The carbon cathode block 80 is electrically connected to the carbon anode 70 and the output busbar 30.

[0047] The flexible connector 20 guides electricity sequentially through the anode aluminum guide rod 60, the carbon anode 70, and the cathode carbon block 80 to the power output bus 30.

[0048] Based on the same inventive concept, this application also proposes an aluminum electrolytic cell that adopts the aforementioned conductive structure. The specific structure of the conductive structure is as described in the above embodiments. Since the conductive structure adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated here.

[0049] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0050] In the description of this invention, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0051] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. In addition, those skilled in the art can combine and integrate the different embodiments or examples described in this specification.

[0052] Although preferred embodiments of this application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this application.

[0053] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if such modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. A conductive structure, characterized in that, include: Power supply busbar; The flexible connector is electrically connected to the power supply busbar; The power output busbar is electrically connected to the flexible connector. The power inlet bus, the flexible connector, and the power outlet bus all include at least one aluminum layer and at least one copper layer, with the aluminum layer connected to the copper layer.

2. The conductive structure according to claim 1, characterized in that, When there are multiple aluminum layers and multiple copper layers, a copper layer is provided between two adjacent aluminum layers, and an aluminum layer is provided between two adjacent copper layers.

3. The conductive structure according to claim 1, characterized in that, The total cross-sectional area of ​​the copper layer accounts for 5% to 20% of the cross-sectional area of ​​the power input busbar, 5% to 20% of the cross-sectional area of ​​the flexible connector, and 5% to 20% of the cross-sectional area of ​​the power output busbar.

4. The conductive structure according to any one of claims 1-3, characterized in that, The power supply bus includes: Column busbar; The inclined busbar is electrically connected to the column busbar and the flexible connector.

5. The conductive structure according to claim 4, characterized in that, The column busbar has heat dissipation grooves.

6. The conductive structure according to any one of claims 1-3, characterized in that, The aluminum layer and the copper layer are metallurgically bonded through rolling composite, heat treatment, explosive welding or brazing.

7. The conductive structure according to any one of claims 1-3, characterized in that, The power output bus has multiple parallel branches, and the resistance of each parallel branch is the same.

8. The conductive structure according to any one of claims 1-3, characterized in that, The two ends of the flexible connector are connected to the power inlet bus and the power outlet bus by welding or high-strength bolts.

9. The conductive structure according to any one of claims 1-3, characterized in that, The conductive structure further includes: The anode aluminum guide rod is electrically connected to the flexible connector. The carbon anode is electrically connected to the aluminum anode rod. The cathode carbon block is electrically connected to the carbon anode and the power output bus.

10. An aluminum electrolytic cell, characterized in that, Includes the conductive structure as described in any one of claims 1-9.

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