Sintered Anode Aluminum Foil with Ultrasonic Particle Gradient
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Solution Overview
Problem
Traditional methods for manufacturing anode aluminum foil face challenges in simultaneously achieving high specific capacitance and withstand voltage performance due to limitations in surface area expansion and environmental pollution concerns, with existing technologies nearing theoretical limits and requiring trade-offs between capacitance and voltage.
Innovation Solution
A preparation method involving ultrasound to alter the stacking structure of aluminum powder on the foil, creating a gradient distribution of particle sizes with larger voids in the lower layer and a denser surface area, enhancing specific capacitance and withstand voltage through a porous structure formed by high-purity spherical aluminum powder and controlled sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of the aluminum powder layer is increased to enhance specific capacitance, then the specific capacitance improves, but the withstand voltage performance decreases
Solution Approach 1:
The patent applies local quality by creating a gradient distribution of aluminum powder particles where the lower layer contains larger particles with larger voids for high specific capacitance, while the upper layer contains finer particles that form a denser structure for high withstand voltage. This spatial variation in particle size and density allows different regions to optimize for different functions simultaneously.
Solution Approach 2:
The patent transitions from a uniform single-layer structure to a multi-layer gradient structure with varying particle sizes through the thickness dimension. This dimensional approach allows the lower layer to be optimized for capacitance (larger particles, more voids) while the upper layer is optimized for voltage resistance (finer particles, denser packing), resolving the trade-off between capacitance and withstand voltage.
2Quantity of substance
If traditional chemical etching is used to increase surface area and specific capacitance, then specific capacitance improves, but environmental pollution and production costs increase
Solution Approach 1:
The patent replaces the chemical etching process with a mechanical additive manufacturing approach using ultrasonic vibration to stack aluminum powder particles. This substitution eliminates the need for harsh chemicals and wastewater treatment, achieving high specific capacitance through physical particle arrangement rather than chemical surface modification.
Solution Approach 2:
The patent converts the potential harm of thick aluminum powder layers (which would normally reduce withstand voltage) into a benefit by using ultrasonic vibration to create an optimized gradient structure. The ultrasonic energy transforms what would be a detrimental uniform thick layer into a beneficial multi-layer structure with improved both capacitance and voltage resistance.
3Area of stationary object
If traditional chemical etching is used to expand surface area, then specific capacitance increases, but the process requires large amounts of acid and pure water leading to wastewater treatment needs
Solution Approach 1:
The patent replaces chemical etching with ultrasonic vibration-assisted additive manufacturing, using mechanical energy to stack aluminum powder particles into a high-surface-area configuration. This eliminates the consumption of large amounts of acid and pure water required for traditional etching processes while achieving comparable or superior surface area expansion.
4Reliability
If aluminum powder layer thickness is reduced to ensure withstand voltage performance, then withstand voltage improves, but specific capacitance weakens
Solution Approach 1:
The patent applies local quality by creating a gradient distribution of aluminum powder particles where the lower layer contains larger particles with larger voids for high specific capacitance, while the upper layer contains finer particles that form a denser structure for high withstand voltage. This spatial variation in particle size and density allows different regions to optimize for different functions simultaneously.
Solution Approach 2:
The patent transitions from a uniform single-layer structure to a multi-layer gradient structure with varying particle sizes through the thickness dimension. This dimensional approach allows the lower layer to be optimized for capacitance (larger particles, more voids) while the upper layer is optimized for voltage resistance (finer particles, denser packing), resolving the trade-off between capacitance and withstand voltage.
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 effectively increases specific capacitance and withstand voltage, meeting medium to high voltage requirements while reducing environmental impact and enabling large-scale production, as demonstrated by samples achieving specific capacitance of above 1.01 μF/cm² and withstand voltage of above 490 V.
Implementation Method 1
utilizing ultrasound to alter the stacking structure of aluminum powder on the surface of the anode aluminum foil
Implementation Method 2
After vacuum drying and high-temperature sintering, a porous structure composed of a hollow-structured aluminum powder layer is formed
Data Source
AI summary
The invention discloses a method for manufacture sintered anode aluminum foil. Ultrasound was used to change the stacking structure of aluminum powder on the surface of the anode aluminum foil, allowing aluminum powder particles of different sizes to form a gradient distribution in the thickness of the aluminum powder layer, with a gradual decrease in average particle size from bottom to top, larger voids in the lower layer, and denser and larger surface area in the upper layer. Therefore, the specific capacitance and the withstand voltage were improved. By introducing ultrasonic vibration, this invention can simultaneously enhance the specific capacitance and withstand voltage of anode aluminum foil after high-temperature sintering and anodizing, while traditional sintering methods cannot obtain high specific capacitance and withstand voltage performance simultaneously.