Capacitor Cathode Foil Graphene Coating Waste Acid Elimination
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Solution Overview
Problem
Existing methods for manufacturing capacitor cathode foils face issues such as high waste acid production, high treatment costs, and surface oxidation affecting electric properties, as well as non-uniform film intensity and instability of metal films used in prior art methods.
Innovation Solution
A manufacturing method that deposits a graphene-based layer on an aluminum foil using a CVD or PVD process, involving heating, precursor gas introduction, and cooling to form stacked graphene-based thin films, which are then coated with an antioxidant and heat-dissipation layer to enhance conductivity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If acid solution treatment is used to remove impurities and form oxidant film, then the aluminum foil surface is cleaned and oxidized, but large volumes of waste acid are produced and surface oxidation affects electric properties
Solution Approach 1:
The patent replaces the chemical acid solution treatment system with a physical vacuum deposition system. Instead of using chemical acids to clean and treat the aluminum foil surface, the invention uses vacuum deposition to directly form metal films (such as titanium film) on the etched aluminum foil surface, thereby eliminating waste acid generation while maintaining or improving electric properties
Solution Approach 2:
The patent employs vacuum environment (inert atmosphere) during the metal film deposition process. By conducting the deposition in a vacuum chamber, the process prevents unwanted surface oxidation of the aluminum foil while forming the functional metal film, thus avoiding the surface oxidation problems caused by acid solution treatment and eliminating the need for waste acid disposal
2Reliability
If metal film is formed through PVD process, then the cathode foil conductivity is improved, but the film intensity is not uniform and surface property is unstable under atmosphere
Solution Approach 1:
The patent optimizes deposition parameters including controlling deposition temperature, vacuum pressure, and deposition rate to achieve uniform film intensity. By carefully adjusting these parameters, the metal film is deposited uniformly across the aluminum foil surface, resolving the non-uniformity issue while maintaining stability under atmospheric conditions
Solution Approach 2:
The patent creates a composite structure by forming metal films (such as titanium film) on the etched aluminum foil surface. This composite cathode foil structure combines the high surface area of etched aluminum with the conductive and stable properties of the metal film layer, achieving both uniform film distribution and atmospheric stability
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 resulting capacitor cathode foil structure achieves excellent electron conductivity, improved mechanical properties, and increased capacitance with enhanced stability and reduced resistance, addressing the limitations of previous methods.
Implementation Method 1
executing a heating process for heating the base foil to a temperature region of 400° C. to 1000° C.
Implementation Method 2
executing a cooling process for cooling the base foil to a temperature below 100° C. to deposit a graphene-based layer on one surface of the base foil
Implementation Method 3
directing a carbon containing precursor gas into the reactor
Implementation Method 4
generating glow discharge between the anode and the cathode to form a graphene-based layer on the base foil
Implementation Method 5
directing a noble gas and a reactive gas into the vacuum reactor
Data Source
AI summary
The instant disclosure relates to a manufacturing method of capacitor cathode foil structure, comprising the following steps. The first step is providing a base foil, subsequently inserting the foil into a reactor. The next step is executing a heating process for heat the base foil to a temperature region of 400° C. to 1000° C. The next step is directing a carbon containing precursor gas into the reactor. The last step is executing a cooling process for cooling the base foil to a temperature below 100° C. to deposit a graphene-based layer on one surface of the base foil, wherein the graphene-based layer is consisted of a plurality of graphene-based thin films in stacked arrangement.