Electrolytic Copper Foil Charpy Impact Strength Control
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Solution Overview
Problem
Conventional copper foils used in lithium-ion batteries and printed circuit boards often develop wrinkles, leading to issues such as uneven coating, breakage, and poor bonding with active materials, which can result in disconnection and reduced production yield.
Innovation Solution
The development of an electrolytic copper foil with a controlled Charpy impact strength ranging from 0.4 J/mm² to 5.8 J/mm², achieved through specific surface treatments and electrolyte composition adjustments, to enhance mechanical properties and wrinkle resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the copper foil thickness is reduced to meet miniaturization demands, then the weight and size of electronic devices are reduced, but the mechanical strength and wrinkle resistance of the copper foil deteriorate
Solution Approach 1:
The patent changes the microstructural parameters of the copper foil by controlling grain size (5-20 μm) and crystal orientation (〈100〉preferred orientation). This allows the foil to maintain adequate mechanical strength at reduced thickness through optimized metallurgical properties rather than relying solely on increased thickness
Solution Approach 2:
The patent creates a composite structure with a copper foil base layer and a nickel-phosphorus alloy coating layer. This composite structure provides the copper foil with enhanced mechanical strength and wrinkle resistance while maintaining thin overall thickness, resolving the contradiction between weight reduction and strength maintenance
2Strength
If the copper foil has high mechanical strength to prevent wrinkles, then the wrinkle resistance is improved, but the ductility and formability of the copper foil may deteriorate
Solution Approach 1:
The patent optimizes the grain size parameter to 5-20 μm and controls the crystal orientation to achieve a balance between strength and ductility. This microstructural parameter control allows the copper foil to resist wrinkles while maintaining adequate formability for manufacturing processes
3Ease of manufacture
If conventional copper foil is used without surface treatment, then the manufacturing process is simple, but the bonding strength with active materials and dielectric materials is insufficient
Solution Approach 1:
The patent applies surface treatment that modifies the surface morphology and chemistry of the copper foil, creating a treatment layer with enhanced surface area and chemical reactivity. This allows for significantly improved bonding strength with active materials and dielectric materials while adding minimal complexity to the manufacturing process
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 controlled Charpy impact strength improves the mechanical properties of the copper foil, reducing wrinkles and breakage, thereby enhancing production yield and ensuring better adhesion with active materials and dielectric materials in subsequent applications.
Implementation Method 1
manufactured by supplying an electrolyte solution including copper ions between an anode and a cathode drum and applying a direct current between the anode and the cathode drum to make the copper ions of the electrolyte solution electrodeposited on the surface of the cathode drum
Data Source
AI summary
Provided are an electrolytic copper foil, and an electrode and a copper-clad laminate comprising the same. The electrolytic copper foil comprises a base copper layer having a drum side and a deposited side; wherein the electrolytic copper foil has a Charpy impact strength from 0.4 J/mm2 to 5.8 J/mm2.