Electrolytic Copper Foil Drum Protrusion Design
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Solution Overview
Problem
Existing methods for manufacturing electrolytic copper foils often result in non-uniform surface characteristics due to foreign matter on the drum surface, leading to differences in gloss and adhesive force, which can lower the electrical characteristics of secondary batteries when used as current collectors, and require additional costly post-processing steps.
Innovation Solution
An apparatus featuring an electrolytic bath with an internal drum and an outer drum having a hollow tube shape with protrusions of varying shapes and sizes, which are conductive materials, to create a copper foil with diverse surface roughness patterns without additional processing, by allowing copper to precipitate on the drum surface during rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a rotating drum is used to manufacture copper foil by electrolysis, then copper foil can be continuously manufactured, but foreign matters on the drum surface cause non-uniform surface characteristics and adhesive force differences
Solution Approach 1:
The drum surface is pre-treated with protrusions before the electrolysis process begins. These protrusions are formed in advance on the drum surface, ensuring that when copper precipitates during electrolysis, it forms on a controlled surface structure rather than a potentially contaminated smooth surface. This preliminary structuring prevents foreign matter interference and ensures uniform copper deposition.
Solution Approach 2:
The drum surface is designed with localized protrusions that create specific micro-regions with different surface properties. These protrusions are distributed across the drum surface in a controlled pattern, creating local variations in surface area and copper deposition characteristics. This local quality enhancement ensures uniform adhesive force across the entire copper foil surface.
2Manufacturing precision
If post-processing methods such as surface etching or additional coating are applied to improve surface characteristics, then adhesive force and gloss uniformity are improved, but manufacturing cost and process time increase
Solution Approach 1:
Instead of applying post-processing treatments after copper foil manufacturing, the desired surface characteristics are built into the drum surface beforehand through protrusion formation. This preliminary action eliminates the need for subsequent etching or coating processes, reducing both process time and manufacturing costs while achieving the same surface uniformity and adhesive force improvement.
Solution Approach 2:
The invention extracts and eliminates the need for separate post-processing steps by integrating the surface preparation function directly into the drum structure. The protrusions on the drum surface perform the function that would otherwise require additional etching or coating processes, thereby removing these unnecessary steps from the manufacturing workflow.
3Manufacturing precision
If the drum surface has foreign matters, then copper precipitation is affected causing shape transfer to the copper foil surface, but removing foreign matters requires additional cleaning processes
Solution Approach 1:
The drum surface is pre-equipped with protrusions that create a controlled surface structure before copper precipitation begins. This preliminary structuring ensures that copper deposits on a known, uniform surface geometry rather than on a surface that may have foreign matters. The protrusions act as a physical barrier and template that prevents foreign matter adhesion and ensures consistent copper foil surface shape.
Solution Approach 2:
The protrusions on the drum surface serve as a protective structure that cushions against the harmful effects of foreign matters. By having this structured surface in place beforehand, the system is prepared to resist foreign matter adhesion and ensure uniform copper deposition, preventing surface defects before they can occur during the electrolysis 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
Enables the manufacture of copper foils with uniform surface characteristics, preventing adhesive force reduction and eliminating the need for post-processing, thus enhancing the electrical properties of secondary batteries and reducing manufacturing costs.
Implementation Method 1
a current is allowed to flow in a pair of electrodes, and a copper thin film precipitated on a surface of the rotating drum
Implementation Method 2
the rotating drum is immersed in the electrolyte including a copper ion, a current is allowed to flow in a pair of electrodes
Data Source
AI summary
An apparatus for manufacturing an electrolytic copper foil includes an electrolytic bath defining a cavity for receiving an electrolyte; an internal drum partially disposed in the cavity; an outer drum in contact with a surface of the internal drum; a counter electrode positioned in the cavity of the electrolytic bath and positioned to be spaced apart from the internal drum by a predetermined distance; and a power supply unit electrically connecting the internal drum and the counter electrode.