Interference Coating via Copper Sulfate Electrolyte
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Solution Overview
Problem
Current methods for manufacturing interference coatings on aluminum alloys fail to meet the requirements of environmental sustainability, visual appeal, and economic efficiency, particularly in achieving a wide range of color variants while ensuring safety and reducing energy consumption.
Innovation Solution
The method involves anodizing aluminum alloys in a sulfuric acid solution with aluminum ions, followed by electrochemical dyeing using an electrolyte comprising copper (II) sulfate, boric acid, and tartaric acid under alternating current, with specific temperature and time conditions, and sealing via hydrothermal, cold, or vapor deposition methods to create a safe and efficient interference coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional anodizing and dyeing processes are used, then coating protection is achieved, but environmental sustainability and safety are compromised due to harmful chemicals
Solution Approach 1:
The patent changes the chemical parameters of the electrolyte by using copper sulfate instead of traditional harmful dyes and acids. This substitution maintains the electrochemical deposition process while eliminating environmentally harmful substances, thus improving environmental sustainability without compromising coating safety
Solution Approach 2:
The patent uses copper sulfate as a replaceable, less harmful electrolyte component that can be easily disposed of or regenerated, replacing persistent harmful chemicals. This allows for safer, more environmentally friendly processing while maintaining coating quality
2Illumination intensity
If multiple anodizing steps are used to achieve interference effect, then visual appeal is improved, but processing time and energy consumption increase
Solution Approach 1:
The patent combines the anodizing and dyeing steps into a single integrated electrochemical process. By using copper sulfate electrolyte during anodizing, the interference coating is formed directly without requiring separate dyeing steps, thus reducing processing time while maintaining the desired visual effect
Solution Approach 2:
The patent performs the dyeing function during the anodizing process itself by pre-preparing the electrolyte with copper sulfate. This preliminary incorporation of the coloring agent eliminates the need for subsequent dyeing steps, reducing overall processing time and energy consumption
3Productivity
If traditional electrolyte composition is used, then dyeing effectiveness is achieved, but environmental safety is compromised
Solution Approach 1:
The patent changes the electrolyte composition parameters by substituting traditional harmful dyes and acids with copper sulfate. This chemical parameter change maintains effective copper ion deposition for interference coating formation while eliminating environmentally harmful substances, thus achieving both productivity and safety
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
This method produces a safe, environmentally friendly interference coating with a wide range of color variants, reducing energy consumption and processing time, making it suitable for applications like beverage cans, while ensuring reproducible quality and economic benefits.
Implementation Method 1
anodizing aluminum alloys in a sulfuric acid solution
Implementation Method 2
electrochemical dyeing with use of alternating current
Data Source
AI summary
A method of manufacturing an interference coating on the surface of an aluminum alloy or aluminum alloys product comprising anodizing and electrochemical dyeing with use of alternating current consisting in that, the electrolyte used during electrochemical dyeing comprises copper (II) sulfate (IV) in an amount from 1 to 100 g/L, boric acid in the amount of 1 to 40 g/L and tartaric acid in the amount of 0.1 to 20 g/L.