Cracked Sintered Electrode Foil for Winding Strength and Low Leakage
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Solution Overview
Problem
The existing methods for producing electrode foils with sintered bodies face challenges such as cracking, increased leakage current, and insufficient bending strength, which hinder their application and industrial production, particularly during the cutting and winding processes in capacitor manufacturing.
Innovation Solution
The introduction of microcracks in the sintered body, oriented in the same direction as the winding process, enhances the bending strength and reduces stress, while maintaining high electrostatic capacity and low leakage current, achieved through hydration treatment followed by physical treatment to generate cracks, and forming an oxide film in a halide-free electrolyte.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If aluminum powder sintered body is laminated on aluminum foil to replace traditional etching process, then environmental pollution is reduced and specific surface area is increased, but the electrode foil becomes prone to cracking and breaking during cutting and winding processes
Solution Approach 1:
The patent applies local quality by creating microcracks only in the sintered body layer while maintaining the integrity of the aluminum foil substrate. This localized structural modification allows the sintered body to flex without causing complete foil failure, thereby improving bending strength while preserving the environmental benefits of the sintered electrode structure
Solution Approach 2:
The patent utilizes composite materials by combining aluminum foil substrate with aluminum powder sintered body in a layered structure. This composite construction allows each layer to contribute its advantageous properties: the foil provides ductility and structural support, while the sintered body provides high surface area, and together they achieve both environmental friendliness and improved bending strength
2Strength
If aluminum alloy porous sintered bodies or increased surface roughness are adopted to improve bending strength, then bending strength is enhanced to some extent, but leakage current increases
Solution Approach 1:
The patent applies parameter changes by controlling the depth of microcracks to be less than or equal to 5 μm. This precise parameter control allows the microcracks to improve bending strength through stress distribution while maintaining the oxide film integrity and preventing leakage current increase that would occur with deeper cracks or alloying
3Strength
If continuous cracks are introduced in the sintered body, then bending strength is significantly improved and stress during winding is reduced, but the structural integrity may be compromised
Solution Approach 1:
The patent applies local quality by confining microcracks to specific regions within the sintered body layer with controlled depth not exceeding 5 μm. This localized cracking approach improves bending strength through stress distribution while the cracks remain contained within the sintered body, preserving the overall structural integrity of the electrode foil
Solution Approach 2:
The patent applies beforehand cushioning by pre-introducing microcracks that serve as stress relief pathways before actual winding or cutting operations. These pre-formed microcracks absorb and distribute mechanical stresses during subsequent processing, preventing catastrophic failure and maintaining structural integrity under operational loads
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 approach effectively improves the bending strength and reduces the risk of fracture during the winding process, maintaining high electrostatic capacity and low leakage current, making the electrode structure more suitable for industrial production.
Implementation Method 1
the sintered body is subjected to hydration treatment and then physical treatment is performed on the sintered body that has been subjected to the hydration treatment to generate cracks
Implementation Method 2
forming an oxide film in a halide-free electrolyte
Data Source
Figure 1~2
Figure 3(a)~3(b)
Figure 4(a)~4(b)
AI summary
The present invention belongs to the technical field of electrode foils, and discloses an electrode structure and preparation methods thereof. The electrode structure comprises a substrate and a sintered body, wherein the sintered body is formed on the surface of the substrate, and the sintered body is provided with cracks that are formed after the hydration treatment of the sintered body. The continuity of cracks of the electrode structure was good, and the preparation method is suitable for industrial production. On the one hand, the electrode structure with cracks can effectively increase the bending strength and reduce the stress during the winding process of the electrode structure, thereby reducing the risk of fracture during the application process; on the other hand, it can improve the flexural strength of the electrode structure while maintaining the original high electrostatic capacity and lower leakage current value of the electrode structure, without negatively affecting the performance of the electrode structure.