Distributed Rectifier Mounting for Even Electrodeposition Current
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Solution Overview
Problem
Conventional electrodeposition devices for copper foil production are inefficient and bulky due to heavy power electronics and rectifier circuits that inefficiently convert input signals, leading to high power usage and space requirements.
Innovation Solution
A series-in-parallel-out rectifier circuit that converts alternating current to multiple direct current signals, applied across different portions of an electrodeposition device for even material deposition, using a front-end stage for AC-DC conversion and a back-end stage with multiple DC-DC converter circuits mounted directly to the anode for efficient current distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional rectifier circuits and power electronics components are used for high current output, then sufficient current for industrial electrodeposition is achieved, but the system becomes very heavy (hundreds of kilograms) and occupies large space
Solution Approach 1:
The rectifier circuit is divided into multiple independent rectifier modules, each capable of generating current signals. These modules are distributed across different locations of the electrodeposition device, eliminating the need for a single heavy centralized power supply system.
Solution Approach 2:
The patent transitions from a centralized vertical power supply architecture to a distributed horizontal arrangement where rectifier modules are placed at multiple locations around the electrodeposition device, spreading the weight and space requirements across different spatial dimensions.
2Power
If conventional rectifier circuits are used for high current output, then sufficient current for industrial electrodeposition is achieved, but the system occupies large space
Solution Approach 1:
The rectifier circuit is divided into multiple independent rectifier modules, each capable of generating current signals. These modules are distributed across different locations of the electrodeposition device, eliminating the need for a single heavy centralized power supply system.
Solution Approach 2:
The patent transitions from a centralized vertical power supply architecture to a distributed horizontal arrangement where rectifier modules are placed at multiple locations around the electrodeposition device, spreading the weight and space requirements across different spatial dimensions.
3Power
If conventional rectifier circuits are used, then power conversion is achieved, but electrical efficiency is low resulting in high power usage and power loss
Solution Approach 1:
Multiple rectifier modules are positioned at different locations around the electrodeposition device, allowing current to be applied locally at each position. This distributed architecture reduces transmission losses and improves overall electrical efficiency by minimizing the distance current must travel through conductors.
Solution Approach 2:
The patent applies current directly at multiple locations simultaneously through distributed rectifier modules, skipping the need for long-distance current transmission through heavy bus bars, thereby reducing resistive power losses.
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 solution provides a lightweight, electrically efficient, and customizable current source for electrodeposition, reducing material usage, weight, and space while ensuring consistent material deposition with improved thermal management and flexibility.
Implementation Method 1
the mounting structure includes a thermally conductive base element (e.g., aluminum), in which the bung element is at least partially disposed, that conducts heat generated by the rectifier circuit to the portion of the electrodeposition device
Implementation Method 2
a front-end stage with an alternating current-to-direct current converter circuit that generates one or more direct current voltage signals from an alternating current voltage signal of an input terminal
Implementation Method 3
a back-end stage with a plurality of direct current-to-direct current converter circuits that convert the one or more direct current voltage signals generated by the front-end stage into a plurality of child direct current voltage signals
Implementation Method 4
an anode (e.g., an anode bath) and a cathode (e.g., a cathode drum) to deposit material on a surface of the cathode via one or more applied currents through an electrolytic material between the anode and the cathode drum
Data Source
AI summary
The present disclosure relates to systems, non-transitory computer-readable media, and methods for applying controllable current to portions of an electrodeposition device via a series-in-parallel-out rectifier circuit. In particular, the rectifier circuit includes a front-end stage that includes an alternating current-to-direct current converter circuit to generate one or more direct current signals from an alternating current signal of an input terminal. Additionally, the rectifier circuit includes a back-end stage including a plurality of direct current-to-direct current converter circuits that convert the one or more direct current signals into a plurality of child direct current signals. Furthermore, the plurality of direct current-to-direct current converter circuits of the disclosed series-in-parallel-out rectifier circuit are in physical contact with an anode of the electrodeposition device at a plurality of different positions to apply separate currents to different portions of the anode.