Distributed Rectifier Circuit for Zoned 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 components and inefficient rectifier circuits, leading to high power usage and electrical inefficiency.
Innovation Solution
A series-in-parallel-out rectifier circuit that converts alternating current to multiple direct current signals, applied across different portions of the anode in an electrodeposition device, providing a lightweight, efficient, and customizable current source with improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional rectifier circuits and power electronics components are used in electrodeposition devices, then sufficient current output for industrial applications is achieved, but the device becomes very heavy and bulky
Solution Approach 1:
The electrodeposition device is divided into multiple independent zones along the anode, with each zone having its own DC-to-DC converter circuit. This segmentation allows the system to achieve high current output through parallel operation of multiple lightweight converter circuits rather than relying on a single bulky power electronics system.
2Power
If conventional rectifier circuits are used to generate high current output, then industrial application requirements are met, but electrical efficiency is poor and power loss is high
Solution Approach 1:
Conventional rectifier circuits are replaced with DC-to-DC converter circuits that use high-frequency switching and magnetic components. This substitution enables much higher electrical efficiency (exceeding 95%) compared to traditional rectifiers, significantly reducing power loss while maintaining the required current output for industrial applications.
3Power
If conventional power electronics components are used, then sufficient power delivery is achieved, but the device occupies a large amount of space
Solution Approach 1:
The power delivery function is segmented across multiple distributed DC-to-DC converter circuits positioned along the anode. Each converter is compact and handles a portion of the total power requirement, allowing parallel operation to achieve high overall power delivery without requiring a single large power electronics system.
Solution Approach 2:
Instead of concentrating all power electronics in a centralized location, the converter circuits are distributed along the length of the anode. This spatial distribution in one dimension reduces the footprint area occupied by power electronics components while maintaining total power delivery capability.
4Productivity
If conventional electrodeposition devices are designed for large surface area deposition, then industrial production capability is achieved, but the device becomes very heavy
Solution Approach 1:
The anode is divided into multiple zones with individual DC-to-DC converter circuits for each zone. This segmentation enables the device to handle large surface area deposition requirements by distributing the current delivery across multiple lightweight converter circuits operating in parallel, rather than using a single heavy power system.
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 achieves high electrical efficiency (~97%) and reduces the size and weight of electrodeposition devices, enabling more flexible and modular designs with improved fault tolerance and reduced material usage.
Implementation Method 1
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
Implementation Method 2
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 3
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.