Quadrangular Segmented Positive Electrode Assembly for Uniform Copper Foil
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Solution Overview
Problem
Existing electrolytic copper foil production methods face challenges in achieving uniform thickness and efficiency due to the use of segmented positive electrodes with high deformation and residual stress, leading to non-uniform copper foil quality and limited productivity with high current applications.
Innovation Solution
A positive electrode assembly with quadrangular segments disposed in both axial and circumferential directions, using thicker segments (1.5 to 7 mm) and minimal fastening force to maintain a flat shape, reducing edge concentration and requiring fewer bolts for uniform copper foil production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the positive electrode is made of thick segments to enable high current use, then productivity improves, but the electrode becomes difficult to deform into the required concave shape
Solution Approach 1:
The positive electrode is divided into multiple segments that can be independently formed and assembled. This segmentation allows each segment to be manufactured with the required concave shape using standard forming processes, while the overall assembly achieves the desired thick electrode configuration for high current application.
Solution Approach 2:
The electrode structure transitions from a single thick curved component to an assembly of multiple thinner segments arranged in a specific dimensional configuration. This dimensional reorganization maintains the functional equivalence of a thick electrode while enabling manufacturability through standard forming processes.
2Reliability
If bolts are used to deform the positive electrode into a concave shape, then the electrode can be fixed to the base, but residual stress and deformation occur
Solution Approach 1:
The concave shape is pre-formed in each positive electrode segment during the manufacturing process, before assembly. This preliminary forming action eliminates the need for field deformation through bolting, thereby avoiding residual stress and maintaining shape precision while ensuring reliable fixation.
3Manufacturing precision
If a single continuous plate is used for the positive electrode, then current density uniformity improves, but manufacturing and maintenance become difficult
Solution Approach 1:
The positive electrode is segmented into multiple manageable sections that can be independently manufactured, assembled, and replaced. This segmentation maintains current density uniformity through proper design and arrangement while significantly improving ease of manufacture and maintenance compared to a single continuous plate.
4Ease of manufacture
If multiple positive electrode segments are used, then the electrode can be manufactured, but uniformity of current density deteriorates
Solution Approach 1:
Each positive electrode segment is designed with specific local characteristics including optimized thickness, shape, and positioning to ensure uniform current density distribution across the entire electrode assembly. This local quality control compensates for the segmentation effect and maintains overall uniformity.
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 enables high-quality, uniformly thick copper foil production with improved productivity and efficiency by allowing high current use, minimizing thickness variations and reducing bolt-induced deformations.
Implementation Method 1
copper foil is formed on the drum-shaped negative electrode assembly 30 based on electrolytic precipitation
Implementation Method 2
manufacture of copper foil using electrolytic reaction
Data Source
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Figure 2
AI summary
Disclosed is a positive electrode assembly for manufacturing copper foil. The positive electrode assembly includes a positive electrode having a concave, partially cylindrical shape corresponding to a drum-shaped negative electrode and a base configured to support the positive electrode. The positive electrode includes a plurality of quadrangular positive electrode segments disposed in each of a circumferential direction and an axial direction. Edges of each of the positive electrode segments are not adjacent to edges of positive electrode segments disposed thereabove and therebelow so as to be adjacent thereto, and each of a plurality of fastening bolts configured to fix the positive electrode segments to the base is spaced apart from fastening bolts disposed thereabove and therebelow by a predetermined distance in the axial direction.