Series-Parallel Rectifier Layout for Modular Anode Current Control
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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 large size.
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 to ensure even electrodeposition, with a front-end stage for AC-DC conversion and a back-end stage for subdividing DC signals, mounted directly to the electrodeposition device for improved efficiency and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional rectifier circuits are used for electrodeposition, then current output is sufficient for industrial applications, but the device becomes very heavy and bulky
Solution Approach 1:
The rectifier circuit is divided into multiple independent bridge rectifier circuits (first, second, third, fourth) that can be distributed across different locations on the anode. Each bridge rectifier circuit has its own DC-to-DC converter circuits, eliminating the need for heavy central power electronics and large bus bars. This segmentation allows the system to achieve sufficient total current output while dramatically reducing device weight and bulk.
2Power
If conventional rectifier circuits are used, then current output is sufficient, but the device takes up a large amount of space
Solution Approach 1:
By distributing multiple bridge rectifier circuits and their associated DC-to-DC converter circuits across different locations on the anode, the system achieves sufficient current output without requiring a large centralized power electronics section. The segmented architecture allows compact integration directly at the electrode locations, minimizing the overall device footprint.
Solution Approach 2:
The patent transitions from a centralized, planar layout of power electronics to a three-dimensional distribution where rectifier circuits are mounted directly on the anode surface at multiple locations. This spatial reorganization allows the system to maintain sufficient power output while reducing the horizontal area occupied by the device.
3Productivity
If conventional rectifier circuits are used, then electrodeposition can be performed, but power usage is high due to electrical inefficiency
Solution Approach 1:
The system employs multiple DC-to-DC converter circuits in parallel that can independently adjust their operating parameters to optimize efficiency. By distributing the current output across multiple converters rather than using a single high-power converter, the system operates each converter in a more efficient range, reducing overall power losses and improving electrical efficiency while maintaining the required electrodeposition capability.
4Power
If conventional rectifier circuits are used, then current output is sufficient, but power loss during operation is high
Solution Approach 1:
The power conversion function is segmented into multiple independent bridge rectifier circuits and DC-to-DC converter circuits. This segmentation allows each converter to operate at lower power levels with higher efficiency, reducing I²R losses and other inefficiencies associated with high-current single-point conversion. The distributed architecture minimizes power loss during operation while maintaining sufficient total current output.
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, efficient, and customizable current source for electrodeposition, reducing size and weight, improving electrical efficiency to approximately 97%, and allowing for modular and fault-tolerant operation.
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 of an input terminal
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
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 4
an electrodeposition device can include 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.