A conductive, corrosion-resistant coating includes a mixture of corrosion-resistant binder and highly conductive corrosion-resistant particles. The size of the particles is equal to or greater than the final thickness of the coating. After the coating is applied and cured, the surface of the coating
A conductive, corrosion-resistant coating includes a mixture of corrosion-resistant binder and highly conductive corrosion-resistant particles. The size of the particles is equal to or greater than the final thickness of the coating. After the coating is applied and cured, the surface of the coating is machined to remove the top surface layer of the binder as well as the top parts of the particles embedded in the binder, thus opening multiple direct conductive paths to the underlying substrate through the conductive particles.
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What is claimed is: 1. A method of making an electrically conductive, corrosion-resistant coating comprising the steps of providing a conductive substrate to be coated; forming a mixture of a binder compound and a plurality of conductive particles; coating said conductive substrate with said mixtur
What is claimed is: 1. A method of making an electrically conductive, corrosion-resistant coating comprising the steps of providing a conductive substrate to be coated; forming a mixture of a binder compound and a plurality of conductive particles; coating said conductive substrate with said mixture; curing said mixture on said conductive substrate, thereby forming a coating having an initial thickness, a bottom surface which is in contact with said conductive substrate, and a top surface which is not in contact with said conductive substrate; removing a layer of said coating from said top surface of said coating, forming an exposed conductive area on at least a portion of said conductive particles on said top surface of said coating, wherein at least some of said conductive particles having said exposed conductive area on said top surface of said coating are simultaneously in contact with said conductive substrate on said bottom surface of said coating with direct conductive paths to said conductive substrate formed through said conductive particles; thereby forming said electrically conductive, corrosion-resistant coating of a final thickness. 2. The method according to claim 1, wherein said conductive particles are selected from the group consisting of metal particles, cut metal wire, cut graphite fiber, graphite particles, mixture of metal particles and cut metal wire, mixture of graphite particles and cut graphite fiber, mixture of metal particles and graphite particles, mixture of cut graphite fiber and cut metal wire, mixture of metal particles and cut graphite fiber, mixture of cut metal wire and graphite particles, mixture of metal particles, graphite particles, and cut metal wire, mixture of metal particles, graphite particles, and cut graphite fiber, mixture of metal particles, cut graphite fiber, and cut metal wire, mixture of graphite particles, cut graphite fiber, and cut metal wire, and mixture of graphite particles, metal particles, cut graphite fiber, and cut metal wire. 3. The method according to claim 2, wherein from about 5% to exactly 100% of said conductive particles have a smallest dimension which is equal to or greater than said final thickness of said coating. 4. The method according to claim 3, wherein said final thickness of said coating ranges from about 25 microns to about 2000 microns. 5. The method according to claim 4, wherein said step of removing removes from about 5% to about 50% of said initial thickness of said coating. 6. The method according to claim 4, wherein said conductive substrate is a bi-polar plate of a fuel cell. 7. The method according to claim 3, wherein said conductive substrate is a bi-polar plate of a fuel cell. 8. The method according to claim 1, wherein from about 5% to exactly 100% of said conductive particles have a smallest dimension which is equal to or greater than said final thickness of said coating. 9. The method according to claim 8, wherein said final thickness of said coating ranges from about 25 microns to about 2000 microns. 10. The method according to claim 9, wherein said step of removing removes from about 5% to about 50% of said initial thickness of said coating. 11. The method according to claim 9, wherein said conductive substrate is a bi-polar plate of a fuel cell. 12. The method according to claim 8, wherein said conductive substrate is a bi-polar plate of a fuel cell. 13. The method according to claim 1, wherein said step of removing removes from about 5% to about 50% of said initial thickness of said coating. 14. The method according to claim 13, wherein said conductive substrate is a bi-polar plate of a fuel cell. 15. The method according to claim 1, wherein said conductive substrate is a bi-polar plate of a fuel cell. 16. An electrically conductive, corrosion-resistant coating on a conductive substrate, comprising: a layer of a cured mixture of a binder compound and a plurality of conductive particles, said mixture being coated on said conductive substrate, said coating having a bottom surface which is in contact with said conductive substrate, and a top surface which is not in contact with said conductive substrate; wherein at least a portion of said conductive particles on said top surface of said coating is directly exposed by a removal of a layer of said coating from said lop surface forming an exposed conductive area on said portion of said conductive particles, wherein at least some of said conductive particles of said portion simultaneously are in contact with said conductive substrate on said bottom surface of said coating, with direct conductive paths to said conductive substrate formed through said conductive particles. 17. An electrically conductive, corrosion-resistant coating according to claim 16, wherein said conductive substrate is a bi-polar plate, a flow-field component of a fuel cell, or a bi-polar plate with flow field channels. 18. An electrically conductive, corrosion-resistant coating according to claim 16, wherein from about 5% to exactly 100% of said conductive particles have a smallest dimension which is equal to or greater than a final thickness of said coating, and wherein the final thickness of said coating ranges from about 25 microns to about 2000 microns. 19. An electrically conductive, corrosion-resistant coating on a conductive substrate, said coating comprising: means for conducting electricity from a top surface of said coating to said conductive substrate; means for sealing said conductive substrate from corrosion; wherein said means for conducting electricity is interspersed among said means for sealing said conductive substrate; and wherein at least a portion of said means for conducting electricity is directly exposed on said top surface of said coating by removing a layer of said coating from said top surface of said coating forming an exposed conductive area on said portion of said means for conducting electricity, wherein at least some of said portion of said means for conducting electricity are simultaneously in contact with said conductive substrate with direct conductive paths to said conductive substrate formed through said means for conducting electricity. 20. An electrically conductive, corrosion-resistant coating according to claim 19, wherein said conductive substrate is a bi-polar plate of a fuel cell, a flow-field component of a fuel cell, or a bi-polar plate of a fuel cell with flow field channels.
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이 특허에 인용된 특허 (5)
Li Yang ; Meng Wen-Jin ; Swathirajan Swathy ; Harris Stephen Joel ; Doll Gary Lynn, Corrosion resistant PEM fuel cell.
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