Highly electrically conductive surfaces for electrochemical applications
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C23C-004/08
C23C-004/00
C23C-004/06
C23C-004/10
C23C-004/18
C23C-004/01
출원번호
US-0350896
(2009-01-08)
등록번호
US-9765421
(2017-09-19)
발명자
/ 주소
Wang, Conghua
출원인 / 주소
TREADSTONE TECHNOLOGIES, INC.
대리인 / 주소
DLA Piper LLP (US)
인용정보
피인용 횟수 :
0인용 특허 :
41
초록▼
A method is described that can be used in electrodes for electrochemical devices and includes disposing a precious metal on a top surface of a corrosion-resistant metal substrate. The precious metal can be thermally sprayed onto the surface of the corrosion-resistant metal substrate to produce multi
A method is described that can be used in electrodes for electrochemical devices and includes disposing a precious metal on a top surface of a corrosion-resistant metal substrate. The precious metal can be thermally sprayed onto the surface of the corrosion-resistant metal substrate to produce multiple metal splats. The thermal spraying can be based on a salt solution or on a metal particle suspension. A separate bonding process can be used after the metal splats are deposited to enhance the adhesion of the metal splats to the corrosion-resistant metal substrate. The surface area associated with the splats of the precious metal is less than the surface area associated with the top surface of the corrosion-resistant metal substrate. The thermal spraying rate can be controlled to achieve a desired ratio of the surface area of the metal splats to the surface area of the corrosion-resistant metal substrate.
대표청구항▼
1. A method, comprising: using a flame spray technique to thermally spray and deposit a highly-electrically-conductive and corrosion-resistant material on a surface of a corrosion-resistant metal substrate to bond a plurality of isolated dots on the surface of the corrosion-resistant metal substrate
1. A method, comprising: using a flame spray technique to thermally spray and deposit a highly-electrically-conductive and corrosion-resistant material on a surface of a corrosion-resistant metal substrate to bond a plurality of isolated dots on the surface of the corrosion-resistant metal substrate, the plurality of isolated dots having no particular pattern and covering a portion of the surface of the corrosion-resistant metal substrate less than the entire surface of the corrosion-resistant metal substrate and being electrically connected to the corrosion resistant metal substrate;wherein the plurality of isolated dots are separated on the corrosion-resistant metal substrate by surface oxide of the corrosion-resistant metal substrate;wherein the plurality of isolated dots having no particular pattern are deposited as isolated dots having no particular pattern;wherein a thickness of plurality of isolated dots is in the range of 1 nanometer to less than 0.5 microns and the plurality of isolated dots cover 0.5% to 50% of the surface area of the corrosion-resistant metal substrate;wherein the highly-electrically-conductive and corrosion-resistant material has an electrical contact resistance of about 50 milliohms-per-square centimeter (mΩ/cm2) or lower, and is a material selected from the group consisting of gold, palladium, platinum, iridium and ruthenium, andwherein the corrosion-resistant metal substrate is made of titanium, niobium, zirconium, tantalum, stainless steel, aluminum, chromium, nickel, or any alloy of any of the foregoing; andwherein the corrosion-resistant metal substrate with the plurality of isolated dots having no particular pattern forms a part of a device selected from the group consisting of a fuel cell, battery, electrolyzer and an electro-chemical gas separation device in which the isolated dots electrically connect the substrate with another component of the device. 2. The method of claim 1, wherein the flame spray technique includes spraying a salt solution or a metal particle suspension. 3. The method of claim 1, wherein a percentage of the portion of the surface area of the corrosion-resistant metal substrate covered by the plurality of isolated dots is 0.5% to 10%. 4. The method of claim 1, further comprising: heat-treating the substrate after the plurality of isolated dots have been deposited. 5. The method of claim 4, wherein the substrate is heated at 450 degrees Celsius for approximately one hour. 6. The method of claim 1, wherein 10% to 30% of the surface area of the corrosion resistant metal substrate is covered by the plurality of dots. 7. A method, comprising: using a plasma spray technique to thermally spray and deposit a highly-electrically-conductive and corrosion-resistant material on a surface of a corrosion-resistant metal substrate to bond a plurality of isolated dots on the surface of the corrosion-resistant metal substrate, the plurality of isolated dots having no particular pattern and covering a portion of the surface of the corrosion-resistant metal substrate less than the entire surface of the corrosion-resistant metal substrate and being electrically connected to the corrosion resistant metal substrate;wherein the plurality of isolated dots are separated on the corrosion-resistant metal substrate by surface oxide of the corrosion-resistant metal substrate;wherein the plurality of isolated dots having no particular pattern are deposited as isolated dots having no particular pattern;wherein a thickness of plurality of isolated dots is in the range of 1 nanometer to less than 0.5 microns and the plurality of isolated dots cover 0.5% to 50% of the surface area of the corrosion-resistant metal substrate;wherein the highly-electrically-conductive and corrosion-resistant material has an electrical contact resistance of about 50 milliohms-per-square centimeter (mΩ/cm2) or lower, and is a material selected from the group consisting of gold, palladium, platinum, iridium and ruthenium, andwherein the corrosion-resistant metal substrate is made of titanium, niobium, zirconium, tantalum, stainless steel, aluminum, chromium, nickel, or any alloy of any of the foregoing; andwherein the corrosion-resistant metal substrate with the plurality of isolated dots having no particular pattern forms a part of a device selected from the group consisting of a fuel cell, battery, electrolyzer and an electro-chemical gas separation device in which the isolated dots electrically connect the substrate with another component of the device.
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