System and method of applying a silver-gallium coating on metallic surfaces and non-metallic surfaces

Abstract

A method of forming an intimate coating that is a non-oxidizing and conductive metal film on the surfaces of various metals is provided. The intimate coating film is a ternary alloy formed by depositing a layer of AgₓGa amalgam near room temperature over a metal substrate, followed by annealing the substrate up to its melting point. The coating protects the substrate from oxidation, enhances electrical conductivity, prevents deformation at high temperatures, and improves surface reflectivity. Another method of forming a conductive "Ag2Ga + zGa" based coating on various materials, forming a flexible and optionally transparent film with excellent electrical conductivity and mechanical compliance. The conductive coating exhibits mechanical flexibility, electrical conductivity, and adhesion to the substrate sufficient to permit bending or rolling of the coated surface without degradation of conductivity.

Description

[0001] System and Method of Applying a Silver-Gallium Coating on Metallic Surfaces and Non-Metallic Surfaces

[0002] The current application is a Patent Cooperation Treaty (PCT) application and claims a priority to the U.S. non-provisional application serial number 19 / 367,581 filed on October 23, 2025. The U.S. non-provisional application 19 / 367,581 is a continuation-in-part (CIP) application of the U.S. non-provisional application serial number 19 / 352,156 filed on October 7, 2025. The U.S. non-provisional application 19 / 352,156 claims a priority to the U.S. provisional patent application serial number 63 / 711,124 filed on October 23, 2024.

[0003] FIELD OF THE INVENTION

[0004] The present invention generally relates to coatings or films comprising silvergallium (i.e., A 2Ga + zGa, wherein z is between 1 and 5) alloys and their derivatives. More specifically, the present invention concerns applying AgxGa coatings to metallic substrates in order to protect the metallic substrates from oxidation enhancing electrical conductivity, preventing deformation at high temperatures, and improving surface reflectivity. The present invention also concerns applying AgsGa + zGa coatings to non-metallic substrates (e.g., plastics, Teflon, silicon, glass, ceramic graphite, concrete, and asphalt) to produce flexible, conductive, and optionally transparent layers suitable for temporary and permanent electrical contact, flexible circuits, transparent conductive films, soldering, and wiring materials.

[0005] BACKGROUND OF THE INVENTION

[0006] In many industries, durable, conductive, and oxidation-resistant coatings are essential to enhance the longevity and performance of materials exposed to harsh environmental conditions. Metals are particularly susceptible to oxidation and degradation when exposed to high temperatures, or reactive chemicals, which can compromise their electrical conductivity, structural integrity, and appearance.

[0007] Applications ranging from electronics and industrial machinery to jewelry demand materials that can withstand such conditions. Traditional methods of preventing oxidation, such as plating and protective coatings, often degrade over time or fail to endure extreme temperatures. Furthermore, these coatings may not provide sufficient electrical conductivity for electronic components or solar cell batteries.

[0008] Modern electronic systems increasingly rely on lightweight, flexible adherable, and sometime transparent conductive materials that can be applied to non-metallic substrates such as polymers, composites, and ceramics. Traditional conductors (e.g., copper, aluminum) offer high electrical performance but are limited by their rigidity, their oxidation susceptibility, and their transparency limitation with flexible or non-metallic surfaces. Traditional transparent conductors (e.g., Indium Tin Oxide (ITO)) are limited by their electrical conductivity, which is about 1000 times less than metallic conductors (e g., silver, copper).

[0009] Recent advances in printed and flexible electronics have introduced conductive inks based on silver nanoparticles, carbon nanotubes, and graphene, yet these materials typically exhibit inferior conductivity, complex processing requirements, and weak adhesion to certain substrates. Furthermore, most metallic conductors rapidly oxidize, leading to loss of conductivity and degradation under environmental exposure.

[0010] Therefore, an objective of the present invention is to provide users with a system and method for application of Ag2Ga + zGa coatings to different materials including non-metallic surfaces, enabling conductive and transparent fdms on materials such as plastic, Teflon, graphite, glass, silicon, polymer, ceramic, concrete, and asphalt.

[0011] When applied to polymeric films or composite substrates, the Ag2Ga + zGa coating adheres strongly and forms a continuous conductive layer without requiring high end coating machinery. Moreover, under controlled annealing or vibrational treatment, the coating can become semi-transparent, forming transparent conductive layers useful for collar cells, displays, sensors, or smart surfaces. Additionally, in electronic assemblies containing sub-micron copper fdms, such as microelectronic circuits and flexible interconnects, applying a thin AgxGa coating (i.e., wherein x is between 0.1 and 2) can protect the copper layer from oxidation and improve its surface conductivity. This combination of thin copper and AgxGa coatings enables high-performance, flexible, and transparent electrical structures that are both oxidationresistant and mechanically durable.

[0012] Additionally, in electronic circuit repairs, silver-gallium amalgam can be used as soldering material to provide electrical connectivity between multiple points in a circuit.

[0013] SUMMARY OF THE INVENTION

[0014] The present invention is a method of forming an intimate coating (i.e. the coating alloys with the metal that adheres with no air at the interface) that is a non-oxidizing and conductive metal film on the surfaces of various metals. The film is formed by depositing a layer of AgxGa amalgam (where x ranges from 0.1 to 2 depending on the application) near room temperature over a metal substrate, followed by annealing the substrate up to its melting point. The coating protects the substrate from oxidation, enhances electrical conductivity, prevents deformation at high temperatures, and improves surface reflectivity. The invention's applications extend to electronic circuit boards, jewelry, mirror manufacturing, protective coatings for metals to prevent oxidation in harsh conditions, conductive paints, solar cells, and battery fabrication.

[0015] The present invention is also a method for producing a conductive “Ag2Ga + excess gallium” based coating on various materials, forming a flexible and optionally transparent film with excellent electrical conductivity and mechanical compliance. The film is formed by depositing a layer of Ag2Ga + zGa amalgam, wherein z ranges from 1 to 5 depending on the application near room temperature in ambient condition, followed by curing or annealing the substrate up to 500 degrees Celsius (°C) to form a network of Ag2Ga nanowires imbedded in a gallium oxide transparent film. The coating exhibits mechanical flexibility, electrical conductivity, ease of coating using traditional brushing or spraying, and sufficient adhesion to the substrate to permit bending or rolling of the coated surface without degradation of conductivity. Moreover, under controlled annealing or vibrational treatment, the coating can become semi-transparent, forming transparent conductive layers useful for collar cells, displays, sensors, or smart surfaces.

[0016] BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a block diagram illustrating the system of the present invention.

[0018] FIG. 2 is a flowchart illustrating an overall process for the method of the present invention.

[0019] FIG. 3 is a table illustrating optimum values of x in AgxGa and y in Ag2GayM for metal substrates for the method of the present invention.

[0020] FIG. 4 is a schematic representation of direct heating (e.g., torch, radiation) of the silvergallium fdm and the treatable apparatus to a melting point of the treatable apparatus, on an anti -vibration stage.

[0021] FIG. 5 is a schematic representation of a ternary crystal formation after high-temperature annealing of AgxGa on one of 24 listed metals.

[0022] FIG. 6 is a flowchart illustrating a subprocess performed over a vibrating platform.

[0023] FIG. 7 is a flowchart illustrating a subprocess performed over an anti-vibrating table. FIG. 8 is a schematic representation of a crystalline structure of Ag^GasCu within bulk copper, featuring a Ga2Os layer at the surface exposed to air.

[0024] FIG. 9 is a table illustrating some properties of silver gallium intimate coating on iron and copper wires and sheets, in comparison with some original base materials.

[0025] FIG. 10 is a block diagram illustrating the alternate system of the present invention. FIG. 11 is a flowchart illustrating an overall process for the alternate method of the present invention.

[0026] FIG. 12 is a schematic representation of a non-transparent film formation before annealing of Ag2Ga + excess Ga onto an exterior surface of the treatable apparatus.

[0027] FIG. 13 is a schematic representation of a transparent film formation after annealing of Ag2Ga + excess Ga onto an exterior surface of the treatable apparatus. FIG. 14 is a schematic representation of coating a silver gallium film over a flexible substrate.

[0028] FIG. 15 is a schematic representation of a rolled conductive material, that has multiple layers of silver gallium coating.

[0029] FIG. 16 is a schematic representation, wherein silver gallium coating acts as a conductive paint between point A and B over a non-conductive surface.

[0030] DETAILED DESCRIPTION OF THE INVENTION

[0031] All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.

[0032] As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art that the present disclosure has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the abovedisclosed aspects of the disclosure and may further incorporate only one or a plurality of the above-disclosed features. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the embodiments of the present disclosure. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present disclosure.

[0033] Accordingly, while embodiments are described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present disclosure and is made merely for the purposes of providing a full and enabling disclosure. The detailed disclosure herein of one or more embodiments is not intended, nor is it to be construed, to limit the scope of patent protection afforded in any claim of a patent issuing here from, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself.

[0034] Thus, for example, any sequence(s) and / or temporal order of steps of various processes or methods that are described herein are illustrative and not restrictive.

[0035] Accordingly, it should be understood that, although steps of various processes or methods may be shown and described as being in a sequence or temporal order, the steps of any such processes or methods are not limited to being carried out in any particular sequence or order, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and orders while still falling within the scope of the present invention. Accordingly, it is intended that the scope of patent protection is to be defined by the issued claim(s) rather than the description set forth herein.

[0036] Additionally, it is important to note that each term used herein refers to that which an ordinary artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used herein — as understood by the ordinary artisan based on the contextual use of such term — differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the ordinary artisan should prevail.

[0037] Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one” but does not exclude a plurality unless the contextual use dictates otherwise. When used herein to join a list of items, “or” denotes “at least one of the items” but does not exclude a plurality of items of the list. Finally, when used herein tojoin a list of items, “and” denotes “all of the items of the list”.

[0038] Coating for Metallic Substrates

[0039] In reference to FIG. 1 through FIG. 9, the present invention is a system and method of applying a non-oxidizing and intimate coating. In order to accomplish the above-described functionality, the system used to execute the method of the present invention begins by providing a treatable apparatus, wherein the treatable apparatus is made of a specific material (Step A). The treatable apparatus is a device or surface over which the intimate coating has to be formed. While FIG. 1 shows the substrate as a flat surface, the invention also claims the same method for intimate coating other surface shapes, including but not limited to cylindrical shapes, tubular shapes, flat surfaces, and corrugated surfaces, as a few examples. In the preferred embodiment, the specific material is a metal, wherein the metal is selected from a group consisting of chromium, copper, cobalt, gold, hafnium, indium, iron, manganese, molybdenum, nickel, niobium, palladium, platinum, scandium, silver, vanadium, yttrium, zirconium, titanium, tantalum, rhodium, ruthenium, osmium, and tungsten.

[0040] As can be seen in FIG. 2, now that the system used to execute the method of the present invention has been described, it is possible to adequately describe an overall process for the method of the present invention. The overall process begins by coating at least one specific exterior surface of the treatable apparatus with a silver-gallium film (Step B). The at least one specific exterior surface is a single portion, multiple portions, or the entirety of the treatable apparatus, wherein the intimate coating is being formed. In the preferred embodiment, a chemical composition of the silver-gallium film is AgxGa, and a value of x is an atomic ratio between silver and gallium, wherein the value of x is optimized between a range of 0.1 to 2. In other words, the silver-gallium film is formed by depositing a layer of AgxGa amalgam (where x ranges from 0.1 to 2 depending on the application) near room temperature. Further, Step B is performed through a coating process selected from a group consisting of brushing, rolling, spraying, evaporation, sputtering, and electrochemical deposition. For example, the deposition of AgxGa may be performed using a high-temperature painting brush on the surface of specific exterior surface. As a second example, AgxGa may be deposited using a commercially available spray with a modified heating reservoir to heat up the AgxGa to the desired temperature. As a third example, the coating of AgxGa may be using one or a plurality of rollers, where the treatable apparatus is passed in between multiple spongy rollers coated with AgxGa. The AgxGa is constantly pumped into the roller from a reservoir to keep the rollers covered with the AgxGa mixture. By adjusting the flow of the AgxGa into the roller, the intimate coating thickness can be controlled to form a uniform intimate coating on the surface of the substrate or specific exterior surface of the treatable apparatus.

[0041] The overall process of the method of the present invention continues by annealing the silver-gallium film and the treatable apparatus up to a melting temperature of the specific material in order to coat the specific exterior surface with a ternary alloy, wherein the ternary alloy is made of the silver-gallium film and the specific material (Step C). Annealing is a heat treatment process that changes the physical and sometimes also the chemical properties of a material to increase ductility and reduce the hardness to make it more workable. The annealing process requires the material above its recrystallization temperature for a set amount of time before cooling. Annealing can occur in air or vacuum. Annealing at extreme temperatures (above the melting point of the substrate) requires a vacuum to prevent oxidation. As seen in FIG. 4, Ag2Ga nanomicrocrystals coexists with excess Ga within the AgxGa intimate coating prior to the annealing of the metal substrate, which is made from one of the 24 metals listed in this invention. The Ag2Ga nano-microcrystals are primarily concentrated at the lower region of the AgxGa mixture, where they contribute to forming a stronger bond with the substrate even prior to the annealing. After annealing the resulting crystal is a ternary alloy of A 2GayM with few atomic layers of gallium oxide forming above the ternary alloy, as shown in FIG. 5. More specifically, wherein the specific material is a metal M, the chemical composition of the ternary alloy is Ag2GayM, wherein a value of y is optimized between a range of 1.17 and 7.125. The composition of the ternary alloy for various different metals can be seen in FIG. 3.

[0042] The overall process continues by sanding the ternary alloy to a specific surface finish in order to form a protective intimate coating on the specific exterior surface (Step D). This process ensures that the final layer of intimate coating has the desired smoothness or surface finish. In other words, sanding the apparatus with various sanding products enable users to achieve the desired surface finish.

[0043] Thus, by following the method of the present invention, a coating layer of a ternary alloy of Ag2GayM is formed on the surface of metal M, protecting against oxidation, even at elevated temperatures. Additionally, Ag2GayM coating enhances the electrical conductivity, chemical stability, and mechanical strength of the metal M.

[0044] A more detailed description of the present invention is provided by the following. An embodiment of the present invention is the annealing process in a stage with vibration capability to allow shaking of the binary and ternary nano and microcrystals in a microscale to affect the size and shape of binary and ternary multi -crystal forming in the intimate coating layer. In other words, the method of the present invention includes vibrating the silver-gallium film and the treatable apparatus during Step C.

[0045] In reference to FIG. 6, a subprocess of the present invention begins by providing a hot plate with a vibrating platform, wherein the hot plate is in thermal communication with the vibrating platform. In other words, the hot plate provides heat to the vibrating platform. Subsequently, the subprocess continues by placing the silver-gallium film and the treatable apparatus onto the vibrating platform. Vibration during low-temperature annealing improves the reaction of the AgxGa layer with the substrate surface and enhances the spreading of the AgxGa on the substrates. Accordingly, the subprocess continues by vibrating the silver-gallium film and the treatable apparatus with the vibrating platform. Subsequently, the subprocess continues by annealing the silver-gallium film and the treatable apparatus with the hot plate during Step C. More specifically, after the substrate is coated with AgxGa, the substrate must be annealed on the hotplate at temperatures between 200°C and 550°C for a few minutes to several hours, depending on the application. The substrate is then polished to achieve a more uniform coating before undergoing high-temperature annealing, which must not exceed the melting point of the substrate.

[0046] In another embodiment, the method of the present invention includes holding still the silver-gallium film and the treatable apparatus during step C. In other words, an embodiment of the method in this invention is an annealing process on an anti -vibration table, to eliminate external vibration to the specimen from the surrounding environment. When annealing occurs without vibration, on the anti-vibration stage, larger binary and ternary crystalline alloys form within the coated multi -crystalline layer on the specimen. The use of the anti-vibration stage during high-temperature annealing helps eliminate vibrations, allowing for the formation of a larger and more uniform crystalline layer on the surface of the substrate. Exceeding the melting point may damage the specimen. High-temperature annealing can be performed under vacuum or at ambient conditions, depending on the application requirements.

[0047] Accordingly, as seen in FIG. 7, a subprocess of the method of the present invention begins by providing a hot plate and an anti-vibration table, wherein the hot plate is placed onto the anti -vibration table. The anti-vibration table eliminates external vibrations from the surrounding environment. Further, the subprocess continues by placing the silver-gallium film and the treatable apparatus onto the hot plate, followed by holding still the silver-gallium film and the treatable apparatus with the anti-vibration table. When annealing occurs without vibration, on the anti-vibration stage, larger binary and ternary crystalline alloys form within the coated multi-crystalline layer on the specimen. Accordingly, the subprocess continues by annealing the silver-gallium film and the treatable apparatus with the hot plate during Step C. During high-temperature annealing, the binary alloys melt, facilitating the formation of ternary alloys. Some of the excess gallium reacts with oxygen to form a gallium oxide (Ga2Os) film, as shown in FIG. 5 and FIG. 8. The gallium oxide forms primarily on the surface of the Ag2GayM crystalline film, with the film thickness varying based on the amount of excess gallium.

[0048] According to the method of the present invention, at least one physical property of the protective intimate coating is modified by adjusting at least one of process parameters during Steps B through D, wherein the process parameter is selected from the group consisting of: an atomic ratio between silver and gallium, a thickness of the silver-gallium film, a kind of deposition method of the silver-gallium film during Step B, an annealing duration, an annealing temperature, a sanding duration, a sanding grit, and a combination thereof.

[0049] Effect of the Process Parameters

[0050] According to the method of the present invention, ternary alloys Ag2GayM are formed when AgxGa is applied to a third metal (M). This process results in a chemical reaction where Ag2Ga and excess Ga combine with M to form a ternary crystalline structure. For example, when AgxGa is applied to copper, the following reaction occurs: AgxGa+ Cu ^Ag2Ga + nGa + Cu — > Ag2GasCu where n=2

[0051] This reaction indicates that for copper, the optimal value of x in AgxGa is 0.67 (2 / 3), ensuring the formation of AgiGaiCu. The invention further provides predictions for other metals, such as n=3 for iron (yielding Ag2Ga4Fe) and n=4 for chromium. Values of x and y are all listed in FIG 3. Also, the Ag to Ga weight ratio is listed in FIG. 3.

[0052] Key Factors for Optimal Coatins Quality The quality of the Ag2Ga intimate coating depends on several critical factors, including:

[0053] 1. Coating Thickness: Thinner layers allow for better control of the film’ s transparency when applied to transparent substrates.

[0054] 2. Annealing Temperature and Time: Lower annealing temperatures produce more uniform but smaller crystals, while higher temperatures yield larger crystals, improving durability and resistance to harsh conditions.

[0055] 3. Post-Annealing Brushing or Polishing: This step enhances the smoothness and uniformity of the coating which also affects the coating color.

[0056] 4. Substrate Type: The choice of metal or non-metal substrate affects the adherence and stability of the coating.

[0057] During high-temperature annealing, a protective gallium oxide layer may form on the surface, providing additional protection against oxidation.

[0058] Controlling the Properties of the Coating

[0059] The invention also allows for precise control over the properties of the AgxGa intimate coating by adjusting parameters such as the atomic ratio (x), annealing time, temperature, and post-annealing brushing. This enables the production of coatings with varying colors — from blue-black tones at lower x values to yellow-white hues at higher x values — allowing for aesthetic customization in applications like jewelry and reflective surfaces.

[0060] Examples of Ternary Alloys Formed by the Invention

[0061] As a first example, wherein the specific material is copper, and wherein a chemical composition of the silver-gallium film is Ago.6?Ga, and wherein an annealing temperature during Step C is 2000 degrees Fahrenheit (°F), then a chemical composition of the ternary alloy is Ag2Ga3Cu.

[0062] In one embodiment, the process described here has been applied to copper sheets and wires, resulting in several Ag2GaaCu coated copper sheets and wires with different colors and patterns, suitable for use in jewelry. From observations and additional studies, the following qualitative rules have been established for controlling the color of Ag2GasCu coatings on copper fdms:

[0063] 1. Effect of Silver-to-Gallium Ratio (x):

[0064] • Lowering the ratio x in AgxGa results in colors within the blue to black spectrum.

[0065] • Increasing the ratio x shifts the colors towards the yellow to white spectrum, making it suitable for producing lighter-colored coatings.

[0066] 2. Impact of Annealing Temperature and Duration:

[0067] • Lower temperatures and shorter annealing times produce colors on the white to-yellow end of the spectrum.

[0068] • Higher temperatures and longer annealing durations result in darker yellow, then brown, and ultimately a graphite-like color as the annealing time increases.

[0069] 3. Influence of Brushing Techniques:

[0070] • Sand brushing the surface after annealing typically yields a yellowish color, independent of the annealing process and ratio of x.

[0071] • Brushing with a metal brush results in a darker surface, producing a graphite-like appearance.

[0072] • During soft brushing, an interesting phenomenon was observed:

[0073] particles removed during brushing tend to redeposit on the specimen's surface and adhere atomically. This was confirmed by weighing the samples before and after brushing, with no significant weight change (within a ±0.001gram resolution), even after extended brushing. This suggests that the particles removed during brushing interact with the film and recombine with the surface crystals.

[0074] 4. Color Variations by Brushing Method:

[0075] • Sand brushing tends to yield a more yellowish finish on the surface.

[0076] • Brushing with a metal brush results in a graphite-like appearance, adding to the aesthetic versatility of the coating. These findings demonstrate the present invention’s ability to precisely control the color and surface appearance of Ag2GasCu coated copper films by adjusting key parameters, making the invention particularly valuable for creating custom j ewelry with a range of color tones and finishes. The control over color variation and surface properties through annealing and brushing techniques provides a versatile approach to jewelry manufacturing.

[0077] As a second example, wherein the specific material is iron, and wherein a chemical composition of the silver-gallium film is AgosGa, and wherein an annealing temperature during Step C is up to 2800°F, then a chemical composition of the ternary alloy is Ag2Ga4Fe.

[0078] In reference to FIG. 9, the table illustrates that, where the metal coated with the ternary alloys, significant improvements in current density limit, malleability and resistance to oxidation are observed, when compared with non-coated metal.

[0079] As a third example, wherein the specific material is chromium, and wherein a chemical composition of the silver-gallium film is Ago / iGa, and wherein an annealing temperature during Step C is up to 3400°F, then a chemical composition of the ternary alloy is Ag2GasCr.

[0080] As a fourth example, wherein the specific material is cobalt, and wherein a chemical composition of the silver-gallium film is Ago.sGa, and wherein an annealing temperature during Step C is up to 2700°F, then a chemical composition of the ternary alloy is Ag2Ga4Co.

[0081] As a fifth example, wherein the specific material is nickel, and wherein a chemical composition of the silver-gallium film is AgcuGa, and wherein an annealing temperature during Step C is up to 2700°F, then a chemical composition of the ternary alloy is Ag2GasNi.

[0082] As a sixth example, wherein the specific material is tungsten, and wherein a chemical composition of the silver-gallium film is AgosvGa, and wherein an annealing temperature during Step C is up to 6000°F, then a chemical composition of the ternary alloy is Ag2Ga3.sW. Applications of Ternary Alloys Formed by the Invention

[0083] An application of AgxGa is being used a conductive adhesive to bond two electrical conductors. The AgxGa mixture is first melted at an elevated temperature, then applied to both conductors. The device is locally annealed and cooled to create a strong electrical bond. This application is particularly useful in wire bonding for electronics, improving connections between copper wires and copper pads on circuit boards, especially when both are made of Ag2GasCu coated coppers.

[0084] Another application of the present invention is application of Ag2GasCu coated copper sheets or AgGayAl coated aluminum sheets to supply electrical power to electric vehicles (EVs) from the road. The EVs receive power through one or more contact points attached to the EVs, which are also coated with AgxGa and maintain contact with the Ag2GayM coated sheets. The road is powered by nearby energy sources (e g. solar cells, wind turbine), which connect to the Ag2GayM electrical grids embedded in the road. The AgxGa intimate coating is electrically conductive, and one can turn any surface into an electrically conductive surface. For example, asphalt and concrete surfaces on the street can be coated with a layer of AgxGa mixture to provide electrical contact for future EVs, where the EV would receive the electrical power from the street through one or multiple contact points attached to the car that are also coated with AgxGa and are in contact with the surface of the street that is also coated with the AgxGa. The electrodes will provide a perfect connection between the Vehicle and the street which is connected to the electrical network of the surrounding road. This will eliminate the need for batteries in EVs in the future, where they will receive electricity from the street, and be powered up.

[0085] In an alternative embodiment, an application of AgxGa binary alloy is coating aluminum foil with AgxGa . Even though there is no binary alloy GaAl, coating Aluminum (Al) with AgxGa can significantly improve its mechanical and electrical properties, offering the potential for diverse applications across multiple industries. These improvements make AgxGa coated aluminum ideal for use in areas requiring increased conductivity, durability, mechanical strength, and surface protection.

[0086] In another alternate embodiment, AgxGa can be easily coated to many different non-conductive materials including but not limited to, glass, plastic, polymer, Teflon, wood, paper etc., where the AgxGa intimate coating provides electrical conductivity, decorative properties, improved reflectivity, and color variation. For example, coating the surface of several glass slides with intimate Ago.gGa coating and sand polishing the surface made an extremely well reflective surface on glass. Thus, a binary alloy of AgxGa, may be used as a coating that adheres strongly to non-metals without interacting chemically, forming a durable, well-bonded coating.

[0087] For example, an application of AgxGa intimate coating is to coat non-conductive, transparent substrates (e.g., plastic, glass) to make them conductive while maintaining transparency. By applying thinner layers of AgxGa on transparent materials (e.g., glass, polymer), semi-transparent conductive coatings can be produced, suitable for solar cell technology. An annealing step is required to enhance the layer’s transparency. The AgxGa layer is annealed at up to 400°C on a hotplate, causing Ag2Ga nano and micro crystals to form interconnected metallic islands, which provide conductivity, while transparent gallium oxide islands form around them. This combination creates a semi-transparent conductive fdm that is approximately times more conductive than Indium Tin Oxide (ITO) fdms currently used in the industry

[0088] Another application of AgxGa is to coat glass substrates to create conductive, semi-transparent glass products. AgxGa (x=0.5) has been applied to several glass slides, which are then immersed in dilute Hydrochloric Acid (HC1 IN) for a few minutes. The HC1 selectively removes excess gallium, leaving a transparent conductive Ag?Ga nanowire network with 86% of the conductivity of a similar silver fdm. To that end, the fdm is immersed in the HC1 bath and air-dried, resulting in a semi-transparent nanowire network. For added durability, drying can be performed inside a critical point dryer to prevent fdm damage.

[0089] Coating for Non-Metallic Substrates

[0090] The system used to execute an alternate method of the present invention includes a treatable apparatus (Step E), wherein the treatable apparatus is made of a specific material. The treatable apparatus is a device or surface over which the conductive coating has to be formed. As FIG. 10 shows the substrate as a flat surface, the present invention allows for the same method to coat other surface shapes, including but not limited to cylindrical shapes, tubular shapes, flat surfaces, and corrugated surfaces. In the preferred embodiment, the specific material is a non-metallic material, which can be, but is not limited to, plastics, Teflon, graphite, ceramic, glass, silicon, concrete, and asphalt. More specifically, the specific material may be opaque, translucent, or transparent. If the specific material is opaque, the specific material can be, but is not limited to, polymer, carbon, wood, graphite, ceramic, concrete, asphalt, glass, or silicon. Further, if the specific material is transparent or translucent, the specific material can be, but is not limited to, glass or polymer.

[0091] As can be seen in FIG. 11, an overall process for this alternate method allows the present invention to efficiently and effectively apply an external surface of an object with a conductive coating. The overall process begins by applying at least one silver-gallium film onto at least one specific exterior surface of the treatable apparatus (Step F). The at least one specific exterior surface is a single portion, multiple portions, or the entirety of the treatable apparatus, wherein the conductive coating is being formed. In the preferred embodiment, a chemical composition of the silver-gallium film is Ag2Ga + zGa, wherein zGa is an excess in gallium, and wherein a value of z is between a range of 1 to 5. In other words, the silver-gallium film is formed by depositing a layer of Ag2Ga nanocrystalline and micro-crystalline wires with an excess of gallium at normal temperature and pressure (NTP) onto the specific exterior surface. Further, Step F may be performed with a coating process that can be, but is not limited to, brushing, rolling, spraying, evaporation, sputtering, or electrochemical deposition. As a first example, the deposition of Ag2Ga + zGa is performed using a painting brush on the specific exterior surface. As a second example, Ag2Ga + zGa is deposited using a commercially available spray with a modified heating reservoir to heat up the desired temperature. As a third example, the coating of Ag2Ga + zGa is using one or more rollers, wherein the treatable apparatus is passed in between multiple spongy rollers coated with Ag2Ga + zGa. A supply of Ag2Ga + zGa is constantly pumped into the roller(s) from a reservoir to keep the roller(s) covered with Ag2Ga + zGa. By adjusting the flow for the supply of Ag2Ga + zGa into the roller(s), the conductive coating thickness can be controlled to form a uniform coating on the specific exterior surface of the treatable apparatus (i.e., a surface of a substrate).

[0092] The overall process continues by curing or annealing the silver-gallium film onto the specific exterior surface in order to coat the specific exterior surface with a continuous conductive film (Step G). Curing is a process that induces a chemical reaction or a series of reactions that lead to the formation of a cross-linked network within a material. Annealing is a heat treatment process that changes the physical and sometimes also the chemical properties of a material to increase ductility and reduce the hardness to make it more workable. The annealing process requires the material above its recrystallization temperature for a set amount of time before cooling. Annealing can occur in air or vacuum. Annealing at extreme temperatures (i.e., above the melting point of the substrate) requires a vacuum to prevent oxidation. The overall process concludes by resulting in a film that exhibits mechanical flexibility, electrical conductivity, and adhesion to the substrate sufficient to permit bending or rolling of the coated surface without degradation of conductivity.

[0093] An application of AgsGa + zGa conductive coating is to coat non-conductive, transparent substrates (e.g., plastic, glass) to make them conductive while maintaining transparency. By applying thinner layers of Ag2Ga + zGa on transparent materials (e.g., glass, polymer), semi-transparent conductive coatings can be produced, suitable for solar cell technology. An annealing step is required to enhance the layer’s transparency. The Ag2Ga + xGa layer is annealed at up to 500°C on a hotplate, causing Ag?Ga nanocrystalline and micro-crystalline structures to form interconnected metallic islands, which provide conductivity, while transparent gallium oxide islands form around them as shown in FIG. 12 and FIG 13.

[0094] More specifically, by annealing treatment of Ag2Ga + zGa in air, excess gallium reacts with oxygen according to the following formula:

[0095] Ag2Ga + 3zGa + zCh — * Ag2Ga + zGasCh (i.e., z is between 1 and 5)

[0096] This combination creates a semi-transparent conductive film that is approximately 1000 times more conductive than Indium Tin Oxide (ITO) films currently used in the industry.

[0097] Another application of Ag2Ga + zGa is to coat glass substrates to create conductive, semi-transparent glass products. A 2Ga + zGa (i.e., the value of z is 1) has been applied to several glass slides, which are then immersed in dilute Hydrochloric Acid (HC1 IN) for a few minutes. The HC1 selectively removes excess gallium, leaving a transparent conductive A 2Ga nanowire network with 86% of the conductivity of a similar silver film. To that end, the film is immersed in the HC1 bath and air-dried, resulting in a semi-transparent nanowire network. For added durability, drying can be performed inside a critical point dryer to prevent film damage.

[0098] When applied to polymeric films or composite substrates, the Ag2Ga + zGa coating adheres strongly and forms a continuous conductive layer without requiring high-temperature annealing. Moreover, under controlled annealing or vibrational treatment, the coating can become semi-transparent, forming transparent conductive layers useful for displays, sensors, or smart surfaces.

[0099] The alternate method of the present invention can also be used to form a continuous conductive film that is transparent as well. As a first example, the specific material is opaque, then a continuous transparent conductive film allows the specific exterior surface to be seen through the continuous transparent conductive film. As a second example, if the specific material is translucent or transparent, then a continuous transparent conductive film allows visible light to be seen through the continuous transparent conductive film and the treatable apparatus. Thus, a thickness of the silvergallium film can be decreased during Step F in order to increase a transparency of the continuous conductive film (i.e., a continuous transparent conductive film).

[0100] In reference to FIG. 14 and FIG. 15, the conductive silver gallium layer is applied to a non-conductive flexible substrate in multiple stacked or rolled layers to form a flexible multi-layer conductor suitable for use as a wiring material capable of transmitting electrical signals. Accordingly, a sub-process of the alternate method comprises the step of executing a plurality of iterations for Step F, wherein the at least one silver-gallium film is a plurality of silver-gallium films, and wherein the plurality of silver-gallium films is layered onto each other during plurality of iterations for Step F. Further, the silver-gallium coating can be applied using a roll-to-roll or spray-on process to produce flexible conductive sheets for large-scale manufacturing.

[0101] In reference to FIG. 16, if the treatable apparatus is a non-metallic substrate comprising polymer, silicon, glass, graphite, graphene, ceramic, or concrete, the silver-gallium conductive layer acts as a temporary conductive interface between two electrical elements (e.g., an element A and an element B) and can be removed or replaced after completion of electrical work.

[0102] It should be noted that the at least one physical property of the protective coating is modified by adjusting at least one of process parameters during Steps F and G, wherein the process parameter can be, but is not limited to, the value of z in Ag2Ga + zGa, a thickness of the silver-gallium film, a kind of application method of the silver-gallium film during Step F, an annealing duration, an annealing temperature, and a combination thereof. In other words, the coating thickness and curing conditions may be controlled to produce an optically transparent and electrically conductive film. For example, the thickness of the silver-gallium film is less than 500 nanometers (nm), conductive film exhibits electrical conductivity greater than 107S / m and optical transparency greater than 80% in the visible spectrum.

[0103] Thus, in summary the above alternate method for producing a conductive A 2Ga + zGa coating on non-metallic materials, forms a flexible and optionally transparent film with excellent electrical conductivity and mechanical compliance.

[0104] The coating may be applied by painting, spraying, rolling, or printing, followed by mild heat, vibration, or ultraviolet (UV) curing. The resulting films can function as the following:

[0105] 1. Multi-layer flexible conductors that can be rolled, bent, or used as wiring materials in reconfigurable electronics.

[0106] 2. Transparent conductive layers when applied in sub-micron thicknesses or controlled compositions.

[0107] 3. Temporary conductive interfaces on graphite, concrete, or asphalt that can be easily removed or re-applied.

[0108] Thus, the present invention bridges the gap between metallic conductors and flexible polymeric materials, offering durable, low-cost, and easily processed conductive coatings for both industrial and consumer applications.

[0109] Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.

Claims

What is claimed is:

1. A method of applying a non-oxidizing and intimate coating, the method comprising the steps of:(A) providing a treatable apparatus, wherein the treatable apparatus is made of a specific material;(B) coating at least one specific exterior surface of the treatable apparatus with a silver-gallium film;(C) annealing the silver-gallium film and the treatable apparatus up to a melting temperature of the specific material in order to coat the specific exterior surface with a ternary alloy, wherein the ternary alloy is made of the silver-gallium film and the specific material; and(D) sanding the ternary alloy to a specific surface finish in order to form a protective intimate coating on the specific exterior surface.

2. The method as claimed in claim 1, wherein the specific material is a metal, and wherein the metal is selected from a group consisting of: chromium, copper, cobalt, gold, hafnium, indium, iron, manganese, molybdenum, nickel, niobium, palladium, platinum, scandium, silver, vanadium, yttrium, zirconium, titanium, tantalum, rhodium, ruthenium, osmium, and tungsten.

3. The method as claimed in claim 1, wherein step (B) is through a coating process selected from a group consisting of: brushing, rolling, spraying, evaporation, sputtering, and electrochemical deposition.

4. The method as claimed in claim 1, wherein a chemical composition of the silver- gallium film is AgxGa, and wherein a value of x is an atomic ratio between silver and gallium, and wherein the value of x is optimized between a range of 0.1 to 2.

5. The method as claimed in claim 1, wherein the specific material is a metal, and wherein a chemical composition of the ternary alloy is Ag2GayM, and wherein a value of y is optimized between a range of 1.17 and 7.125.

6. The method as claimed in claim 1 further comprising the step of:vibrating the silver-gallium fdm and the treatable apparatus during step (C).

7. The method as claimed in claim 6 further comprising the steps of:providing a hot plate with a vibrating platform, wherein the hot plate is in thermal communication with the vibrating platform;placing the silver-gallium fdm and the treatable apparatus onto the vibrating platform;vibrating the silver-gallium fdm and the treatable apparatus with the vibrating platform; andannealing the silver-gallium fdm and the treatable apparatus with the hot plate during step (C).

8. The method as claimed in claim 1 further comprising the step of:holding still the silver-gallium fdm and the treatable apparatus during step (C).

9. The method as claimed in claim 8 further comprising the steps of:providing a hot plate and an anti-vibration table, wherein the hot plate is placed onto the anti-vibration table;placing the silver-gallium fdm and the treatable apparatus onto the hot plate;holding still the silver-gallium fdm and the treatable apparatus with the anti-vibration table; andannealing the silver-gallium fdm and the treatable apparatus with the hot plate during step (C).

10. The method as claimed in claim 1, wherein at least one physical property of the protective intimate coating is modified by adjusting at least one of processparameters during steps (B) through (D), wherein the process parameter is selected from the group consisting of: an atomic ratio between silver and gallium, a thickness of the silver-gallium film, a kind of deposition method of the silvergallium film during step (B), an annealing duration, an annealing temperature, a sanding duration, a sanding grit, and a combination thereof.

11. The method as claimed in claim 1, wherein the specific material is copper, and wherein a chemical composition of the silver-gallium film is Ago.6?Ga, and wherein an annealing temperature during step (C) is 2000 degrees Fahrenheit (°F), and wherein a chemical composition of the ternary alloy is Ag2GaaCu.

12. The method as claimed in claim 1, wherein the specific material is iron, and wherein a chemical composition of the silver-gallium film is Ago.sGa, and wherein an annealing temperature during step (C) is up to 2800°F, and wherein a chemical composition of the ternary alloy is Ag2Ga4Fe.

13. The method as claimed in claim 1, wherein the specific material is chromium, and wherein a chemical composition of the silver-gallium film is A o.4Ga, and wherein an annealing temperature during step (C) is up to 3400°F, and wherein a chemical composition of the ternary alloy is Ag2GasCr.

14. The method as claimed in claim 1, wherein the specific material is cobalt, and wherein a chemical composition of the silver-gallium film is Ago.sGa, and wherein an annealing temperature during step (C) is up to 2700°F, and wherein a chemical composition of the ternary alloy is Ag2Ga4Co.

15. The method as claimed in claim 1, wherein the specific material is nickel, and wherein a chemical composition of the silver-gallium film is Ago4Ga, and wherein an annealing temperature during step (C) is up to 2700°F, and wherein a chemical composition of the ternary alloy is Ag2GasNi.

16. The method as claimed in claim 1, wherein the specific material is tungsten, and wherein a chemical composition of the silver-gallium film is Ago.svGa, and wherein an annealing temperature during step (C) is up to 6000°F, and wherein a chemical composition of the ternary alloy is Ag2Ga3.sW.

17. A method of applying a conductive coating, the method comprising the steps of:(E) providing a treatable apparatus, wherein the treatable apparatus is made of a specific material;(F) applying at least one silver-gallium film onto at least one specific exterior surface of the treatable apparatus; and(G) curing or annealing the silver-gallium film onto the specific exterior surface in order to coat the specific exterior surface with a continuous conductive film.

18. The method as claimed in claim 17, wherein the specific material is an opaque material.

19. The method as claimed in claim 18, wherein the opaque material is selected from a group consisting of: polymer, carbon, wood, graphite, ceramic, concrete, asphalt, glass, and silicon.

20. The method as claimed in claim 17, wherein the specific material is a transparent or translucent material.

21. The method as claimed in claim 20, wherein the transparent or translucent material is selected from a group consisting of: glass and polymer.

22. The method as claimed in claim 17, wherein a chemical composition of the silver- gallium film is Ag2Ga + zGa, and wherein a value of z is optimized between a range of 1 to 5.

23. The method as claimed in claim 17, wherein step (F) is executed by a coating process selected from a group consisting of: brushing, rolling, spraying, evaporation, sputtering, and electrochemical deposition.

24. The method as claimed in claim 17, wherein step (F) is executed by depositing a layer of Ag2Ga nano-crystalline and micro-crystalline wires with an excess of gallium at normal temperature and pressure (NTP) onto the specific exterior surface.

25. The method as claimed in claim 17, the method further comprising the step of:increasing a transparency of the continuous conductive film by decreasing a thickness of the silver-gallium film during step (F).

26. The method as claimed in claim 17, the method further comprising the step of:executing a plurality of iterations for step (F), wherein the at least one silver-gallium film is a plurality of silver-gallium films, and wherein the plurality of silver-gallium films is layered onto each other during plurality of iterations for step (F).

27. The method as claimed in claim 17, wherein at least one physical property of the continuous conductive film is modified by adjusting at least one of process parameters during steps (F) and (G), wherein the process parameter is selected from the group consisting of: the value of z in Ag2Ga + zGa, a thickness of the silver-gallium film, a kind of application method of the silver-gallium film during step (F), an annealing duration, an annealing temperature, and a combination thereof.

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