Cold-Sprayed Busbar Coatings for Uniform Corrosion Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Busbar contact degradation due to environmental corrosion is a significant issue, and existing coating methods like galvanic plating often result in non-uniform coatings that decrease busbar life and are costly to achieve desired thicknesses.
Innovation Solution
A method of cold spraying a powder comprising metal particles, such as nickel, tin, silver, or copper, onto busbars at high velocity to form a coherent coating with an average thickness of greater than 10 micrometers, providing improved uniformity and roughness compared to traditional galvanic coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If galvanic plating is used to coat busbars, then corrosion protection is provided, but the coating becomes non-uniform and busbar life decreases
Solution Approach 1:
The patent replaces the electrochemical galvanic plating process with a cold spray deposition process that uses high-velocity particle impact and plastic deformation to form coatings. This mechanical/physical approach eliminates the diffusion-controlled non-uniformity of galvanic plating, producing consistent coating thickness and uniform corrosion protection across the busbar surface.
Solution Approach 2:
The patent changes the fundamental deposition parameters by using cryogenically cooled substrate temperatures (e.g., -196°C to -50°C) and high-velocity particle impact (supersonic or near-supersonic speeds) instead of electrochemical parameters. This parameter transformation enables precise control over coating morphology, adhesion, and uniformity, directly resolving the coating non-uniformity issue while maintaining corrosion protection.
2Reliability
If galvanic plating is used to achieve increased coating thickness, then corrosion resistance improves, but manufacturing cost increases significantly
Solution Approach 1:
The patent employs cold spray deposition, a more cost-effective manufacturing process compared to expensive galvanic plating facilities and materials. The cold spray process uses readily available metal powders and eliminates the need for complex electrochemical equipment, chemical baths, and extensive post-processing, thereby reducing manufacturing costs while achieving the required coating thickness for corrosion resistance.
Solution Approach 2:
By changing from electrochemical deposition parameters to high-velocity particle deposition parameters, the patent enables direct control over coating thickness during the spraying process. This eliminates the need for multiple plating passes and expensive thick-plating operations, achieving cost-effective thick coatings (e.g., 20 micrometers or more) in a single or few passes with precise thickness control.
3Manufacturing precision
If cold spray deposition is used to form thick coatings, then coating uniformity improves, but process complexity increases
Solution Approach 1:
The patent replaces complex electrochemical control systems with a mechanically simpler cold spray system that relies on high-velocity gas flow and particle dynamics. The uniformity is achieved through inherent process characteristics (supersonic particle acceleration, cryogenic substrate cooling) rather than complex feedback control, actually reducing overall system complexity while improving coating uniformity.
Solution Approach 2:
The cold spray process uses periodic or pulsed gas flow to deliver metal particles to the substrate in controlled bursts. This periodic action, combined with cryogenic substrate cooling, ensures uniform particle deposition and prevents overheating, achieving consistent coating thickness without requiring overly complex continuous control systems.
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 cold spray method produces a more uniform and durable coating with reduced thickness variations and increased surface roughness, enhancing corrosion resistance and extending busbar life while being cost-effective.
Implementation Method 1
cold spraying a powder comprising a plurality of metal particles onto the busbar at a velocity sufficiently high to cause the plurality of metal particles to deform upon contact with the busbar thereby forming the coating on the busbar
Implementation Method 2
cause the plurality of metal particles to deform upon contact with the busbar
Data Source
AI summary
In an aspect, a method of forming a coating on a busbar comprises cold spraying a powder comprising a plurality of metal particles onto the busbar at a velocity sufficiently high to cause the plurality of metal particles to deform upon contact with the busbar thereby forming the coating on the busbar; wherein the plurality of metal particles comprises greater than or equal to 50 weight percent of at least one of nickel, tin, silver, zinc, or copper based on the total weight of the metal particles; and wherein the coating has an average thickness of greater than or equal to 10 micrometers. In another aspect, a coated busbar is formed by cold spraying.