Discrete Conductive Coating for Fuel Cell Corrosion and Cost
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Solution Overview
Problem
Conductive articles, such as fuel cell components, face corrosion issues due to exposure to fluids and gases, leading to performance loss and failure, with existing corrosion-resistant coatings being either too expensive or ineffective in maintaining conductivity.
Innovation Solution
A coating comprising a corrosion-resistant layer formed by sublayers like titanium oxide or nitride, underlaid with a conductive external layer of discrete, non-continuous areas, such as gold or graphite, applied using sputter deposition to ensure conductivity and protection without the need for extensive noble metal coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a continuous coating of noble metal such as gold is applied to ensure sufficient conductivity and corrosion resistance, then the required conductive characteristics and corrosion protection are achieved, but the cost becomes prohibitively expensive
Solution Approach 1:
The conductive coating is divided into discrete, non-continuous areas or islands rather than forming a continuous layer. This segmentation allows the coating to provide sufficient conductive pathways while using significantly less noble metal material, thereby reducing cost while maintaining the required conductive characteristics
Solution Approach 2:
The coating is applied selectively only in specific locations where conductivity is required, rather than uniformly across the entire surface. This local application of noble metal in discrete areas optimizes material usage and reduces overall cost while maintaining necessary conductive properties
2Quantity of substance
If the depth of the noble metal coating is reduced to decrease expense, then the cost is reduced, but the conductive and corrosion resistant characteristics are not achieved
Solution Approach 1:
By segmenting the coating into discrete areas, each area can be optimized for maximum effectiveness at minimal thickness. The concentrated material in each discrete region provides sufficient conductivity and corrosion resistance locally, eliminating the need for thick uniform coverage across the entire surface
Solution Approach 2:
The patent combines noble metal coating with other materials or structures to create a composite coating system. This composite approach allows the noble metal to be used more efficiently in discrete areas, reducing the total quantity needed while maintaining or enhancing both conductive and corrosion resistant properties
3Reliability
If the noble metal coating is applied to provide corrosion protection, then the base material is protected from corrosion, but the bonding may be insufficient resulting in coating removal and subsequent corrosion
Solution Approach 1:
Surface preparation and treatment steps are performed before applying the noble metal coating to ensure optimal bonding. This preliminary action includes cleaning, activating, or treating the substrate surface to create better adhesion conditions, preventing coating removal and ensuring long-term corrosion protection
Solution Approach 2:
The coating system uses composite material layers including intermediate or adhesion layers between the substrate and the noble metal. These composite structures improve bonding strength and prevent coating delamination, ensuring the corrosion protection function is maintained over time
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 coating effectively protects against corrosion while maintaining conductivity, reducing the need for expensive noble metals and preventing pinhole formation, thus extending the life and performance of conductive articles like fuel cell components.
Implementation Method 1
A coating comprising a corrosion-resistant layer formed by sublayers like titanium oxide or nitride, underlaid with a conductive external layer of discrete, non-continuous areas, such as gold or graphite, applied using sputter deposition
Data Source
AI summary
The invention to which this application relates is for the formation of a coating onto a surface of an article and, in particular, although not necessarily exclusively, to form a coating which has conductive characteristics in order for the purpose of use of the article to be achieved. In one embodiment, the article base to which the coating is applied is a fuel cell or plate for a fuel cell. The coating includes at least one layer and an external layer applied thereto, said external layer provide as a discontinuous layer formed of discrete portions. The invention also relates to the method of application of a coating having the required characteristics.