Doped ITO Electrode Plate Coating for Corrosion-Resistant Conductivity
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Solution Overview
Problem
Existing electrode plates for fuel cells, electrolyzers, and redox flow cells face challenges in achieving high electrical conductivity, long-term stability, and corrosion resistance while minimizing the use of precious metals.
Innovation Solution
A layer system comprising a homogeneous polycrystalline doped indium tin oxide layer and a cover layer of nanofiber network is applied to the substrate, which is produced through PVD, CVD, or PACVD processes, utilizing doping elements like carbon, nitrogen, and others, to enhance conductivity and corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precious metals are used for coating, then electrical conductivity and corrosion resistance are improved, but cost increases significantly
Solution Approach 1:
The patent changes the chemical composition parameters of the coating by using doped metal oxides (such as tin oxide doped with fluorine, sulfur, or carbon) instead of precious metals. The doping elements are introduced in specific concentration ranges (0.1-10 at%) to optimize both conductivity and corrosion resistance while maintaining cost-effectiveness
Solution Approach 2:
The patent employs composite coating structures consisting of multiple layers with different functions: a base layer of doped metal oxide for corrosion protection, intermediate layers for adhesion and conductivity, and top layers for surface properties. This multi-layer composite approach achieves precious metal-level performance without using expensive materials
2Reliability
If conventional coating methods are used, then manufacturing simplicity is maintained, but long-term stability under harsh conditions is insufficient
Solution Approach 1:
The patent achieves long-term stability by precisely controlling deposition parameters (temperature 100-500°C, pressure, deposition rate) and post-treatment parameters (annealing temperature 200-600°C, time 1-24 hours). These parameter optimizations create dense, adherent coatings with controlled porosity and crystallinity that resist degradation in fuel cell and electrolyzer environments
Solution Approach 2:
The patent incorporates preliminary surface preparation steps (cleaning, activation, or primer application) before coating deposition to ensure optimal adhesion. Additionally, the coating composition and structure are pre-optimized during manufacturing to preemptively resist harsh operating conditions, reducing the need for complex post-processing or maintenance
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 layer system provides high electrical conductivity, excellent corrosion protection, and long-term stability, reducing the need for precious metals, with contact resistance and corrosion currents maintained at low levels under harsh conditions.
Implementation Method 1
The layer system is preferably formed by a PVD or CVD process (PVD: Physical Vapor Deposition; CVD: Chemical Vapor Deposition)
Implementation Method 2
The layer system is preferably formed by a PVD or CVD process (PVD: Physical Vapor Deposition; CVD: Chemical Vapor Deposition)
Implementation Method 3
The layer system is preferably formed by a PVD or CVD process (PVD: Physical Vapor Deposition; CVD: Chemical Vapor Deposition) or a PACVD process (PACVD: Plasma-assisted Chemical Vapor Deposition)
Data Source
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Figure 3~4
AI summary
The invention relates to a layer system (1) for coating of a substrate (2a) to form an electrode plate (2), comprising at least one coating (1a) of metal oxide, wherein the coating (1a) includes a homogeneous polycrystalline doped indium tin oxide layer, atop which is a polycrystalline doped indium tin oxide layer composed of a network of nanofibers (6), wherein the indium tin oxide is doped with at least one element from the group comprising carbon, nitrogen, boron, fluorine, hydrogen, phosphorus, sulfur, chlorine, bromine, aluminium, silicon, titanium, chromium, cobalt, nickel, copper, zirconium, niobium, molybdenum, silver, antimony, hafnium, tantalum, tungsten. The invention further relates to an electrode plate comprising such a layer system, to a process for production thereof, and to a fuel cell, an electrolyzer or a redox flow cell comprising at least one such electrode plate.