Electrolysis Electrode Arc Ion Plating Amorphous Oxide Interlayer
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Solution Overview
Problem
Conventional methods for manufacturing electrodes for industrial electrolysis, such as copper foil and aluminum electrolysis, face issues with high electrode catalyst consumption and corrosion due to oxygen generation, leading to inadequate corrosion resistance and conductivity, despite the use of interlayers like tantalum and niobium oxides.
Innovation Solution
A manufacturing process involving an arc ion plating undercoating layer with crystalline tantalum and titanium components, followed by heat sintering to form an amorphous oxide interlayer, which enhances bonding with the electrode catalyst layer and provides improved corrosion resistance and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional interlayers (tantalum/niobium oxide) are used to protect the electrode substrate from corrosion, then corrosion resistance is improved, but electrode catalyst consumption increases and conductivity deteriorates
Solution Approach 1:
The protective layer is divided into two distinct segments: an underlying interlayer (tantalum/niobium oxide) for corrosion protection, and an upper conductive oxide layer (rutile-type TiO2 or mixed metal oxide) for maintaining conductivity and catalyst stability. This segmentation allows each layer to perform its specialized function without compromising the other.
Solution Approach 2:
The invention uses composite material structures: either a dual-layer composite (interlayer + conductive oxide layer) or a multi-element mixed oxide composite (Ti-Nb-Ta-O system). These composites combine the corrosion resistance of tantalum/niobium oxides with the high conductivity and catalytic stability of rutile-type oxides.
2Reliability
If conventional interlayers are used to isolate the substrate from oxygen generation area, then substrate corrosion is reduced, but electrode density decreases and manufacturing complexity increases
Solution Approach 1:
The invention optimizes the thickness parameters of each layer (interlayer: 0.01-1 μm, conductive oxide layer: 0.1-5 μm) and controls the composition ratios in mixed metal oxides to achieve the desired balance between protection and density. By adjusting these parameters, the electrode maintains high density while incorporating the protective layered structure.
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 process results in electrodes with higher density, enhanced corrosion resistance, and prolonged electrolysis life by preventing electrolyte intrusion and catalyst detachment, thus addressing the limitations of previous interlayer technologies.
Implementation Method 1
an arc ion plating undercoating layer with crystalline tantalum and titanium components is formed on the surface of an electrode substrate
Implementation Method 2
followed by heat sintering to transform tantalum component only of the arc ion plating undercoating layer into amorphous substance and to form an oxide interlayer
Data Source
Figure 1
Figure 2A~2B
AI summary
The present invention relates to a manufacturing process of the electrodes for electrolysis, characterized by the process to form an arc ion plating undercoating layer comprising valve metal or valve metal alloy containing crystalline tantalum component and crystalline titanium component on the surface of the electrode substrate comprising valve metal or valve metal alloy by the arc ion plating method, the heat sintering process in which metal compound solution containing valve metal as a chief element is coated on the surface of the arc ion plating undercoating layer, followed by heat sintering to transform tantalum component only of the arc ion plating undercoating layer comprising valve metal or valve metal alloy containing crystalline tantalum component and crystalline titanium component into amorphous substance and to form an oxide interlayer comprising valve metal oxides component as a chief element on the surface of the arc ion plating undercoating layer containing transformed amorphous tantalum component and crystalline titanium component, and the process to form electrode catalyst layer on the surface of said oxide interlayer.