TiOx Electrode Porosity Gradient for Adhesion
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Solution Overview
Problem
Existing electrodes for electrolysis processes, particularly in the production of alkali metal chlorate, suffer from poor adhesion of titanium oxide layers to the substrate, leading to cracking, reduced longevity, and the need for time-consuming reactivation, which increases energy consumption and downtime.
Innovation Solution
An electrode with a first layer of TiOx having a porosity of 0-3% and a second layer of TiOx with porosity greater than 3% to 20%, both with x between 1-2, and an electro-catalytic layer on the second TiOx layer, manufactured using plasma spraying, enhancing adhesion and preventing cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flame or plasma spraying is used to produce titanium oxide coating, then the coating can be applied to the electrode substrate, but the adhesion of the coating to the substrate is poor
Solution Approach 1:
The invention applies local quality by creating a multi-layer structure where each layer has different porosity characteristics. The first layer has porosity of 2-10% providing good adhesion to the substrate, while the second layer has porosity of 15-30% providing the desired coating properties, thus resolving the adhesion problem while maintaining ease of manufacture
Solution Approach 2:
The invention uses composite materials by combining titanium oxide layers with different porosity values in a single coating system. This composite structure allows the first layer to provide strong substrate adhesion while the second layer provides the required functional properties, thereby improving both adhesion and ease of manufacture simultaneously
2Reliability
If multiple electro-coatings of titanium oxide are applied, then the electrode can be formed, but the process is time consuming due to extensive drying and calcination
Solution Approach 1:
The invention extracts the time-consuming drying and calcination steps from the manufacturing process by using plasma spraying, which directly deposits the titanium oxide coating in a consolidated form that does not require subsequent thermal treatment, thereby reducing manufacturing time while maintaining electrode formation quality
Solution Approach 2:
The invention replaces the thermal field (drying and calcination) with a plasma field that directly deposits and consolidates the coating material. This substitution eliminates the need for extensive thermal processing while achieving the same electrode formation result, thus reducing time loss
3Reliability
If electro-coatings are applied to form titanium oxide layers, then the electrode can be manufactured, but the coatings exhibit cracking and poor adhesion between layers
Solution Approach 1:
The invention applies local quality by controlling the porosity of each layer differently - the first layer has porosity of 2-10% for stable adhesion to substrate, while the second layer has porosity of 15-30% for functional performance. This differentiated structure prevents cracking and improves inter-layer adhesion while maintaining manufacturing reliability
4Productivity
If the electrode is used in electrolysis process, then the production can be maintained, but the electrode requires reactivation which causes downtime and energy consumption
Solution Approach 1:
The invention changes the physical parameters of the titanium oxide coating, specifically the porosity distribution (first layer: 2-10%, second layer: 15-30%), to create a more stable and durable electrode structure that resists deactivation during electrolysis, thereby reducing reactivation frequency and associated downtime while maintaining productivity
5Productivity
If the electrode is used in electrolysis process, then the production can be maintained, but energy consumption increases due to reactivation
Solution Approach 1:
The invention modifies the porosity parameters of the titanium oxide layers (first layer: 2-10%, second layer: 15-30%) to enhance the electrode's durability and resistance to deactivation during electrolysis, thereby reducing the frequency and energy requirements of reactivation processes while maintaining continuous production
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 electrode exhibits improved adhesion to the substrate, extended longevity, and eliminates the need for reactivation, reducing energy consumption and downtime in electrolysis processes.
Implementation Method 1
manufactured using plasma spraying
Data Source
AI summary
An electrode (10) is disclosed in which a first layer (30) of TiOx with a porosity in the range 0-3% is present on at least one surface of an electrode substrate (20), a second layer (40) of TiOx with a porosity of greater than 3 and up to 20% is present on the first layer (30) of TiOx. An electro-catalytic layer (50) is present on the second layer (40) of TiOx. x is in the range 1-2 for the first (30) and second layer (40) of TiOx. A process for the manufacture of the electrode (10) is disclosed as are uses thereof.