A component for an electrochemical device, the component including: a metallic substrate; and a plurality of particles bonded to a surface of the substrate by a metallurgical bond, wherein the particles include a metal, carbon, or a combination thereof, wherein the metallurgical bond is between the particles and the substrate, wherein a total projected area of the metallurgical bond is less than 90% of a total projected area of the substrate, and wherein the metallurgical bond has a composition which is a combination of a composition of the metallic substrate and a composition of the particle, a reaction product of the metallic substrate and the particle, or a combination thereof.
Disclosed is a component for solid oxide fuel cells that is excellent in both electrical conductivity and chromium poisoning resistance. As a substrate, a ferritic stainless steel having a chemical composition containing, in mass%, Cr: 14.0 % to 32.0 % and Al: 2.50 % to 7.00 % is used. Precious metal particles are coated on a surface of the substrate. The precious metal particles have: an average particle size of 1 μm or more and 10 μm or less; a coating thickness of 0.5 μm or more and 10 μm or less; and a surface coverage of 1.0 % or more.
Disclosed is a component for solid oxide fuel cells that is excellent in both electrical conductivity and chromium poisoning resistance. As a substrate, a ferritic stainless steel having a chemical composition containing, in mass %, Cr: 14.0% to 32.0% and Al: 2.50% to 7.00% is used. Precious metal particles are coated on a surface of the substrate. The precious metal particles have: an average particle size of 1 μm or more and 10 μm or less; a coating thickness of 0.5 μm or more and 10 μm or less; and a surface coverage of 1.0% or more.
H01M 8/0217 - Complex oxides, optionally doped, of the type AMO3, A being an alkaline earth metal or rare earth metal and M being a metal, e.g. perovskites
H01M 8/0245 - Composites in the form of layered or coated products
4.
COMPONENT HAVING IMPROVED SURFACE CONTACT RESISTANCE AND REACTION ACTIVITY AND METHODS OF MAKING THE SAME
A component for an electrochemical device, the component including: a metallic substrate; and a plurality of particles bonded to a surface of the substrate by a metallurgical bond, wherein the particles include a metal, carbon, or a combination thereof, wherein the metallurgical bond is between the particles and the substrate, wherein a total projected area of the metallurgical bond is less than 90% of a total projected area of the substrate, and wherein the metallurgical bond has a composition which is a combination of a composition of the metallic substrate and a composition of the particle, a reaction product of the metallic substrate and the particle, or a combination thereof.
C23C 16/513 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating using electric discharges using plasma jets
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
5.
COMPONENT HAVING IMPROVED SURFACE CONTACT RESISTANCE AND REACTION ACTIVITY AND METHODS OF MAKING THE SAME
A component for an electrochemical device, the component including: a metallic substrate; and a plurality of particles bonded to a surface of the substrate by a metallurgical bond, wherein the particles include a metal, carbon, or a combination thereof, wherein the metallurgical bond is between the particles and the substrate, wherein a total projected area of the metallurgical bond is less than 90% of a total projected area of the substrate, and wherein the metallurgical bond has a composition which is a combination of a composition of the metallic substrate and a composition of the particle, a reaction product of the metallic substrate and the particle, or a combination thereof.
C23C 16/513 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating using electric discharges using plasma jets
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
A component for an electrochemical device, the component including: a metallic substrate; and a plurality of particles bonded to a surface of the substrate by a metallurgical bond, wherein the particles include a metal, carbon, or a combination thereof, wherein the metallurgical bond is between the particles and the substrate, wherein a total projected area of the metallurgical bond is less than 90% of a total projected area of the substrate, and wherein the metallurgical bond has a composition which is a combination of a composition of the metallic substrate and a composition of the particle, a reaction product of the metallic substrate and the particle, or a combination thereof.
C23C 14/16 - Metallic material, boron or silicon on metallic substrates or on substrates of boron or silicon
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
C23F 1/26 - Acidic compositions for etching refractory metals
C22F 1/18 - High-melting or refractory metals or alloys based thereon
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
C23C 14/02 - Pretreatment of the material to be coated
C23C 14/35 - Sputtering by application of a magnetic field, e.g. magnetron sputtering
C23F 1/28 - Acidic compositions for etching iron group metals
C23F 17/00 - Multi-step processes for surface treatment of metallic material involving at least one process provided for in class and at least one process covered by subclass or or class
C23C 14/16 - Metallic material, boron or silicon on metallic substrates or on substrates of boron or silicon
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
C23F 1/26 - Acidic compositions for etching refractory metals
C22F 1/18 - High-melting or refractory metals or alloys based thereon
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
C23C 14/35 - Sputtering by application of a magnetic field, e.g. magnetron sputtering
C23F 1/28 - Acidic compositions for etching iron group metals
C23F 17/00 - Multi-step processes for surface treatment of metallic material involving at least one process provided for in class and at least one process covered by subclass or or class
A method is described that can be used in electrodes for electrochemical devices and includes disposing a precious metal on a top surface of a corrosion-resistant metal substrate. The precious metal can be thermally sprayed onto the surface of the corrosion-resistant metal substrate to produce multiple metal splats. The thermal spraying can be based on a salt solution or on a metal particle suspension. A separate bonding process can be used after the metal splats are deposited to enhance the adhesion of the metal splats to the corrosion-resistant metal substrate. The surface area associated with the splats of the precious metal is less than the surface area associated with the top surface of the corrosion-resistant metal substrate. The thermal spraying rate can be controlled to achieve a desired ratio of the surface area of the metal splats to the surface area of the corrosion-resistant metal substrate.
C23C 4/04 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
C23C 4/08 - Metallic material containing only metal elements
C22F 1/18 - High-melting or refractory metals or alloys based thereon
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
C23C 14/16 - Metallic material, boron or silicon on metallic substrates or on substrates of boron or silicon
C23C 14/35 - Sputtering by application of a magnetic field, e.g. magnetron sputtering
C23F 1/28 - Acidic compositions for etching iron group metals
C23F 17/00 - Multi-step processes for surface treatment of metallic material involving at least one process provided for in class and at least one process covered by subclass or or class
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
Method for forming a metallic component surface to achieve lower electrical contact resistance. The method comprises modifying a surface chemical composition and creating a micro-textured surface structure of the metallic component that includes small peaks and/or pits. The small peaks and pits have a round or irregular cross-sectional shape with a diameter between 10 nm and 10 microns, a height/depth between 10 nm and 10 microns, and a distribution density between 0.4 million/ cm2 and 5 billion cm2.
C23C 14/02 - Pretreatment of the material to be coated
C23C 8/02 - Pretreatment of the material to be coated
C23C 10/02 - Pretreatment of the material to be coated
C23C 14/04 - Coating on selected surface areas, e.g. using masks
C23C 14/06 - Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
C23C 14/22 - Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
12.
Corrosion resistant and electrically conductive surface of metal
Methods for coating a metal substrate or a metal alloy with electrically conductive titania-based material. The methods produce metal components for electrochemical devices that need high electrical conductance, corrosion resistance and electrode reaction activities for long term operation at a low cost.
H01M 4/86 - Inert electrodes with catalytic activity, e.g. for fuel cells
C25B 9/10 - Cells comprising dimensionally-stable non-movable electrodes; Assemblies of constructional parts thereof with diaphragms including an ion-exchange membrane in or on which electrode material is embedded
C25B 11/04 - ElectrodesManufacture thereof not otherwise provided for characterised by the material
C25B 13/04 - DiaphragmsSpacing elements characterised by the material
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
C23C 16/513 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating using electric discharges using plasma jets
H01M 8/20 - Indirect fuel cells, e.g. fuel cells with redox couple being irreversible
13.
CORROSION RESISTANT AND ELECTRICALLY CONDUCTIVE SURFACE FOR ELECTROLYZERS
Methods for providing a metal surface structure and treatment process to prevent the corrosion (e.g., high electrochemical potential oxidization and hydrogen embrittlement) of a metallic component used in electrolyzer operational conditions. The oxide surface scale of a metal plate is used to prevent the corrosion, and electrical conductive materials such as e.g., precious metals or carbon are used to provide the surface electrical conductance of the metallic components. The methods advantageously produce, at a low cost, metal components for electrolyzers that need high electrical conductance and corrosion resistance for long term operation.
Methods for providing a metal surface structure and treatment process to prevent the corrosion (e.g., high electrochemical potential oxidization and hydrogen embrittlement) of a metallic component used in electrolyzer operational conditions. The oxide surface scale of a metal plate is used to prevent the corrosion, and electrical conductive materials such as e.g., precious metals or carbon are used to provide the surface electrical conductance of the metallic components. The methods advantageously produce, at a low cost, metal components for electrolyzers that need high electrical conductance and corrosion resistance for long term operation.
Design and fabrication methods for high performance battery electrodes and current collectors involving coating a metal substrate with electrically conductive dots or splats of active materials for use in battery applications that improve the corrosion resistant metallic component electrode activity, or electrical conductivity of those components at reduced or lower costs.
B05D 1/02 - Processes for applying liquids or other fluent materials performed by spraying
B32B 3/00 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form
C23C 16/453 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating passing the reaction gases through burners or torches, e.g. atmospheric pressure CVD
16.
Corrosion resistant and electrically conductive surface of metallic components for electrolyzers
Methods for providing a metal surface structure and treatment process to prevent the corrosion (e.g., high electrochemical potential oxidization and hydrogen embrittlement) of a metallic component used in electrolyzer operational conditions. The oxide surface scale of a metal plate is used to prevent the corrosion, and electrical conductive materials such as e.g., precious metals or carbon are used to provide the surface electrical conductance of the metallic components. The methods advantageously produce, at a low cost, metal components for electrolyzers that need high electrical conductance and corrosion resistance for long term operation.
B32B 15/00 - Layered products essentially comprising metal
C25B 11/04 - ElectrodesManufacture thereof not otherwise provided for characterised by the material
C25B 1/08 - Electrolytic production of inorganic compounds or non-metals of hydrogen or oxygen by electrolysis of water in cells with flat or plate-like electrodes of the filter-press type
C25B 9/20 - Assemblies comprising a plurality of cells of the filter-press type
17.
Corrosion resistant and electrically conductive surface of metal
Methods for coating a metal substrate or a metal alloy with electrically conductive titania-based material. The methods produce metal components for electrochemical devices that need high electrical conductance, corrosion resistance and electrode reaction activities for long term operation at a low cost.
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
H01M 8/18 - Regenerative fuel cells, e.g. redox flow batteries or secondary fuel cells
18.
CORROSION RESISTANT AND ELECTRICALLY CONDUCTIVE SURFACE OF METAL
Methods for coating a metal substrate or a metal alloy with electrically conductive titania-based material. The methods produce metal components for electrochemical devices that need high electrical conductance, corrosion resistance and electrode reaction activities for long term operation at a low cost.
A method to use a novel structured metal-ceramic composite powder to improve the surface electrical conductivity of corrosion resistant metal substrates by thermal spraying the structured powder onto a surface of a metallic substrate is disclosed. The structured powder has a metal core and is wholly or partially surrounded by an electrically conductive ceramic material such as a metal nitride material. The metal cores may have the ceramic material formed on them prior to a thermal spraying process performed in an inert atmosphere, or the thermal spraying may be performed in a reactive atmosphere such that the ceramic coating forms on the cores during the thermal spraying process and/or after deposition. The metal cores will bond conductive ceramic material onto the surface of the substrate through the thermal spray process.
C23C 4/12 - Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
B22F 1/02 - Special treatment of metallic powder, e.g. to facilitate working, to improve properties; Metallic powders per se, e.g. mixtures of particles of different composition comprising coating of the powder
20.
HIGH POWER FUEL STACKS USING METAL SEPARATOR PLATES
A separator plate for use in a fuel cell stack in a fuel cell device includes a porous core with a metal layer on either side of the porous core. The metal layer has through holes formed therein such as by perforation. The metal layers are contoured to provide flow field channels, and the porous layer may have channels formed therein that are parallel to the metal layers that can be used for cooling water. A monopolar fuel stack includes twin cell units that include a center separator plate, a pair of membrane electrode assemblies, one on each side of the center separator plate, and a pair of outer plates which may have through holes formed therein, one on each side of the membrane electrode assemblies opposite the center separator plate. The outer plates cover substantially an entire electrode to which they are adjacent.
A method is described that can be used in electrodes for electrochemical devices and includes disposing a precious metal on a top surface of a corrosion-resistant metal substrate. The precious metal can be thermally sprayed onto the surface of the corrosion-resistant metal substrate to produce multiple metal splats. The thermal spraying can be based on a salt solution or on a metal particle suspension. A separate bonding process can be used after the metal splats are deposited to enhance the adhesion of the metal splats to the corrosion- resistant metal substrate. The surface area associated with the splats of the precious metal is less than the surface area associated with the top surface of the corrosion-resistant metal substrate. The thermal spraying rate can be controlled to achieve a desired ratio of the surface area of the metal splats to the surface area of the corrosion-resistant metal substrate.
A method is described that can be used in electrodes for electrochemical devices and includes disposing a precious metal on a top surface of a corrosion-resistant metal substrate. The precious metal can be thermally sprayed onto the surface of the corrosion-resistant metal substrate to produce multiple metal splats. The thermal spraying can be based on a salt solution or on a metal particle suspension. A separate bonding process can be used after the metal splats are deposited to enhance the adhesion of the metal splats to the corrosion-resistant metal substrate. The surface area associated with the splats of the precious metal is less than the surface area associated with the top surface of the corrosion-resistant metal substrate. The thermal spraying rate can be controlled to achieve a desired ratio of the surface area of the metal splats to the surface area of the corrosion-resistant metal substrate.
An apparatus and a method for generating hydrogen, the apparatus including a first electrode and a second electrode. The first electrode includes a catalytic material for promoting the formation of protons. The apparatus also includes a proton conductive electrolyte disposed between the first and second electrodes and a voltage source connected to the first electrode and to the second electrode. The voltage source is configured to provide a driving voltage having a base voltage and a pulsed voltage superposed on the base voltage to generate hydrogen. The apparatus has an input through which syngas or a hydrocarbon compound or both is introduced into the first electrode; and an output for discharging the generated hydrogen, the output being disposed opposite the input on an opposite side of the proton conductive electrolyte.
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