CA2244158A1 - Method of applying conductive coating - Google Patents

Method of applying conductive coating Download PDF

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Publication number
CA2244158A1
CA2244158A1 CA002244158A CA2244158A CA2244158A1 CA 2244158 A1 CA2244158 A1 CA 2244158A1 CA 002244158 A CA002244158 A CA 002244158A CA 2244158 A CA2244158 A CA 2244158A CA 2244158 A1 CA2244158 A1 CA 2244158A1
Authority
CA
Canada
Prior art keywords
coating
substrate
applying
titanium suboxide
laser
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA002244158A
Other languages
French (fr)
Inventor
Keith Gordon Ellis
Andrew Hill
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Atraverda Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Atraverda Ltd filed Critical Atraverda Ltd
Publication of CA2244158A1 publication Critical patent/CA2244158A1/en
Abandoned legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/10Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • C23C4/11Oxides
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25BELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B11/00Electrodes; Manufacture thereof not otherwise provided for
    • C25B11/04Electrodes; Manufacture thereof not otherwise provided for characterised by the material
    • C25B11/051Electrodes formed of electrocatalysts on a substrate or carrier
    • C25B11/073Electrodes formed of electrocatalysts on a substrate or carrier characterised by the electrocatalyst material
    • C25B11/091Electrodes formed of electrocatalysts on a substrate or carrier characterised by the electrocatalyst material consisting of at least one catalytic element and at least one catalytic compound; consisting of two or more catalytic elements or catalytic compounds
    • C25B11/093Electrodes formed of electrocatalysts on a substrate or carrier characterised by the electrocatalyst material consisting of at least one catalytic element and at least one catalytic compound; consisting of two or more catalytic elements or catalytic compounds at least one noble metal or noble metal oxide and at least one non-noble metal oxide

Abstract

A titanium suboxide of the formula TiOx where x is 1.55 to 1.95, is applied to a substrate by a thermal process to form a coating of the same composition.
The thermal process may be plasma spraying, and the formed article may be an electrode of enhanced corrosion resistance and electrical conductivity.

Description

CA 022441~8 1998-07-21 METHOD QF APPLYING
COi\lDUCTlVE COATING
.~

The invention relates to a method for the formation of a corrosion resistant electrically conductive coating on a substrate. The substrate may be an electrode, for say an electrochemical cell.

It has been realised that titanium suboxides are useful as coatings. It is also known that a layer of such a ,I,aLe,ial may be formed on a substrate by flame spraying or plasma spraying, see e.g. GB-A-1438462; US-A-5225382; and G8-A-159506~. In these disclosures mixtures which are precursors for titanium suboxide are plasma sprayed on to a substrate under conditions selected to form the suboxide. Typically the suboxides are of the formula TiOx, where x is between 1.95 and 1.99, see e.g. GB-A-1438462 and lJS
5225382. While such suboxides are corrosion resistant, their electrical conductivity is not acceptable.

US-A-4252629 discloses a corrosion resistant carrier consisting of sintered TiOx where x is 0.25 to 1.5 having a coating of manganese dioxide. The carrier can be made by plasma spraying the titanium oxide under argon.

EP-A-00475g5 discloses that bulk titanium suboxide of the formula TiOx where x is 1.55 to 1.95 has corrosion resistance and electrical conductivity. The disclosure teaches that the material may be formed into shapes by pressing or extrusion.

CA 022441~8 1998-07-21 W O 97/27344 PCTtGB97/00202 It has now been discovered that if a m~Lerial of known stoichiometry is appiied to a substrate one can obtain a coating of predetermined composition and which has a particularly enhanced corrosion resistance and electrical conductivity.

According to the invention in one aspect there is provided a method of forming acorrosion resistant electrically conductive coating on a substrate, com~ ,ing forming a predetermined titanium suboxide of the forrrlula TiOx where x is 1.5~ to 1.95 and then applying that ~I,aLenal on to the substrate to form a coating of the same substantially stoichiometry on the substrate.

The ~l~ lial may be applied by any suitable sFF'iG; ~ion technique which will not affect the sloichio.,lel~y of the ,-,dlerial. Such techniques include plasma spraying and laser coating. De-gun coating in which the material is melted and then projected by delondliu,~
and other thermal coating techniques may also be considered.

Because the starting Illd~ lial is of a known :,: hio~ L,y having desired properties one can obtain directly a coating of the desired stoichiometry and hence the desiredcombination of properties, e.g. electrical conductivity, co., osion resistance etc. It is possible to apply a mixture of the suboxides or just a single one. Most preferably the plasma spraying of the defined titanium suboxide is carried out under conditions which preclude the risk that the stoicl,;o~,lelly will be affected. To this end the applicalion for example may be carried out under vacuum or under a shield of a suitable inert gas, e.g. v argon.

CA 022441~8 1998-07-21 It is advantageous to pretreat the surface of the substrate to enhance the adhesion of the applied coating. The pretreatment may be mec;hani~al, chemical or ele.,l,uchemical, e.g.
sand/grit blasting, deposition, laser ablation, etching, stove codlil 19, or the iike.

~) The method may include the variation of adding minor properties of a dopant to the ,I,dLeridl to be applied. Examples include electrocatalysts and other stabilisers, e.g. Pt, Ir, Ta, Nb, Ru, V; and the like, and oxides, e.g. tin oxide and mixtures thereof. These may influence conductivity, adhesion, CGr. osion resisLa"ce properties. Typically the composition will be in particulate form, e.g. a powder. Such additions may be made as a subsequent treatment, e.g. a further coating of an electrocatalyst may be applied by electroplating, thennal stove-coating, or the like to influence the electrochemical properties of the end product.

The application equipment, e.g. plasma gun, may be of known type with appropriate additional ~LIacllments to ensure an inert gas blanket, e.g. as described in GB-A-2281488.

The laser will be adapted to melt the powder en route to the substrate, but is particularly efficacious since it can be operated in a more co,..~ Iete vacuum or purer inert gas atmosphere. In addition it is possible to clean the surface of the substrate to be coated by a laser surface ablation technique wherein a second laser process can deliver a high energy pulse (typically 35MW over 20 nS) to blast away surface oxides and other conldllli, la-.L:, from the substrate immediately prior to the arrival of the molten powder.

CA 022441~8 1998-07-21 The coated item can be used as an eiectrode (either anode or cathode) in low current density applications directly, or where necessary for high current density with the ~FP'i- on of a suitable electrocatalyst as noted above. The surface may also be electroplated with, for instance, lead or zinc metals to assist electrical connectivity to or adhesion of active materials in a battery. The electrode may be used in electrochemical cells, metal winning, chlorine cells, effluent treatment; and the like.

The method allows coatings to be applied up to thicknesses well in excess of those required for corrosion resistance alone, whilst ~"ai"Ldi~-ing good conductivities. The coating thickness may range from about 50 to about 1000xS0~3mm. For very high corrosion resistances a typical coating would be either of the order of 200-500x103mm where x is about 1.75 to 1.8, or a thinner coating of about 100-200 x10 3 of a stoichiometry where x is about 1.85 to 1.9. For less arduous duty, high conductivity coatings of about 100-200x10~3mm and a stoichiometry of x = 1.75-1.8 are preferred. A
coating of the invention will have conductivity of the order of 10 to 100 S/cm. In even less arduous corrosion duty, dopants can be added which further increase the conductivity.

In order that the invention may be well understood it will now be described with reference to the following examples which are given by way of illu:,L,dlion only.

EXAMPLE I
Test electrodes for electrowinning of zinc were prepared in the following manner Two sheets of commercial grade aluminium 2 mm thick and 230 x 80 mm width and breadth, were lightly filed around all edges to remove sharp edges and burrs, and then grit blasted. The items were then plasma sprayed using a Metco gun equipped with a CA 022441~8 1998-07-21 Shroud as described in GB-A-2281488 which was controlled by a robot which ensured an even coating over the entire surface and edges. The gun was fed with a pre-prepared powder of whose ~i- h;a.~etry had been measured by X-ray diffraction as being as of composition TiOx where x = 1.72. The conductivity was found to be ~0S/cm. The coating was found to be 120 microns thick with a bulk density of 3.84 gm/cc. Subsequently adiusl"~enb were made to the argon and hydrogen flowrates and pressures and a stoichiometry of TiOx where x = 1.76 was obtained and a bulk density of 4.03 gm/cc obtained. (It is generally accepted that if the bulk density is within 5% of the theoretical full density then no interconnected porosity is present).

The coated anode was further treated with an electrocatalytic coating based on mixed oxides of tantalum and iridium. During bhe stove coating one of the test electrodes lost a high proportion of its coating due to the thermal expansion difference between the ceramic and metallic components and was discarded. However the other survived temperature cycling to about 400~C through 30 coats. This anode was used in a test cell as an anode in the electrodeposition of zinc from a solution of 50 gmAitres Zn2+ and 180--200 gm/litre H2SO4 with traces of fluoride (- 10 mgAitre) Mn2+ (5-8 mg/litre) and other conld",il,ant ",ale,ia;s found in a commercial zinc electrowinning stream performing sucGessfully at a current density of 450A/m2 for over 1000 hours of operation. It was notable in this test that although the electrode potential did rise from an initially low (and preferred) level in the long term the anode had a potenbal of about 250mV lower than the Pb/Ag anode ,-,aterial more conventionally used and that any MnO2 which formed on the anode fell off of its own accord from time to time or could be assisted by occasional ullldsol1ic treatment.

CA 022441~8 1998-07-21 Token pieces of titanium metal were coated by the process of Example 1. Because of the smaller difference between the expansion coefficients of the metai and the coating, they were stove coated with electrocatalysts without any spalling of the coating layer. ",~

Solid pieces and expanded metai meshes of aluminium and of titanium were coated with conductive ceramic by the method of Example I and then electrocoated at modest temperatures with lead dioxide7 platinum metal, and antimony/tin oxide coatings.

EXAMPLE IV
Conductive ceramic coatings were applied using the method of Example I to test pieces made of steel, brass, copper, lead and KEVL~R (which is not metallic).

Claims (14)

1. A method of forming a corrosion resistant electrically conductive coating on a substrate, comprising forming a predetermined titanium suboxide of the formula TiOx where x is 1.55 to 1.95 and then applying that material on to the substrate to form a coating of substantially the same stoichiometry on the substrate.
2. A method according to Claim 1, wherein the material is applied by plasma spraying.
3. A method according to Claim 1, wherein the material is applied by laser coating.
4. A method according to Claim 1, wherein the material is applied by a de-gun coating technique.
5. A method according to Claim 1, 2, 3, or 4, including adding a dopant to the titanium suboxide and applying that doped composition on to the substrate.
6. A method according to Claim 5, wherein the dopant is an electrocatalyst and/or other stabilizer.
7. A method according to any preceding Claim, wherein the coating is applied to a thickness of the order of 50-1000x10-3 mm.
8. A method according to any preceding Claim, including the preliminary step of treating the surface of the substrate by mechanical, laser, chemical or electrochemical treatment before the composition is applied thereon.
9. A method according to Claim 8, wherein the pretreatment is blasting, chemical or deposition; stove coating; or the like.
10. A method according to any preceding Claim, wherein the application of the material is carried out under vacuum.
11. A method according to Claim 10, wherein the application of the material is carried out in an atmosphere comprising a gas selected to exclude ingredients which will affect the titanium suboxide.
12. A method according to Claim 11, wherein the gas is argon.
13. A method according to any preceding Claim, including the subsequent step of applying an electrocatalytic material, whereby the surface is further coated with an electrocatalyst including precious metals, mixtures thereof and their oxides and mixtures thereof, lead dioxide, doped tin oxide and the like.
14. A method according to any preceding Claim, wherein the substrate comprises an electrode for an electrochemical cell.
CA002244158A 1996-01-22 1997-01-22 Method of applying conductive coating Abandoned CA2244158A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB9601236.4 1996-01-22
GBGB9601236.4A GB9601236D0 (en) 1996-01-22 1996-01-22 Conductive coating

Publications (1)

Publication Number Publication Date
CA2244158A1 true CA2244158A1 (en) 1997-07-31

Family

ID=10787366

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002244158A Abandoned CA2244158A1 (en) 1996-01-22 1997-01-22 Method of applying conductive coating

Country Status (5)

Country Link
CN (1) CN1212025A (en)
AU (1) AU1451497A (en)
CA (1) CA2244158A1 (en)
GB (2) GB9601236D0 (en)
WO (1) WO1997027344A1 (en)

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DE10000979C1 (en) * 1999-10-01 2001-05-10 Daimler Chrysler Ag Coating powder used in plasma spraying, high speed flame spraying and detonation spraying of components of engines is based on a titanium sub-oxide
US6524750B1 (en) 2000-06-17 2003-02-25 Eveready Battery Company, Inc. Doped titanium oxide additives
US7993773B2 (en) 2002-08-09 2011-08-09 Infinite Power Solutions, Inc. Electrochemical apparatus with barrier layer protected substrate
US20070264564A1 (en) 2006-03-16 2007-11-15 Infinite Power Solutions, Inc. Thin film battery on an integrated circuit or circuit board and method thereof
ITRM20020622A1 (en) * 2002-12-13 2004-06-14 Ct Sviluppo Materiali Spa PROCEDURE FOR PLASMA THERMAL SPRAYING OF DRY SEMICONDUCTIVE OXIDE-BASED COATINGS.
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US7608358B2 (en) 2006-08-25 2009-10-27 Bdf Ip Holdings Ltd. Fuel cell anode structure for voltage reversal tolerance
TWI441937B (en) 2007-12-21 2014-06-21 Infinite Power Solutions Inc Method for sputter targets for electrolyte films
US8518581B2 (en) 2008-01-11 2013-08-27 Inifinite Power Solutions, Inc. Thin film encapsulation for thin film batteries and other devices
US8906523B2 (en) 2008-08-11 2014-12-09 Infinite Power Solutions, Inc. Energy device with integral collector surface for electromagnetic energy harvesting and method thereof
US8599572B2 (en) 2009-09-01 2013-12-03 Infinite Power Solutions, Inc. Printed circuit board with integrated thin film battery
US20130017471A1 (en) * 2009-12-22 2013-01-17 Ford Motor Company Fuel cell with selectively conducting anode component
CN102947976B (en) 2010-06-07 2018-03-16 萨普拉斯特研究有限责任公司 Chargeable, highdensity electrochemical apparatus
FI2823079T3 (en) 2012-02-23 2023-05-04 Treadstone Tech Inc Corrosion resistant and electrically conductive surface of metal
ITMI20120873A1 (en) * 2012-05-21 2013-11-22 Industrie De Nora Spa ELECTRODE FOR EVOLUTION OF GASEOUS PRODUCTS AND METHOD FOR ITS ACHIEVEMENT
CN104241655A (en) * 2014-07-04 2014-12-24 超威电源有限公司 Conductive ceramic battery grid
CN105297073A (en) * 2015-10-30 2016-02-03 昆明理工大学 Preparation method of copper-based titanium black electrode plate
CN105776429B (en) * 2016-03-15 2019-08-09 中国矿业大学(北京) With active tubular ring Asia oxidation titanium film electrode of electrochemical oxidation and preparation method thereof
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Also Published As

Publication number Publication date
GB9601236D0 (en) 1996-03-20
GB2309230A (en) 1997-07-23
CN1212025A (en) 1999-03-24
WO1997027344A1 (en) 1997-07-31
AU1451497A (en) 1997-08-20
GB9701229D0 (en) 1997-03-12

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