WO2003025783A2 - Porously coated open-structure substrate and method of manufacture thereof - Google Patents

Porously coated open-structure substrate and method of manufacture thereof Download PDF

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Publication number
WO2003025783A2
WO2003025783A2 PCT/US2002/029499 US0229499W WO03025783A2 WO 2003025783 A2 WO2003025783 A2 WO 2003025783A2 US 0229499 W US0229499 W US 0229499W WO 03025783 A2 WO03025783 A2 WO 03025783A2
Authority
WO
WIPO (PCT)
Prior art keywords
open
coating
substrate
paste
structure substrate
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.)
Ceased
Application number
PCT/US2002/029499
Other languages
English (en)
French (fr)
Other versions
WO2003025783A3 (en
Inventor
Alfred I-Tsung Pan
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.)
HP Inc
Original Assignee
Hewlett Packard Co
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 Hewlett Packard Co filed Critical Hewlett Packard Co
Priority to EP02773436A priority Critical patent/EP1428137A2/en
Priority to AU2002336579A priority patent/AU2002336579A1/en
Priority to JP2003529341A priority patent/JP2005527934A/ja
Publication of WO2003025783A2 publication Critical patent/WO2003025783A2/en
Publication of WO2003025783A3 publication Critical patent/WO2003025783A3/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/002—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/4582—Porous coatings, e.g. coating containing porous fillers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/90—Selection of catalytic material
    • H01M4/9075—Catalytic material supported on carriers, e.g. powder carriers
    • H01M4/9083—Catalytic material supported on carriers, e.g. powder carriers on carbon or graphite
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/90—Selection of catalytic material
    • H01M4/92—Metals of platinum group
    • H01M4/925—Metals of platinum group supported on carriers, e.g. powder carriers
    • H01M4/926—Metals of platinum group supported on carriers, e.g. powder carriers on carbon or graphite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00853—Uses not provided for elsewhere in C04B2111/00 in electrochemical cells or batteries, e.g. fuel cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0471—Processes of manufacture in general involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]

Definitions

  • a fuel cell is an electrochemical apparatus wherein chemical energy generated from a combination of a fuel with an oxidant is converted to electrical energy in the presence of a catalyst.
  • the fuel is fed to an anode, which has a negative polarity, and the oxidant is fed to a cathode, which, conversely, has a positive polarity.
  • the two electrodes are connected within the fuel cell by an electrolyte to transmit protons from the anode to the cathode.
  • One of the essential requirements of typical fuel cells is the easy access to the catalyst and a large surface area for reaction.
  • an electrode made of an electrically conductive porous substrate that renders the electrode permeable to fluid reactants and products in the fuel cell.
  • the catalyst can also be filled into or deposited onto a porous substrate.
  • These modifications result in a fragile porous electrode that needs additional mechanical support.
  • An alternative is to sinter a porous coating on a solid substrate and then fill or re-coat the porous coating with a catalyst.
  • the substrate can be made of conductive materials or patterned with a conductive material.
  • the porous coating can be made of non-conductive materials, such as ceramics or silicon, or conductive materials such as carbon, ceramic-metal mixture or metals.
  • the coating material in the form of fine powders, is mixed with a liquid organic "binder" such as glycol to form a coating mixture.
  • a liquid organic "binder” such as glycol
  • the coating mixture is spread on the substrate and is baked in an oven.
  • the binder is burned off and the coating material is sintered on the substrate to form a porous layer.
  • a catalyst is deposited in the porous layer to provide a large catalytic surface.
  • the substrate is then etched from the backside to create openings so that fuel on the cathode side and oxygen on the anode side can reach the active catalytic surfaces through the openings and the porous layer.
  • the etching process is time consuming and requires specially designed machinery. Summary A method for sintering an open-structure substrate with a porous coating is disclosed.
  • the open-structure substrate is a substrate with pre-formed openings (i.e., pre- formed pores, channels, passageways, etc.), which allow liquids and gases to pass from one side of the substrate to the other side of the substrate.
  • the method is based on the fact that a viscous solution can remain a continuous layer after being applied onto open- structure substrates, such as screens or expanded foils, without dripping through the openings of the substrate.
  • a coating paste is prepared by mixing a solid coating material with a liquid binder. The coating material and the binder is mixed at a ratio such that the viscosity of the paste is high enough to prevent the paste from dripping through the openings on the substrate.
  • the paste is spread on the surface of the open-structure substrate, and is subjected to a heating process to remove the binder and to sinter the coating material on the surface of the open-structure substrate to form a porous coating. Since the openings on the substrate are pre-formed before the coating process, this method eliminates the expensive and time-consuming etching step after the sintering.
  • the method can be used to manufacture electrodes for fuel cells or any other applications which require a porous coating on an open-structure substrate.
  • the paste comprises fine metal powders, such as zinc or silver powders, a viscous binder, such as glycol, and, optionally, a flux.
  • a flux is a reducing agent that serves to remove the oxidized surface layer of metal particles.
  • the porous coating on the open-structure substrate may be further coated with a catalyst.
  • the paste may be prepared in the form of a solgel.
  • a solgel is prepared by peptizing a coating material, such as silicon oxide or metal oxide, with water or a water-miscible alcohol, such as methanol, ethanol, isopropanol, ethylene glycol and the like, to form a viscous polymeric sol.
  • the viscous polymeric sol is heated at a relatively low temperature (usually less than 100°C) to form a heat-set gel.
  • Figure 1A depicts an open-structure substrate.
  • Figure 1 B depicts an open-structure substrate covered with a paste.
  • Figure 1 C depicts an open-structure substrate with sintered porous coating.
  • Figure ID depicts a porous coated open-structure substrate with optional catalyst coating.
  • Figure 1A shows an open-structure substrate 100 having an upper surface 102, a lower surface 104, and a plurality of openings 106.
  • the number and size of the openings 106 can be variable, so long as they provide enough permeability so that the liquid on one side of the substrate may reach the other side in sufficient quantities.
  • the substrate 100 may be made of conductive materials, such as metal, carbon, metal-ceramic mixture, or non-conductive materials, such as glass, ceramic, flex material such as Kapton (Dupont) or Upilex (Ube), for example.
  • a non-conductive substrate 100 may be patterned with a conductive material (not shown in the figure) for certain electrical applications.
  • Figure 1 B shows the open-structure substrate 100 covered with a coating paste 120.
  • the coating paste 120 comprises a coating material 122 and a binder 124.
  • the coating material 122 may be in the form of fine particles.
  • the diameters of the particles may vary depending on the desired porosity of the porous coating. In general, smaller particles lead to smaller pores and a larger surface area, while larger particles result in larger pores and a smaller surface area.
  • the coating material may be carbon particles, glass beads, silicon powder, ceramic powder, metal particles, or any other material or a mixture of materials that may form a porous layer after a sintering process.
  • Nonconductive coating materials such as silicon or ceramic, may be pre-coated with a thin layer of conductive material, such as zinc, before sintering so that the final coating would be conductive.
  • Metals that are used for the porous coating are not limited to specific kinds.
  • the following substances may be preferably used: Ni, Cu, Al, Fe, Zn, In, Ti, Pb, V, Cr, Co, Sn, Au, Sb, Ca, Mo, Rh, Mn, B, Si, Ge, Se, La, Ga and Ir.
  • Each metal listed above may be used in the form of oxide and sulfide thereof and a simple substance or a mixture, including compounds of these metals.
  • the metals may be used in a powder form to increase the surface area.
  • the peripheral surfaces of the metal powders are desired not to be convex or concave so that they do not intertwine one another.
  • the metal powders are preferably spherical, dice-shaped, square piller and columner.
  • the temperature for sintering a metal powder should be high enough to partially melt the metal particles in order to form a sintered porous metal layer. However, overheating may completely melt the metal particles and destroy the porosity of the sintered layer.
  • metal particles hereafter defined as "core particles”
  • core particles may be pre-coated with a thin layer of a cover metal with a lower melting temperature.
  • copper core particles may be coated with a cover layer of zinc. The coated core particles are then sintered at the melting temperature of the cover metal. Since the melting temperature of the cover metal is lower than the melting temperature of the core metal, the core particles will not melt and will maintain the porosity of the layer after the sintering process.
  • non-conductive core particles may be pre-coated with a layer of cover material having a melting temperature lower than that of the core particles, and sintered at the melting temperature of the cover material .
  • the binder 124 may be glycol, wax, a solvent, or any other viscous liquid that is evaporable during the sintering process.
  • the binder 124 and the coating material 122 are mixed at a ratio that results in a paste 120 with a viscosity high enough to prevent the paste 120 from dripping through the openings 106 on the substrate 100.
  • the paste 120 is then applied to the upper surface 102 of the open-structure substrate 100 to form a pre-sintering coating.
  • the paste 120 may be screen printed on the open- structure substrate 100 so that the location and shape of the sintered porous coating can conform to the patterned conductive layer.
  • the coating material is metal particles
  • a reducing agent called a flux
  • the choice of flux is dependent on the type of metal that needs the treatment.
  • the next step is to bake the paste 120 in an oven to dry out the binder 124.
  • the coating material 122 is sintered and forms a porous coating 130 on the surface of the open-structure substrate 100 after the baking process.
  • the baking conditions i.e., baking time and temperature, may vary depending on the coating material 122 and the binder 124.
  • the paste 120 is preferably baked under a condition that partially melts the metal particles in order to form a layer of porous metal.
  • Figure ID shows an optional step of further depositing a layer of catalytic coating 140 on the porous coating 130.
  • catalytic materials such as Pt-Ru and Pt-Ru-Os, are found to be effective in converting methanol to protons without poisoning other fuel cell constituents.
  • the catalyst may be deposited onto the porous coating 130 by electroplating, electroless plating, atomic layer deposition, or any other process that is capable of coating the surface of a conductive porous layer.
  • the porous coating 130 may function as a current collector.
  • a conductive material may be deposited onto the surface of the non-conductive porous coating 130 by electroless plating, atomic layer deposition, or any other process that is capable of coating the surface of a non- conductive porous layer.
  • the catalyst 140 is then deposited onto the conductive material by electroplating, electroless plating, atomic layer deposition, or any other process that is capable of coating the surface of a conductive porous layer.
  • the non- conductive porous coating 130 may be directly coated with the catalyst 140 by atomic layer deposition, or any other process that is capable of coating the surface of a non- conductive porous layer.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Electrochemistry (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Composite Materials (AREA)
  • Inert Electrodes (AREA)
  • Catalysts (AREA)
  • Fuel Cell (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
PCT/US2002/029499 2001-09-20 2002-09-18 Porously coated open-structure substrate and method of manufacture thereof Ceased WO2003025783A2 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP02773436A EP1428137A2 (en) 2001-09-20 2002-09-18 Porously coated open-structure substrate and method of manufacture thereof
AU2002336579A AU2002336579A1 (en) 2001-09-20 2002-09-18 Porously coated open-structure substrate and method of manufacture thereof
JP2003529341A JP2005527934A (ja) 2001-09-20 2002-09-18 多孔質コーティングを有する開放構造基材及びその製造方法

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US09/956,432 US6656526B2 (en) 2001-09-20 2001-09-20 Porously coated open-structure substrate and method of manufacture thereof
US09/956,432 2001-09-20

Publications (2)

Publication Number Publication Date
WO2003025783A2 true WO2003025783A2 (en) 2003-03-27
WO2003025783A3 WO2003025783A3 (en) 2003-11-06

Family

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Family Applications (1)

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PCT/US2002/029499 Ceased WO2003025783A2 (en) 2001-09-20 2002-09-18 Porously coated open-structure substrate and method of manufacture thereof

Country Status (5)

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US (2) US6656526B2 (enExample)
EP (1) EP1428137A2 (enExample)
JP (1) JP2005527934A (enExample)
AU (1) AU2002336579A1 (enExample)
WO (1) WO2003025783A2 (enExample)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102020135064A1 (de) 2020-12-29 2022-06-30 Ara-Coatings GmbH & Co. KG Beschichtung und Verfahren zum Beschichten eines Substrats
WO2022144299A1 (de) 2020-12-29 2022-07-07 Ara-Coatings GmbH & Co. KG Beschichtung und verfahren zum beschichten eines substrats
DE102020135064B4 (de) 2020-12-29 2022-12-22 Ara-Coatings GmbH & Co. KG Beschichtung und Verfahren zum Beschichten eines Substrats

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EP1428137A2 (en) 2004-06-16
US20040033312A1 (en) 2004-02-19
WO2003025783A3 (en) 2003-11-06
US6656526B2 (en) 2003-12-02
JP2005527934A (ja) 2005-09-15
US6800323B2 (en) 2004-10-05

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