Method for Producing Gas-Tight Layers and Layer Systems by Means of Thermal Spraying

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This patent describes a method for producing gas-tight layers and multilayer systems using thermal spraying, especially using suspension plasma spraying. The process involves first depositing a porous layer with a burner, then immediately thermally treating it with the same burner—without process interruption—to create a gas-tight coating. This method provides efficient, cost-effective fabrication of gas-impermeable coatings with strong adhesion, suitable for applications such as fuel cells where gas separation is critical.

Use CasesContent extracted from patent full text and abstract with AI.

• Manufacturing of fuel cell components (anode, electrolyte, cathode layers requiring gas-tightness)
• Production of gas-separation membranes for industrial or chemical processes
• Creation of protective coatings for filters or sensors to prevent gas leakage
• Fabrication of multilayer ceramic or metal/ceramic systems for electronics or energy devices
• Production of thermal barrier coatings in high-temperature components like turbines or engines

BenefitsContent extracted from patent full text and abstract with AI.

• Enables the creation of gas-tight layers and systems without process interruptions, improving adhesion between layers and overall integrity
• Reduces manufacturing time and cost by performing deposition and densification in a single uninterrupted step
• Allows precise control over the properties and microstructure (e.g., gradation, porosity, segmentation cracks) of each layer
• Applicable to a wide variety of materials (oxides, ceramics, cermets), expanding the technique's versatility
• Improves reliability and lifetime of devices by enabling dense and robust gas-separating layers, especially in demanding environments (e.g., fuel cells, chemical plants)

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Patent Abstract

The invention relates to a method for producing gas-tight layers and layer systems by means of a thermal spraying method. A layer is firstly applied by thermal spraying using a burner and is subjected to a subsequent thermal treatment by the same burner. This interruption-free method makes possible a simple and cost-effective production of gas-tight layers and layer systems having good adhesive properties. The method is particularly suited for producing fuel cell structures due to the fact that a gas-tight layer can be placed at any location in a layer system.