Electrode with two layer coating, method of use, and preparation thereof

Patent metadata

Field	Value
Publication number	US-10415146-B2
Application number	US-201515521109-A
Country	US
Kind code	B2
Filing date	Oct 20, 2015
Priority date	Oct 21, 2014
Publication date	Sep 17, 2019
Grant date	Sep 17, 2019

Abstract

Systems and methods for manufacturing and use of a two layer coated electrode are provided. The two layer coated electrode may comprise a substrate, a first coating layer, and a second coating layer. The first coating layer may comprise a mixture of iridium oxide and tin oxide, and the second coating layer may comprise a mixture of iridium oxide and tantalum oxide. The electrode may be used in, for example, an electrolytic cell.

First claim

The invention claimed is:

1. An electrode, comprising:
an electrically conductive substrate;
a first coating covering at least a portion of a surface of the electrically conductive substrate, the first coating consisting of a mixture of iridium oxide and tin oxide, having 45 wt. % to 65 wt. % iridium oxide; and
a second coating covering at least a portion of the first coating, the second coating consisting of a mixture of iridium oxide and tantalum oxide.

2. The electrode of claim 1 , wherein the electrically conductive substrate comprises a valve metal.

3. The electrode of claim 2 , wherein the valve metal is selected from the group consisting of titanium, zirconium, niobium, and tantalum.

4. The electrode of claim 3 , wherein the valve metal is titanium.

5. The electrode of claim 1 , wherein the second coating comprises 40 wt. % to 75 wt. % iridium oxide.

6. The electrode of claim 5 , wherein the second coating comprises 65 wt. % iridium oxide.

7. The electrode of claim 1 , wherein a molar ratio of iridium oxide in the first coating to the iridium oxide in the second coating is selected from the group consisting of 1:2, 1:1, and 2:1.

8. The electrode of claim 7 , wherein the molar ratio of iridium oxide in the first coating to the iridium oxide in the second coating is 1:1.

9. The electrode of claim 8 , wherein the electrode provides for a 175% longer normalized life than a reference electrode comprising a single layer coating consisting of a composition of the second coating,
wherein the normalized life is calculated by the following equation:
((x−y)/y)*100, where

x is the electrode's lifetime, and
y is the reference electrode's lifetime; and

lifetime is measured in A*hr/g Ir and determined by applying a constant current until a rise in voltage is measured.

10. The electrode of claim 8 , wherein the electrode provides for a 110% longer normalized life than a reference electrode comprising a single layer coating consisting of a composition of the first coating,
wherein the normalized life is calculated by the following equation:
((x−y)/y)*100, where

x is the electrode's lifetime, and
y is the reference electrode's lifetime; and

lifetime is measured in A*hr/g Ir and determined by applying a constant current until a rise in voltage is measured.

11. The electrode of claim 1 , wherein the electrode is an anode.

12. A system comprising an electrolytic cell, comprising:
an electrode comprising:
an electrically conductive substrate;
a first coating covering at least a portion of a surface of the electrically conductive substrate, the first coating consisting of a mixture of iridium oxide and tin oxide, having 45 wt. % to 65 wt. % iridium oxide; and
a second coating covering at least a portion of the first coating, the second coating consisting of a mixture of iridium oxide and tantalum oxide; and
a power source for supplying a current to the electrode.

13. The system of claim 12 , wherein the electrode is immersed in an electrolyte.

14. An electrode, comprising:
an electrically conductive substrate;
a first coating covering at least a portion of a surface of the electrically conductive substrate, the first coating consisting of a mixture of iridium oxide and tin oxide; and
a second coating covering at least a portion of the first coating, the second coating consisting of a mixture of iridium oxide and tantalum oxide, having 40 wt. % to 75 wt. % iridium oxide.

15. The electrode of claim 14 , wherein the electrically conductive substrate comprises a valve metal.

16. The electrode of claim 15 , wherein the valve metal is selected from the group consisting of titanium, zirconium, niobium, and tantalum.

17. The electrode of claim 16 , wherein the valve metal is titanium.

18. The electrode of claim 14 , wherein the first coating comprises 30 wt. % to 85 wt. % iridium oxide.

19. The electrode of claim 18 , wherein the first coating comprises 45 wt. % to 65 wt. % iridium oxide.

20. The electrode of claim 14 , wherein the second coating comprises 65 wt. % iridium oxide.

21. The electrode of claim 14 , wherein a molar ratio of iridium oxide in the first coating to the iridium oxide in the second coating is selected from the group consisting of 1:2, 1:1, and 2:1.

22. The electrode of claim 14 , wherein the electrode is an anode.

23. A system comprising an electrolytic cell, comprising:
an electrode comprising:
an electrically conductive substrate;
a first coating covering at least a portion of a surface of the electrically conductive substrate, the first coating consisting of a mixture of iridium oxide and tin oxide; and
a second coating covering at least a portion of the first coating, the second coating consisting of a mixture of iridium oxide and tantalum oxide, having 40 wt. % to 75 wt. % iridium oxide; and
a power source for supplying a current to the electrode.

24. The system of claim 23 , wherein the electrode is immersed in an electrolyte.

Assignees

• Evoqua Water Tech Llc

Inventors

• Ivanter Irina A
• Chang-Ng Julio W

Classifications

• H01M4/9016

  Oxides, hydroxides or oxygenated metallic salts · CPC title

• H01M4/8885

  Sintering or firing · CPC title

• H01M4/886

  Powder spraying, e.g. wet or dry powder spraying, plasma spraying · CPC title

• H01M4/8817

  Treatment of supports before application of the catalytic active composition (coated porous composites H01M8/0245) · CPC title

• H01M4/8657 Primary

  layered · CPC title