Electrode

Patent metadata

Field	Value
Publication number	US-11041249-B2
Application number	US-201615761124-A
Country	US
Kind code	B2
Filing date	Sep 22, 2016
Priority date	Sep 25, 2015
Publication date	Jun 22, 2021
Grant date	Jun 22, 2021

Abstract

An electrode (10) is disclosed in which a first layer (30) of TiOx with a porosity in the range 0-3% is present on at least one surface of an electrode substrate (20), a second layer (40) of TiOx with a porosity of greater than 3 and up to 20% is present on the first layer (30) of TiOx. An electro-catalytic layer (50) is present on the second layer (40) of TiOx. x is in the range 1-2 for the first (30) and second layer (40) of TiOx. A process for the manufacture of the electrode (10) is disclosed as are uses thereof.

First claim

What is claimed is:

1. A cathode comprising:
a cathode substrate comprising titanium and/or an alloy thereof and having at least one surface;
a first layer of TiO x with a porosity of from 0.1% to 3% disposed on the at least one surface of the cathode substrate;
a second layer of TiO x with a porosity of greater than 3% and up to 20% disposed on the first layer of TiO x ; and
an electro-catalytic layer disposed on the second layer of TiO x and comprising RuO 2 ,
wherein x is from 1 to 1.99 for the first and second layers of TiO x , and
wherein a thickness of the first layer of TiO x is at least 20 μm and a thickness of the second layer of TiO x is at least 20 μm.

2. The cathode according to claim 1 , wherein a total thickness of the first layer of TiO x and the second layer of TiO x is from 40 to 190 μm.

3. The cathode according to claim 1 , wherein x is from 1.6 to 1.9 for the first layer of TiO x or the second layer of TiO x .

4. The cathode according to claim 1 , wherein the electro-catalytic layer further comprises Ru x Ti 1-x O y , wherein x of the Ru x Ti 1-x O y is from 0.5 to 1 and y of the Ru x Ti 1-x O y is up to 2.

5. The cathode according to claim 1 , wherein the electro-catalytic layer has a metals and/or oxides content of from 1 to 40 g/m 2 .

6. A method comprising using the cathode of claim 1 as a cathode in an electrolytic process.

7. The method according to claim 6 , wherein the electrolytic process comprises manufacture of alkali metal chlorate.

8. A process of manufacturing a cathode, the process comprising the steps of:
(i) providing a cathode substrate comprising titanium and/or an alloy thereof;
(ii) coating at least one surface of the cathode substrate by plasma spraying to form a first layer of TiO x with a porosity of from 0.1% to 3%;
(iii) coating by plasma spraying on the first layer of TiO x to form a second layer of TiO x with a porosity of greater than 3% and up to 20%; and
(iv) coating an electro-catalytic layer on the second layer of TiO x ,
wherein x is from 1 to 1.99 for the first and second layers of TiO x , thereby forming the cathode comprising:
the cathode substrate having the at least one surface;
the first layer of TiO x with a porosity of from 0.1% to 3% disposed on the at least one surface of the cathode substrate;
the second layer of TiO x with a porosity of greater than 3% and up to 20% disposed on the first layer of TiO x ; and
the electro-catalytic layer disposed on the second layer of TiO x and comprising RuO 2 ,

wherein a thickness of the first layer of TiO x is at least 20 μm and a thickness of the second layer of TiO x is at least 20 μm.

9. The process according to claim 8 , wherein the at least one surface of the cathode substrate is roughened to provide an R a value of from 1 to 6 μm prior to step (ii).

10. The process according to claim 9 , wherein the roughened cathode substrate does not undergo a pickling procedure.

11. The process according to claim 8 , wherein coating the electro-catalytic layer on the second layer of TiO x further comprises thermolysis of a combination of ruthenium and titanium compounds.

12. The process according to claim 8 , wherein coating the electro-catalytic layer on the second layer of TiO x provides a metals and/or oxides content of from 1 to 40 g/m 2 to the electro-catalytic layer.

13. The cathode according to claim 1 , wherein
a total thickness of the first layer of TiO x and the second layer of TiO x is from 40 to 190 μm wherein the first layer has a porosity either of from 0.1 to 2.5% or from 0.5 to 1.8%;
a thickness of the first layer of TiO x and a thickness of second layer of TiO x is at least 20 μm;
x is from 1.6 to 1.9 for the first layer of TiO x and/or the second layer of TiO x ; and
the electro-catalytic layer has a metals and/or oxides content of from 1 to 40 g/m 2 .

14. The cathode according to claim 1 wherein the first layer has a porosity of from 0.1 to 2.5%.

15. The cathode according to claim 13 , wherein the cathode substrate is Commercially Pure Grade 1 Titanium.

16. The cathode according to claim 1 , wherein the cathode substrate is Commercially Pure Grade 1 Titanium.

17. The process according to claim 8 , wherein the cathode substrate is Commercially Pure Grade 1 Titanium.

18. The process according to claim 1 , wherein the first and second layers are devoid of cracking.

Assignees

• Akzo Nobel Chemicals Int Bv
• Nouryon Chemicals Int Bv

Inventors

• Rosvall Magnus
• Nordin Bernth

Classifications

• C25B11/093 Primary

  at least one noble metal or noble metal oxide and at least one non-noble metal oxide · CPC title

• C25B11/061

  Metal or alloy · CPC title

• C02F2001/46142

  Catalytic coating · CPC title

• C02F1/46109

  Electrodes · CPC title

• C25B11/051 Primary

  Electrodes formed of electrocatalysts on a substrate or carrier · CPC title