Electrode With Two Layer Coating, Method of Use, and Preparation Thereof

Patent metadata

Field	Value
Publication number	US-2017356095-A1
Application number	US-201515521109-A
Country	US
Kind code	A1
Filing date	Oct 20, 2015
Priority date	Oct 21, 2014
Publication date	Dec 14, 2017
Grant date	—

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

1 . An electrode comprising:
an electrically conductive substrate; a first coating covering at least a portion of a surface of the electrically conductive substrate, comprising a mixture of iridium oxide and tin oxide; and a second coating covering at least a portion of the first coating, comprising 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 first coating comprises about 30 wt. % to about 85 wt. % iridium oxide.

6 . The electrode of claim 5 , wherein the first coating comprises about 45 wt. % to about 65 wt. % iridium oxide.

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

8 . The electrode of claim 7 , wherein the second coating comprises about 65 wt. % iridium oxide.

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

10 . 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.

11 . The electrode of claim 10 , wherein the molar ratio of iridium oxide in the first coating to the iridium oxide in the second coating is 1:1.

12 . The electrode of claim 11 , wherein the electrode provides for about a 175% longer normalized life than an electrode comprising a single layer coating consisting of a composition of the second coating.

13 . The electrode of claim 11 , wherein the electrode provides for about a 110% longer normalized life than an electrode comprising a single layer coating consisting of a composition of the first coating.

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

15 . A method of preparing an electrode, comprising:
applying a first coating layer comprising iridium oxide and tin oxide to at least a portion of a surface of an electrically conductive substrate; and applying a second coating layer comprising iridium oxide and tantalum oxide to at least a portion of the first coating layer.

16 . The method of claim 15 , further comprising, prior to applying the first coating layer, preparing the electrically conductive substrate to remove contaminants and to develop the surface.

17 . The method of claim 15 , further comprising, after applying the first coating layer, drying the first coating layer.

18 . The method of claim 15 , further comprising, after applying the second coating layer, drying the second coating layer.

19 . The method of claim 15 , wherein a molar ratio of iridium oxide in the first coating to iridium oxide in the second coating is about 1:2 to 2:1.

20 . A method of manufacturing an electrochemical device, comprising:
preparing an electrode comprising:
an electrically conductive substrate;
a first coating covering at least a portion of a surface of the electrically conductive substrate, comprising a mixture of iridium oxide and tin oxide; and
a second coating covering at least a portion of the first coating, comprising a mixture of iridium oxide and tantalum oxide; and
installing the electrode in an electrolytic cell.

21 . 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, comprising a mixture of iridium oxide and tin oxide; and
a second coating covering at least a portion of the first coating, comprising a mixture of iridium oxide and tantalum oxide; and
a power source for supplying a current to the electrode.

22 . The system of claim 21 , wherein the electrode is immersed in an electrolyte.

Assignees

• Evoqua Water Tech Llc

Inventors

• Ivanter Irina A
• Chang-Ng Julio W

Classifications

• H01M4/8657 Primary

  layered · 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

• H01M4/9016

  Oxides, hydroxides or oxygenated metallic salts · CPC title