Electrode

Patent metadata

Field	Value
Publication number	US-2018258543-A1
Application number	US-201615761124-A
Country	US
Kind code	A1
Filing date	Sep 22, 2016
Priority date	Sep 25, 2015
Publication date	Sep 13, 2018
Grant date	—

Abstract

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

First claim

1 . An electrode comprising:
an electrode substrate, a first layer of TiO x with a porosity in the range 0-3% on at least one surface of the electrode substrate, a second layer of TiO x with a porosity of greater than 3% and up to 20% on the first layer of TiO x , an electro-catalytic layer on the second layer of TiO x ; wherein x is in the range 1-2 for the first and second layers of TiO x .

2 . The electrode according to claim 1 , wherein the electrode substrate is selected from one of steel or iron, or is selected from one of an alloy of iron comprising at least one of the metals molybdenum, tungsten, chromium, and titanium or any combination of these metals, or is selected from one of the metals titanium, tantalum, tungsten, zirconium, hafnium or niobium or an alloy thereof.

3 . The electrode according to claim 1 , wherein a total thickness of the first layer of TiO x and the second layer of TiO x is in the range of between 40-190 μm.

4 . The electrode according to claim 1 , wherein a thickness of the first layer of TiO x or a thickness of second layer of TiO x is at least 20 μm.

5 . The electrode according to claim 1 , wherein x is between 1.6-1.9 for the first layer of TiO x or the second layer of TiO x .

6 . The electrode according to claim 1 , wherein the electro-catalytic layer is Ru x Ti (1-x) O y .

7 . The electrode according to claim 1 , wherein the electro-catalytic layer has a metals and/or oxides content of the electro-catalytic layer in the range of between 1-40 gm −2 .

8 . A method comprising using the electrode according to claim 1 as a cathode in an electrolytic process.

9 . The method according to claim 8 , wherein the electrolytic process comprises manufacture of alkali metal chlorate.

10 . A process of manufacturing an electrode, the process comprising the steps:
(i) providing an electrode substrate, (ii) coating at least one surface of the electrode substrate by plasma spraying to form a first layer of TiO x with a porosity of between 0-3%, (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%, (iv) coating an electro-catalytic layer on the second layer ( 40 ) of TiO x ;
wherein x is between 1-2 for the first and second layers of TiO x .

11 . The process according to claim 10 , wherein the electrode substrate is selected from one of steel or iron, or is selected from one of an alloy of iron comprising at least one of the metals molybdenum, tungsten, chromium, and titanium or any combination of these metals, or is selected from one of the metals titanium, tantalum, tungsten, zirconium, hafnium or niobium or an alloy thereof.

12 . The process according to claim 10 , wherein a surface of the electrode substrate is roughened to provide an R a value in the range of between 1-6 μm prior to step (ii).

13 . The process according to claim 12 , wherein the roughened electrode substrate does not undergo a pickling procedure.

14 . The process according to claim 10 , wherein coating by plasma spraying achieves a thickness of the first layer of TiO x or a thickness of second layer of TiO x of at least 20 μm.

15 . The process according to claim 10 , wherein coating the electro-catalytic layer on the second layer of TiO x comprises thermolysis of a combination of ruthenium and titanium compounds.

16 . The process according to claim 10 , wherein coating the electro-catalytic layer on the second layer of TiO x provides a metals and/or oxides content in the range of between 1-40 gm −2 to the electro-catalytic layer.

17 . An electrode obtainable by the process according claim 10 .

Assignees

• Akzo Nobel Chemicals Int Bv

Inventors

• Rosvall Magnus
• Nordin Bernth

Classifications

• C02F1/46109

  Electrodes · CPC title

• C02F2001/46142

  Catalytic coating · CPC title

• C25B11/0484

  Chemistry & Metallurgy · mapped topic

• C25B11/0431

  Chemistry & Metallurgy · mapped topic

• C25B11/0405 Primary

  Chemistry & Metallurgy · mapped topic