Porous Electrode

Patent metadata

Field	Value
Publication number	US-2024234746-A1
Application number	US-202218559034-A
Country	US
Kind code	A1
Filing date	May 23, 2022
Priority date	May 25, 2021
Publication date	Jul 11, 2024
Grant date	—

Abstract

A porous electrode comprising:an electrically conductive porous network of interconnected wires, andan electrically conductive support structure,wherein the network is in direct physical and electrical contact with the support structure, wherein the network has a volumetric surface area of from 2 m2/cm3 to 90 m2/cm3, and a porosity of from 50% to 90%,wherein a surface of the support structure, facing away from the network, has openings representing from 2 to 90% of its surface area, and wherein the openings are fluidly connected to the pores of the network.

First claim

1 . A porous electrode comprising:
an electrically conductive porous network of interconnected wires, and an electrically conductive support structure, wherein the electrically conductive porous network is in direct physical and electrical contact with the electrically conductive support structure, wherein the electrically conductive porous network has a volumetric surface area of from 2 m 2 /cm 3 to 90 m 2 /cm 3 , and a porosity of from 50% to 90%, wherein a surface of the electrically conductive support structure, facing away from the electrically conductive porous network, has openings representing from 2 to 90% of its surface area, and wherein the openings are fluidly connected to the pores of the electrically conductive porous network.

2 . The electrode according to claim 1 , wherein the electrically conductive porous network of interconnected wires comprises Ni.

3 . The electrode according to claim 1 , wherein the electrically conductive porous network of interconnected wires has a total thickness of from 1 to 100 μm.

4 . The electrode according to claim 1 , wherein the electrically conductive support structure comprises Ni or Cu.

5 . The electrode according to claim 1 , wherein the interconnected wires are from 10 to 200 nm thick.

6 . The electrode according to claim 1 being a gas-diffusion electrode.

7 . A method for a formation of a porous electrode according to claim 1 , comprising:
Forming a first mold comprising a network of interconnected channels, the first mold being suitable for molding a network of interconnected wires having a volumetric surface area of from 2 m 2 /cm 3 to 90 m 2 /cm 3 , and a porosity of from 50% to 90%, Forming a second mold on top of the first mold, the second mold being suitable for molding a support structure having a surface, facing away from the network of interconnected wires, having openings representing from 2 to 90% of its surface area, and wherein the openings are fluidly connected to the pores of the network of interconnected wires, Filling in the first mold with a first conductive material, and Filling in at least partially the second mold with a second conductive material, wherein the first and the second conductive materials are different or the same.

8 . The method according to claim 7 , wherein forming the first mold comprises anodizing a metal layer.

9 . The method according to claim 7 , wherein forming the second mold comprises printing the second mold on the first mold.

10 . The method according to claim 9 , wherein the printing is an ink-jet printing.

11 . The method according to claim 7 , wherein the second mold is made of a wax.

12 . An electrochemical device comprising a porous electrode according to claim 1 , the electrochemical device being selected from an electrolyzer, a fuel cell, and a battery.

13 . An electrolyzer according to claim 12 , comprising an anode and a cathode.

14 . A fuel cell according to claim 12 , comprising an anode and a cathode.

15 . A battery according to claim 12 , being a redox flow battery comprising an anode and a cathode.

16 . The electrode according to claim 1 , wherein the electrically conductive porous network of interconnected wires has a total thickness from 2 to 10 μm.

17 . The electrode according to claim 1 , wherein the interconnected wires are from 30 to 60 nm thick.

18 . The method according to claim 7 , wherein the forming of the second mold is performed after the forming of the first mold.

19 . The method according to claim 7 , wherein the forming of the second mold is performed before the filling of the first mold.

20 . The method according to claim 7 , wherein the forming of the second mold is performed after the filling of the first mold.

Assignees

• Imec Vzw
• Univ Leuven Kath

Inventors

• Plankensteiner Nina
• Singh Sukhvinder
• Vereecken Philippe
• Mees Maarten
• Wodarz Siegfried

Classifications

• H01M8/188

  by recharging of redox couples containing fluids; Redox flow type batteries · CPC title

• H01M4/8832

  Ink jet printing · CPC title

• H01M4/8673

  Electrically conductive fillers · CPC title

• H01M4/8605

  Porous electrodes · CPC title

• Y02E60/50

  Fuel cells · CPC title