High surface area plating for oxygen evolution electrodes

Patent metadata

Field	Value
Publication number	US-2025323282-A1
Application number	US-202519177086-A
Country	US
Kind code	A1
Filing date	Apr 11, 2025
Priority date	Apr 11, 2024
Publication date	Oct 16, 2025
Grant date	—

Abstract

Oxygen evolution electrodes having high surface area plating and methods of forming such oxygen evolution electrodes are described. According to one aspect, an electrode for an oxygen evolution reaction (OER) may include a substrate including at least one surface and a layer of nickel coated on the at least one surface of the substrate. The at least one surface of the substrate has a first surface area, the layer of nickel has a second surface area, and a ratio of the second surface area to the first surface area is greater than about 10:1 and less than about 50:1.

First claim

What is claimed is:

1 . A method of making an oxygen evolution electrode for a metal-air battery, the method comprising:
at least partially immersing a cathode and an anode in a solution, the solution including cations of a metal; applying electric current between the cathode and the anode in the solution, the electric current generating bubbles on at least one surface of a substrate of the cathode as the cations of the metal chemically reduce around the bubbles on the at least one surface of the substrate and form a layer of the metal on the at least one surface of the substrate; and with the layer formed on the surface of the substrate, removing the substrate from the solution.

2 . The method of claim 1 , wherein the solution further includes ammonium cations.

3 . The method of claim 1 , herein the solution is an aqueous solution, and the bubbles on the at least one surface of the substrate are hydrogen.

4 . The method of claim 3 , wherein at least partially immersing the cathode and the anode in the solution includes dissolving a metal salt in water.

5 . The method of claim 4 , wherein the metal salt includes a nickel salt, and the layer formed on the at least one surface of the substrate of the cathode includes nickel.

6 . The method of claim 5 , wherein the nickel salt includes nickel chloride.

7 . The method of claim 3 , wherein at least partially immersing the cathode and the anode in the solution includes dissolving ammonium chloride in the aqueous solution.

8 . The method of claim 3 , wherein at least partially immersing the cathode and the anode in the solution includes dissolving ammonium sulfamate in the aqueous solution.

9 . The method of claim 1 , wherein at least a portion of the at least one surface of the substrate is flat.

10 . The method of claim 1 , wherein at least one portion of the at least one surface of the substrate is three-dimensional.

11 . The method of claim 10 , wherein the at least one portion of the surface of the substrate includes a mesh, defines perforations, or a combination thereof.

12 . The method of claim 1 , wherein, at least along the surface, the substrate is formed of nickel, steel, copper, or a combination thereof.

13 . An electrode for an oxygen evolution reaction (OER), the electrode comprising:
a substrate including at least one surface; and a layer of nickel coated on the at least one surface of the substrate, the at least one surface of the substrate has a first surface area, the layer of nickel has a second surface area, and a ratio of the second surface area to the first surface area is greater than about 10:1 and less than about 50:1.

14 . The electrode of claim 13 , wherein the substrate is formed of nickel, steel, copper, or a combination thereof.

15 . The electrode of claim 13 , wherein at least a portion of the at least one surface of the substrate is three-dimensional.

16 . The electrode of claim 15 , wherein at least one portion of the at least one surface of the substrate is a mesh.

17 . The electrode of claim 13 , wherein the layer of nickel defines a plurality of pores.

18 . The electrode of claim 17 , wherein at least a subset of the plurality of pores has a size of greater than about 1 micron and less than about 100 microns.

19 . The electrode of claim 18 , wherein average pore size of the plurality of pores is greater than 20 microns and less than 40 microns.

20 . A battery comprising the electrode of claim 13 .

Assignees

• Form Energy Inc

Inventors

• Sullivan Anthony Edwards
• Hitt Jeremy
• Nasir Muhammad
• Hickey Anne Katherine
• Becerra Daniel Louis
• Kaufman Zachary Dean

Classifications

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M12/06

  with one metallic and one gaseous electrode · CPC title

• H01M4/9041

  Metals or alloys (H01M4/92 takes precedence) · CPC title

• H01M4/8853 Primary

  Electrodeposition · CPC title

• H01M2004/028

  Positive electrodes · CPC title