阅读说明：本技术 用于制造气体扩散电极的方法和气体扩散电极 (Method for producing a gas diffusion electrode and gas diffusion electrode ) 是由 M.K.汉森 K.T.瑟基尔德森 于 2017-06-23 设计创作，主要内容包括：本发明提供一种用于制造气体扩散电极的方法和一种气体扩散电极。具体地,提供一种用于连续制造具有减小的厚度的气体扩散电极的方法。为此,将不导电的增强幅材用作基础物以在该增强幅材上施加颗粒。具体地,增强幅材可包括聚合物的网状物,所述聚合物例如是聚丙烯、聚苯硫醚、尼龙或另外的有机聚合物。以该方式,可通过连续制造工艺获得非常稳健且薄的气体扩散电极。(The invention provides a method for manufacturing a gas diffusion electrode and a gas diffusion electrode. In particular, a method for continuously manufacturing a gas diffusion electrode having a reduced thickness is provided. For this purpose, a non-conductive reinforcing web is used as a base for applying the particles on the reinforcing web. In particular, the reinforcing web may comprise a network of polymers, such as polypropylene, polyphenylene sulfide, nylon, or another organic polymer. In this way, a very robust and thin gas diffusion electrode can be obtained by a continuous manufacturing process.)

1. A method for manufacturing a gas diffusion electrode, comprising the steps of:

(S1) providing a raw electrode layer (100) comprising a non-conductive web (110);

(S2) adjusting the thickness of the original electrode layer (100); and

(S3) applying a non-solvent onto the prime electrode layer (100).

2. The method of claim 1, wherein the nonconductive web (110) comprises an organic polymer.

3. The method of claim 1 or 2, wherein the thickness of the non-conductive web (110) is less than 149 microns.

4. A method according to any one of claims 1 to 3, wherein the prime electrode layer (100) comprises at least one layer (21) comprising particles of electrode material and a binder.

5. The method of any one of claims 1 to 4, wherein applying (S2) a non-solvent onto the virgin electrode layer (100) comprises applying a first non-solvent onto a surface of the virgin electrode layer (100) in a closed volume of steam and/or spraying the first non-solvent onto a surface of the virgin electrode layer (100).

6. The method according to any one of claims 1 to 5, wherein applying a non-solvent onto the prime electrode layer (100) comprises applying a second non-solvent in a non-solvent bath.

7. The method of any one of claims 1 to 6, wherein (1) providing a prime electrode layer comprises:

providing a first original electrode layer and a second original electrode layer; and

the first and second prime electrode layers are pressed together.

8. The method of claim 7, wherein the first and second pristine electrode layers each comprise a non-conductive web (110).

9. The method according to any one of claims 1 to 8, wherein a physical barrier (35) is placed in front of the surface of the original electrode layer (100) before applying the non-solvent onto the original electrode layer (100).

10. The method according to claim 9, comprising controlling the distance between the physical barrier (35) and the surface of the virgin electrode layer (100).

11. The method according to any one of claims 1 to 10, wherein the virgin electrode layer (100) is transported vertically when (S2) a non-solvent is applied onto the virgin electrode layer (100).

12. A gas diffusion electrode (200, 300) includes a non-conductive reinforcing web (110).

13. The gas diffusion electrode (200, 300) of claim 12, wherein the non-conductive reinforcing web (110) has a thickness of less than 149 microns.

14. The gas diffusion electrode (300) of claim 12 or 13, wherein the gas diffusion electrode (300) comprises at least two layers (310, 320), each layer (310, 320) comprising a non-conductive reinforcing web (110).

15. The gas diffusion electrode (200, 300) according to any of claims 12 to 14, wherein the gas diffusion electrode (200, 300) has an asymmetric cross-section.

Prior Art

Electrochemical conversion processes such as electrolysis are used for a variety of purposes (uses). For example, hydrogen and/or oxygen can be produced from a Hydrogen Evolution Reaction (HER) and an Oxygen Evolution Reaction (OER) by electrolysis of an electrolyte (usually water) in an electrolytic cell. Another example of an electrochemical conversion process is the electrochemical reduction of carbon dioxide, for example. An electrochemical conversion apparatus, such as an electrolytic cell, in which such an electrochemical conversion process is performed includes electrodes called gas diffusion electrodes. These electrodes conduct electrical energy to the electrolyte and decompose the electrolyte and/or other reactants to produce desired products, such as oxygen, hydrogen, and the like.

Another important component used in such electrochemical conversion processes is a gas-tight membrane or membrane, which is called a gas separator (separator) membrane or simply a gas separator (separator). The means divides the electrochemical conversion device into a plurality of chambers or compartments and allows ions to flow from one such chamber to another but does not allow gases such as oxygen or hydrogen to flow from one chamber to another. The products of the electrochemical conversion are separated in this way. Electrochemical cell (unit cell) components, i.e. gas separator membranes and/or gas diffusion electrodes, are currently manufactured by using mass production.

US 3,553,032 a1 discloses a method of manufacturing a fuel cell electrode comprising a porous water-repellent polymer particle-bonded substrate having a thin silver coating and particles of an electrically conductive material dispersed therein and adhered thereto, the method comprising: forming a mixture of a water-repellent polymer, particles of an electrically conductive material and silver carbonate particles, moulding the mixture under pressure to form a coherent structure, and heating the resulting coherent structure to a temperature above the decomposition temperature of the silver carbonate but below the softening point of the polymer to form silver and release carbon dioxide gas which diffuses through the structure to render it substantially porous.

There is a need for an efficient method for manufacturing a gas diffusion electrode that can manufacture a gas diffusion electrode at high quality with low production costs. Thus, there is a need for a continuous process for manufacturing gas diffusion electrodes while still maintaining important parameters of the gas diffusion electrode such as porosity, hydrophobicity and catalytic performance. Furthermore, there is a need for a simple method for manufacturing a gas diffusion electrode, which results in a thin gas diffusion electrode with high quality.

Summary of The Invention

This is achieved by the features of the independent claims.

According to a first aspect, the present invention provides a method for manufacturing a gas diffusion electrode. The method includes the step of providing a virgin electrode layer, wherein the virgin electrode layer comprises a non-conductive web. Further, the method comprises the steps of adjusting the thickness of the prime electrode layer and applying a non-solvent to the prime electrode layer.

According to another aspect, the present invention provides a gas diffusion electrode comprising a non-conductive reinforcing web.

Thus, by manufacturing the gas diffusion electrode using a non-conductive reinforcing web, a simple manufacture of such a gas diffusion electrode can be achieved and at the same time the thickness of the gas diffusion electrode can be reduced. In this way, a simple manufacture of a robust (robust) and thin gas diffusion electrode can be achieved and at the same time the manufacturing costs of such a gas diffusion electrode can be reduced.

By manufacturing the gas diffusion electrode on the basis of the reinforcement web, a continuous manufacturing process of the gas diffusion electrode can be achieved. For example, the web may be cast with a suspension of particles in a binder solution. Depending on the desired properties of the layer, the suspension may comprise conductive particles or particles of a hydrophobic material. The original electrode layer may be subjected to phase inversion (phaseinversion) to achieve porosity. It is even possible to cast another suspension onto the first suspension on the original electrode layer or to apply a different suspension to different locations of the reinforcing web before phase-reversing the original electrode.

This process of casting the reinforcing web with one or more suspensions and phase inversion by applying one or more non-solvents to the original electrode layer can be done in a continuous process and the gas diffusion electrode can be produced in a simple manufacturing process requiring low cost. Meanwhile, a high-quality cast diffusion electrode can be realized.

By using a non-conductive reinforcing web, the stability of the reinforcing web is high even if the thickness of the reinforcing web is very low. In this way, reinforcing webs having only a very small thickness, for example a few micrometers, for example 10, 20, 50, 100 or 140 micrometers, can be used in the production process of gas diffusion electrodes.

In one embodiment, the nonconductive web comprises an organic polymer. For example, the non-conductive reinforcing web may comprise polypropylene (PP) or Polyphenylene Sulfide (PPs). However, any other suitable polymer may be used. For example, nylon or other suitable organic polymers may also be used as the reinforcing web. In this way, reinforcing webs having a very small thickness of only a few micrometers, in particular 10, 20, 50, 100 or 150 micrometers, can be used as reinforcing webs. The reinforcing web can have any suitable width. For example, the reinforcing web may have a width of about one or several centimeters. The width may also be several tens of centimeters to 100 centimeters or more. Thus, the final size of the gas diffusion electrode is limited only by the size of the reinforcing web on which the particles of the gas diffusion electrode are cast. Furthermore, the length of the reinforcing web, and thus the length of the original electrode layer, may be several meters to many meters.

According to one embodiment, the thickness of the reinforcing web, in particular of the non-conductive web, is less than 150 microns, in particular less than 149 microns. In one embodiment, the thickness of the non-conductive reinforcing web is less than 100 microns, in particular less than 50 microns or even less than 20 microns or less than 10 microns. In this way the thickness of the resulting gas diffusion electrode can be minimized.

According to one embodiment, the number of electrode layers comprises at least one layer comprising particles of electrode material and a binder. For example, the prime electrode layer may include particles of conductive material and a binder. In this way an electrochemically active layer can be realized. Alternatively or additionally, the prime electrode layer may comprise a layer comprising particles of a hydrophobic material and a second binder. Further, particles of any other suitable material may also be cast onto the non-conductive web.

According to one embodiment, the step of applying a non-solvent to the primed electrode layer comprises applying a first non-solvent to the surface of the primed electrode layer and/or spraying the first non-solvent onto the surface of the primed electrode layer in a closed volume (a) of vapour. The original electrode layer is subjected to phase inversion in this way, so that the porosity of the gas diffusion electrode can be achieved.

According to one embodiment, applying the non-solvent to the pristine electrode layer includes applying a second non-solvent in a non-solvent bath. Optionally, additional tasks for applying additional non-solvents may also be applied to the original electrode layer to perform phase inversion and achieve porosity in the electrode layer.

According to another embodiment, providing the prime electrode layer comprises providing a first prime electrode layer and a second prime electrode layer. In this case, the first electrode layer and the second original electrode layer are pressed together. Thus, the first and second original electrode layers may be combined into a common original electrode layer and sequential (successive) steps applied to the combination of the first and second original electrode layers. Thus, the first and second prime electrode layers may have different properties, in particular the first and second prime electrode layers may comprise particles of different materials. Thus, a sandwich structure of two or even more layers can be achieved.

According to another embodiment, both the first and second virgin electrode layers comprise a non-conductive web. In particular, the nonconductive webs of the first and second virgin electrode layers may both be webs of organic polymer, and may both have a thickness of less than 149 microns.

According to another embodiment, the physical barrier is placed before the surface of the pristine electrode layer before the non-solvent is applied to the pristine electrode layer. In this manner, the physical barrier may limit or prevent the application of the non-solvent onto the respective surface of the pristine electrode layer. Thus, the impact of the non-solvent on the respective surface is limited, and thus an asymmetric cross section of the gas diffusion electrode can be achieved.

According to one embodiment, the method comprises controlling a distance between the physical barrier and a surface of the prime electrode layer. By adjusting the distance between the physical barrier and the surface of the original electrode layer, the impact of the non-solvent can be controlled and thus the properties of the respective side of the electrode layer facing the physical barrier can be influenced.

According to one embodiment, the prime electrode layer is supplied vertically when the non-solvent is applied to the prime electrode layer. In this way, the phase inversion can be carried out in a very efficient manner by applying a non-solvent.

According to one embodiment of the gas diffusion electrode, the non-conductive reinforcing web has a thickness of less than 149 microns. In particular, the thickness of the reinforcing web is less than 140 microns, or even less than 120 microns or less than 100 microns. In particular, the thickness of the non-conductive reinforcing web may even be less than 50 microns or less than 20 microns or even less than 10 microns.

According to one embodiment of the gas diffusion electrode, the gas diffusion electrode comprises at least two layers. In this case, each layer comprises a separate non-conductive reinforcing web having the properties described above.

According to one embodiment, the gas diffusion electrode has an asymmetric cross-section. Thus, different sides of the gas diffusion electrode have different properties.

According to one embodiment, the non-conductive reinforcing web comprises an organic polymer. For example, the organic polymer may include polypropylene (PP), Polyphenylene Sulfide (PPs), or nylon. However, any other suitable polymer may also be used to make the reinforced web.

The invention will be further described hereinafter with reference to embodiments shown in the drawings, in which:

FIG. 1: schematically showing a cross-section of a virgin electrode layer according to an embodiment;

FIG. 2: schematically illustrating a method for manufacturing a gas diffusion electrode according to an embodiment;

FIG. 3: schematically illustrating a method for manufacturing a gas diffusion electrode according to another embodiment;

FIG. 4: schematically illustrating a method for manufacturing a gas diffusion electrode according to yet another embodiment;

FIG. 5: a gas diffusion electrode according to an embodiment is schematically shown in cross-section.

FIG. 6: schematically showing a cross-section of a gas diffusion electrode according to another embodiment; and

FIG. 7: a flow diagram of a method for manufacturing a gas diffusion electrode according to an embodiment is schematically shown.

The above and other features of the present invention are described in detail below. Various embodiments are described with reference to the drawings, wherein like reference numerals are used to refer to like embodiments throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide an understanding of one or more embodiments. It should be noted that the illustrated embodiments are intended to illustrate rather than to limit the invention. It may be evident that such embodiment(s) can be practiced without these specific details.

Fig. 1 shows a cross-section of a raw electrode layer 100, which can be used as a raw electrode layer for the manufacture of a gas diffusion electrode. The original electrode layer comprises a web 110. The web 110 may be used as a reinforcing web. In this way, the desired stability of the original electrode layer 100 and the resulting gas diffusion electrode may be achieved. In particular, the web 110 is made of a porous, electrically non-conductive material. Such a porous non-conductive web 110 may be realized, for example, by a web comprising polypropylene (PP), Polyphenylene Sulfide (PPs), nylon or another suitable polymer. For example, the web 110 may be realized by a web comprising a polymer, such as the above-mentioned polymer or another suitable organic polymer. In this way, a strong and strong web 110 can be achieved, which can be used as a reinforcing web for the original electrode layer 100 and the resulting gas diffusion electrode. Due to the robustness of such non-conductive webs 110, especially meshes of organic polymers, very thin and strong reinforcing webs 110 can be achieved. For example, even if the thickness t is less than 200 microns, or even less than 150 microns, 149 microns, less than 100 microns, or less than 50 microns, a desired robustness of the enhanced web 110 may be achieved. Even a reinforced web with a thickness of 20 microns or less, for example 10 microns, can be achieved. In contrast, metal mesh-based, electrically conductive reinforcing webs typically have a significantly higher thickness to achieve the required robustness.

The reinforcing web 110 is cast with a suspension 120-i. The suspension 120-i may include particles and a binder. Depending on the selected particles in the suspension, the properties of the resulting gas diffusion electrode can be adjusted. Suspension 120-i can be cast onto at least one side of reinforcing web 110. However, the suspension 120 may also be cast onto both sides of the reinforcing web 110. Further, different suspensions may be cast onto the reinforcing web 110. For example, a first suspension 120-1 comprising first particles may be cast onto one side of the reinforcing web; and a second suspension 120-2 containing second particles can be cast onto the other side of the reinforcing web 110.

In addition, multiple layers may also be cast onto one side or at least one side of the reinforcing web 110. For example, a first layer of a first suspension may be cast directly onto the surface of the reinforcing web, and then a second suspension comprising a second type of particles may be cast onto the layer of the first suspension. The width w of the original electrode layer 100 is limited only by the width of the reinforcing web 110 on which the suspension is cast. For example, the reinforcing web or the resulting virgin electrode layer 100 may have a width w of at least 5 centimeters, 10 centimeters, 20 centimeters, 50 centimeters, 1 meter, or more. Further, the length of the raw electrode layer 110 may be many meters. For example, the length of the raw electrode layer may be 5 meters, 10 meters, 50 meters, 100 meters, or even longer.

Fig. 2 shows a schematic view of a method for manufacturing a gas diffusion electrode according to an embodiment. First, at least one prime electrode layer 100 is provided. For example, a roll of the original electrode layer 110 may be provided at location 10, already prepared. Alternatively, it is also possible to provide only the reinforcing web 110 and subsequently to cast one or more layers of a suitable suspension on the provided reinforcing web 110. After providing the original electrode layer 110, the thickness of the original electrode layer may be adjusted at location 20. For example, the thickness of the preliminary electrode layer may be set by conveying the preliminary electrode layer 100 to two rolls having a predetermined distance. In this way, the thickness of the original electrode layer 100 can be adjusted according to the distance between the two rolls. Alternatively, the original electrode layer may be transported through a slit having a predetermined width. Further, any other suitable configuration for adjusting the thickness of the original electrode layer 100 is also possible.

After adjusting the thickness of the original electrode layer 100 accordingly, a non-solvent is applied to the original electrode layer 100. In this manner, phase inversion may be performed, which may achieve enhanced porosity of the suspension 120-i on the web 110. For example, at least one or two non-solvents may be applied to the original electrode layer for phase inversion. As shown in fig. 2, a first non-solvent may be applied to the pristine electrode layer 100 at location 31. For example, the first non-solvent may be a closed volume of a suitable vapor or liquid that is ultimately sprayed onto the virgin electrode layer. In addition, a non-solvent bath comprising a non-solvent in liquid form may be applied to the virgin electrode layer at location 32. The non-solvent may be, for example, water or a suitable organic solvent or a mixture thereof. Since suitable non-solvents for performing the phase inversion are already well known, these solvents are not discussed in more detail herein.

Optionally, other additional non-solvent baths may be applied at location 40 in subsequent steps. For example, another non-solvent bath may be water or other suitable non-solvent. However, position 40 may also be omitted.

If any type of pore former is added to the suspension cast onto the original electrode layer 100, it may be removed in a subsequent bath 50. If desired, a suspension of hydrophobic particles, such as Polytetrafluoroethylene (PTFE), may be sprayed onto at least one side of the resulting electrode structure at location 60. Finally, a final cleaning bath 70 may be applied to the electrode structure before the gas diffusion electrode may be rolled up at location 90.

In this way a continuous manufacturing process of the gas diffusion electrode can be achieved. This allows a very fast manufacturing of a high quality gas diffusion electrode in a process requiring only low manufacturing costs. Since the gas diffusion electrode is based on a very thin non-conductive reinforcing web 110, a very robust gas diffusion electrode with a minimum thickness can be achieved.

Fig. 3 shows a schematic view for manufacturing a gas diffusion electrode according to another embodiment. As can be seen from this figure, two virgin electrode layers 100 are provided by the roll 10. Accordingly, the thickness of each provided original electrode layer 100 can be individually adjusted by the roller pairs 11 and 12. In this embodiment, each of the virgin electrode layers 100 may include a respective reinforcing web 110. Subsequently, the two (or more) original electrode layers 100 are pressed together by a roller pair 20 or another suitable means for combining the individual original electrode layers 100. Next, the combination of the individual pristine electrode layers is subjected to one or more non-solvents, as already described in connection with fig. 2. The process for manufacturing a gas diffusion electrode according to fig. 3 therefore mainly corresponds to the process described in connection with fig. 2.

Fig. 4 schematically shows a process for manufacturing a gas diffusion electrode according to another embodiment. This embodiment essentially corresponds to the previous embodiment, wherein an additional physical barrier 35 is arranged in front of at least one surface of the original electrode layer 100. In this way the influence of the non-solvent on the suspension of the original electrode layer 100 can be adjusted. If the physical barrier 35 is arranged very close to the surface of the original electrode layer, no or only a small amount of non-solvent is applied to the respective side of the original electrode layer 100. By increasing the distance between the original electrode layer 100 and the physical barrier 35, a greater amount of non-solvent can reach the corresponding surface of the original electrode layer 100, and the influence of the non-solvent increases.

Although a single physical barrier 35 is shown on only one side of the original electrode layer 100, physical barriers may be provided on both sides of the original electrode layer 100. For example, a first physical barrier 35 may be applied on one side of the original electrode layer 100 when a first non-solvent is applied, and a second physical barrier may be applied on the other side of the original electrode layer when another non-solvent is applied.

The remaining steps, in particular the additional optional steps of manufacturing the gas diffusion electrode as already described in connection with fig. 2, may also apply in this embodiment any other described embodiment.

Fig. 5 shows a cross-section through the resulting gas diffusion electrode 200 according to an embodiment. It can be seen that the resulting gas diffusion electrode comprises a non-conductive reinforcing web 110. Furthermore, porous structures 220 and 230 are arranged on the reinforcing web 110. Although the same porous structure may be formed on both sides of the reinforcement web 110, it is also possible that the gas diffusion electrode 200 comprises different porous structures 220 and 230 on each side of the reinforcement web 110. For example, conductive particles may be disposed on a first side of the reinforcement web 110 to form an active layer. Further, particles of hydrophobic material may be applied to one side of the reinforcement web 110. Furthermore, any suitable configuration of the gas diffusion electrode comprising the non-conductive reinforcing web 110 is also possible. It is also possible that more than one layer of different particles may be arranged on the same side of the reinforcement web 110 to form different functional layers.

Fig. 6 schematically shows another configuration of a gas diffusion electrode according to an embodiment. As can be seen in this figure, the gas diffusion electrode comprises at least two structures, each structure comprising a respective reinforcing web 110. In this configuration, multiple prime electrode layers are combined as described in connection with fig. 3. Thus, the resulting gas diffusion electrode 300 comprises a plurality of layers 310, 320, each layer 310, 320 having particles of the respective material.

Fig. 7 schematically shows a flow diagram of a method for manufacturing a gas diffusion electrode according to an embodiment.

In step S1, at least one prime electrode layer 100 is provided. Each of the original electrode layers 100 includes a non-conductive reinforcing web 110. In particular, the non-conductive reinforcing web 110 may be formed from a mesh of a polymer, such as polypropylene, polyphenylene sulfide, nylon, or other suitable polymer. In this way, a reinforcing web 110 having only a small thickness of less than 200 microns, in particular less than 149 microns, less than 100 microns or even less than 50, 20 or 10 microns can be achieved.

In step S2, the thickness of the original electrode layer 100 is adjusted. For example, the starting electrode layer 100 may be conveyed to a slit having a predetermined width or a roller pair having a predetermined distance. Further, in step S3, at least one non-solvent is applied to the primitive electrode layer 100. Two or more steps of applying the non-solvent may also be performed, if desired. For example, the first non-solvent may be applied by a volume of vapor or by spraying a liquid non-solvent onto the surface of the virgin electrode layer 100. In addition, suitable non-solvent baths may also be employed. In this way, the phase inversion can be achieved and the porous structure of the casting of the pristine electrode layer is obtained.

In summary, the present invention provides a method for manufacturing a gas diffusion electrode. In particular, a method of continuously manufacturing a gas diffusion electrode having a reduced thickness is provided. For this purpose, a non-conductive reinforcing web is used as a base for applying the particles on the reinforcing web. In particular, the reinforcing web may comprise a network of a polymer, such as polypropylene, polyphenylene sulfide, nylon, or another organic polymer. In this way, a very robust and thin gas diffusion electrode can be obtained by a continuous manufacturing process.