Process of increasing energy conversion and electrochemical efficiency of a scaffold material using a deposition material

Abstract

A process for increasing the energy conversion and electrochemical efficiency of a scaffold material using a deposition material comprises flowing by at least one surface of the scaffold material a solution which comprises the deposition material, forming agglomerations of the deposition material with at least one surface of the scaffold material, wherein the deposition material fills pores on the at least one surface of the scaffold material (“scaffold pores”) thereby increasing the surface area of the scaffold material, electrically connecting deposition material to the scaffold material via the formation of agglomerations, wherein said scaffold material is conductive and flow-through and wherein deposition material has a pore size (“deposition material pore size”) which is no larger than the scaffold pore size.

Description

FIELD OF THE INVENTION[0001]The present invention relates to improving the efficiency of electrochemical cells.BACKGROUND ON THE INVENTION[0002]In a bid to develop efficient and compact electrochemical energy conversion devices much attention has been devoted towards increasing the electrochemical surface area (ESA) per unit volume of electrode. Whether for batteries, fuel cells or capacitors, electrodes with nanoscopic features and porosity are necessary to achieve the highest energy densities. Among the options available for conductive electrode materials, carbon continues to be principal due to its low cost, chemical resistance and potentially high surface area. As an inexpensive and abundant material, natural carbon has typically been processed into high surface area particles for electrochemical applications such as activated carbon for electrosorption or carbon black as a catalyst support in fuel cells. As a randomly aggregated electrode material, these powders require some fo...

AI Technical Summary

Benefits of technology

The present invention provides a process to increase the energy conversion and electrochemical efficiency of a flow-through, conductive scaffold material by connecting it with a deposition material that increases the surface area of the scaffold material, making it more available for reactions. The process involves flowing a solution containing nanomaterials through the scaffold material, where the nanomaterials form self-assembling agglomerations on the surface of the scaffold material and connect electrically with it. The invention also provides a scaffold material with increased energy conversion and electrochemical efficiency properties, where the deposition material is deposited in pores on the surface of the scaffold material. The process is simple, uses only water as a solvent, and is non-destructive to the substrate or scaffold material. The deposition materials form agglomerations with the surface of the scaffold material, which enhance the efficiency of the electrode.

Problems solved by technology

As a randomly aggregated electrode material, these powders require some form of structural support which may interfere with the mass transport of reactants.

In addition, amorphous natural carbon with a low degree of graphitization suffers from poor electrical conductivity which is exacerbated by high contact resistance between particles when packed too loosely.

To attain the ideal nanometer scale pore size distribution while maintaining good electrical conductivity, many recent efforts have been made towards the development of carbon nanofoams.4,5 Unfortunately these materials typically suffer from poor mechanical properties such as brittleness and micrometer-sized cracks which skew their overall pore size distribution6.

Other methods of catalyst deposition such as sputtering, chemical and physical vapor deposition are unlikely to be adopted commercially due to their higher cost.

Despite the promise of these nanomaterials, there are challenges to be overcome.

Creating high surface area electrodes with good mass transport characteristics at a low cost is the current challenge in all electrochemical industries.

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