Three-dimensional electrode primer
A three-dimensional dual-carbon interfacial layer using RNG addresses the environmental and cost issues of traditional primers by enhancing electrode performance and reducing emissions, achieving higher energy efficiency and longer cell life.
WO2026107256A1PCT designated stage Publication Date: 2026-05-21ZETA ENERGY CORP
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Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- ZETA ENERGY CORP
- Filing Date
- 2025-11-13
- Publication Date
- 2026-05-21
AI Technical Summary
Technical Problem
Existing electrode primers, such as carbon black, are expensive and environmentally harmful due to the burning of hydrocarbons for production, generating CO2 emissions that are difficult to capture and reuse.
Method used
A three-dimensional dual-carbon interfacial layer is formed using renewable natural gas (RNG) to produce a cost-effective and environmentally friendly primer, comprising a porous carbon nanotube (CNT) carpet and dense carbon sublayer, which enhances adhesion and reduces contact resistance in electrodes.
Benefits of technology
The dual-carbon interfacial layer improves electrode performance by increasing energy efficiency, reducing corrosion, and extending cell life, while minimizing environmental impact through a negative-carbon footprint production process.
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Figure US2025055420_21052026_PF_FP_ABST
Abstract
An electrochemical cell electrode features a conductive current collector coated with a three-dimensional dual-carbon interfacial layer serving as a high-performance, cost-effective, and environmentally sustainable primer. The layer comprises a dense amorphous carbon sublayer (20-500 nm) conformally bonded to the collector and a porous forest of vertically aligned carbon nanotubes (CNTs) (0.1-10 p m thick, > 109 tubes / cm 2 ) grown therefrom via chemical vapor deposition (CVD). A thin iron catalyst (0.5-10 nm) on an aluminum oxide buffer enables simultaneous formation of both carbon structures from acetylene derived from renewable natural gas (RNG) via plasma pyrolysis.
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