Electrolysis Cathode Preheating for Catalyst Layer Control
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Solution Overview
Problem
In the manufacturing of cathodes for electrolysis, especially in soda electrolysis and other industrial processes, the formation of a cathode catalyst layer on conductive bases with multiple intersection portions leads to excessive catalyst usage and peeling issues due to liquid pooling and nickel layer precipitation, resulting in high costs and reduced durability.
Innovation Solution
A method involving preheating the conductive cathode base to a temperature range of 43°C to 120°C before applying the catalyst layer, which prevents liquid pooling and nickel layer formation by creating mesh-shaped pores with high porosity, reducing the amount of catalyst used and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the application liquid is applied to the conductive cathode base having multiple intersection portions, then the cathode catalyst layer is formed on the base, but excessive liquid pools in the intersection portions causing excessive catalyst usage
Solution Approach 1:
The conductive cathode base is preheated to a specific temperature range (43°C to 120°C) before applying the application liquid. This preliminary heating action prevents liquid pooling by ensuring the liquid evaporates or absorbs properly during application, thereby controlling the catalyst layer thickness and reducing excessive catalyst usage in intersection portions.
Solution Approach 2:
The temperature parameter of the conductive cathode base is changed and controlled within a specific range (43°C to 120°C) during the application process. This parameter change affects the liquid's behavior, preventing pooling and ensuring uniform catalyst distribution, thus resolving the contradiction between catalyst quantity and layer precision.
2Reliability
If the application liquid is applied to form the cathode catalyst layer, then the catalyst component is deposited on the base, but nickel layer precipitates causing the catalyst layer to peel off
Solution Approach 1:
The conductive cathode base is preheated before applying the application liquid. This preliminary action prevents nickel layer precipitation by controlling the evaporation rate and chemical reactions during application, thereby preventing catalyst layer peeling and improving adhesion reliability.
Solution Approach 2:
The temperature parameter is controlled within a specific range (43°C to 120°C) to prevent nickel layer precipitation. By changing and controlling this parameter, the harmful chemical reactions are suppressed, ensuring the catalyst layer adheres properly without peeling.
3Quantity of substance
If the cathode catalyst layer is formed by repeated application and drying, then the desired catalyst amount is achieved, but the process becomes time-consuming and costly
Solution Approach 1:
The conductive cathode base is preheated before application, which accelerates the drying process and reduces the number of repeated applications needed. This preliminary action saves time and reduces manufacturing costs while achieving the desired catalyst amount.
Solution Approach 2:
The temperature parameter is optimized to enhance evaporation and drying efficiency. By controlling the temperature within the specified range, the drying time is reduced, allowing fewer application cycles to achieve the desired catalyst quantity, thus saving time and cost.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively reduces the amount of expensive catalyst materials used while maintaining performance and improving the durability of the cathode, achieving economic efficiency and preventing peeling issues during electrolysis.
Implementation Method 1
the conductive cathode base is heated such that the temperature of the conductive cathode base immediately before the application liquid is applied is in the range of 43°C to 120°C
Implementation Method 2
the application liquid is dried and baked to form a cathode catalyst layer
Data Source
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AI summary
Provided is an economical cathode for electrolysis in which the amount of expensive cathode catalyst component used in a base is effectively reduced, without damaging the performance of the cathode, and an increase in the amount of cathode catalyst consumed due to long-term electrolysis can be prevented. A cathode for electrolysis and a simple method for manufacturing the cathode for electrolysis are provided. The cathode for electrolysis includes a conductive base, which is, for example, a wire mesh, includes a plurality of intersection portions, and is made of nickel and a cathode catalyst layer that includes a catalyst component, such as platinum, and is formed by applying an application liquid to the base and dying and solidifying the application liquid. A solidified portion of a liquid pool of the application liquid is not formed in the intersection portion of the base, or even if the solidified portion is formed, the cross-sectional shape of the solidified portion has mesh-shaped pores and the average porosity of the solidified portion is equal to or greater than 15%. In the method for manufacturing the cathode for electrolysis, the base is preheated to 43°C to 120°C immediately before the application liquid is applied, and thereafter the cathode catalyst layer is formed.