Electrolysis Electrode with Multi-Layer Coating for Low Overvoltage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrodes for chlorine evolution in brine electrolysis face challenges such as high overvoltage and low durability, with conventional production methods being complex and inefficient, making it difficult to achieve long-term durability with low overvoltage and high industrial productivity.
Innovation Solution
An electrode comprising a first layer of ruthenium oxide, iridium oxide, and titanium oxide on a conductive substrate, with a second layer of a platinum-palladium alloy, where the second layer contains palladium oxide to maintain low overvoltage and enhance durability, is developed, along with a production method involving thermal decomposition of coating films under oxygen.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a coating of palladium oxide or platinum-palladium alloy is formed by thermal decomposition on a titanium substrate, then chlorine overvoltage is reduced and catalytic properties are improved, but durability is low
Solution Approach 1:
The patent applies composite materials by forming a multi-layer coating structure consisting of a first layer containing ruthenium oxide, iridium oxide, and titanium oxide on a titanium substrate, and a second layer containing platinum-palladium alloy on top of the first layer. This composite structure combines the advantages of different materials: the first layer provides stable adhesion and corrosion resistance, while the second layer provides low chlorine overvoltage and high catalytic activity, thereby achieving both low overvoltage and high durability
Solution Approach 2:
The patent segments the coating into two distinct layers with different compositions and functions. The first layer (ruthenium oxide, iridium oxide, titanium oxide) serves as an adhesive and protective layer, while the second layer (platinum-palladium alloy) serves as the catalytic layer. This segmentation allows each layer to be optimized for its specific function, resolving the contradiction between catalytic performance and durability
2Ease of manufacture
If conventional production methods are used for electrodes, then manufacturing is possible, but the number of steps is large and industrial productivity is low
Solution Approach 1:
The patent merges multiple coating steps into a simplified two-layer formation process. By combining ruthenium oxide, iridium oxide, and titanium oxide in the first layer, and platinum-palladium alloy in the second layer, the method reduces the number of separate coating and firing steps compared to conventional methods, thereby improving industrial productivity while maintaining manufacturability
Solution Approach 2:
The patent optimizes the thermal decomposition parameters and coating composition ratios to achieve the desired layer structure in fewer steps. By controlling the firing temperature and atmosphere, the method transforms the coating materials into the desired oxide and alloy phases efficiently, reducing production time and increasing industrial productivity
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
The electrode achieves low overvoltage and high durability, maintaining catalytic activity over a long period, reducing oxygen gas concentration in chlorine gas and decreasing power consumption in brine electrolysis, while ensuring high purity chlorine production and improved industrial productivity.
Implementation Method 1
a first layer formed on a conductive substrate and a second layer formed on the first layer, wherein the first layer contains at least one oxide selected from the group consisting of ruthenium oxide, iridium oxide, and titanium oxide
Implementation Method 2
baking, under presence of oxygen, of a coating film formed through application of a solution containing at least one compound selected from the group consisting of ruthenium compound, iridium compound, and titanium compound onto a conductive substrate to form a first layer
Data Source
AI summary
An electrode for electrolysis includes a conductive substrate, a first layer formed on the conductive substrate, and a second layer formed on the first layer. The first layer contains at least one oxide selected from the group consisting of ruthenium oxide, iridium oxide, and titanium oxide. The second layer contains an alloy of platinum and palladium. The electrode for electrolysis shows low overvoltage and has excellent durability over a long period.