Gas-Diffusion Electrode for Chlor-Alkali Percolating Cells

The patent employs composite materials consisting of a porous conductive polymer matrix combined with metallic catalyst particles (silver, nickel, or their oxides). The polymer provides corrosion resistance and mechanical integrity, while the metallic particles provide electrical conductivity and catalytic activity for oxygen reduction. This composite structure eliminates metal mesh while maintaining necessary electrical and mechanical properties in aggressive alkaline environments.

The patent replaces expensive and corrosion-prone metal meshes with a cost-effective conductive polymer-based electrode structure. The polymer matrix, combined with catalytic particles, provides a durable alternative that resists corrosion without requiring periodic replacement due to degradation, thereby reducing operational costs and metal ion contamination.

The patent merges the functions of the current collector, gas diffusion layer, and catalytic electrode into a single integrated porous conductive polymer structure. The polymer matrix itself provides electrical conductivity pathways, eliminating the need for separate metal mesh current collectors. Catalyst particles are directly embedded within this integrated structure, creating a multifunctional electrode that simplifies assembly and reduces component count.

The porous conductive polymer structure serves multiple functions simultaneously: it acts as the current collector, gas diffusion medium, catalyst support, and structural framework. This multi-functional design eliminates several separate components (metal mesh, porous substrate, catalyst layer) and integrates them into one universal electrode structure, reducing device complexity.

The patent creates a composite material where a conductive polymer matrix (such as polyacetylene, polypyrrole, or polythiophene derivatives) provides both mechanical strength and electrical conductivity. Metallic catalyst particles are dispersed within this polymer matrix, creating a composite that combines the corrosion resistance and mechanical stability of the polymer with the electrical and catalytic properties of the metal particles. This composite structure outperforms pure carbonaceous substrates in mechanical stability while maintaining cost-effectiveness.

The patent modifies the physical and chemical parameters of the polymer matrix through controlled synthesis conditions, cross-linking, and doping to enhance its mechanical strength and electrical conductivity. By adjusting parameters such as polymerization degree, cross-link density, and catalyst particle size and distribution, the material achieves optimal balance between mechanical stability and electrical performance, surpassing conventional carbonaceous substrates.