Phase-Inverted Porous Electrodes Without Support Structures
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Solution Overview
Problem
Existing porous electrodes for water electrolysis are brittle, have high internal electrical resistance due to large pores, and require additional supportive structures, making them costly and less efficient.
Innovation Solution
A method for producing self-standing porous electrodes comprising a polymeric binder material and electrochemically active particles, achieved by preparing a slurry, shaping it into a green body, and subjecting it to phase inversion, which eliminates the need for additional supportive structures and reduces complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If porous electrodes are produced using conventional methods with large pores, then porosity is improved for mass transport, but internal electrical resistance increases and mechanical strength decreases
Solution Approach 1:
The patent employs porous silicon particles as the electrochemically active material, creating an intrinsically porous structure that provides both high porosity for mass transport and sufficient mechanical strength. The porous structure eliminates the need for additional supportive compounds while maintaining electrical conductivity and structural integrity during electrolysis operations.
2Length of moving object
If porous electrodes are produced using conventional methods, then porosity is improved, but additional supportive structures are required increasing device complexity
Solution Approach 1:
The porous silicon particles serve as both the electrochemically active material and the structural support simultaneously. The particles' inherent porosity and mechanical strength eliminate the need for separate supportive compounds or structures, simplifying the electrode design and reducing device complexity while maintaining functionality.
3Length of moving object
If porous electrodes are produced using conventional methods with large pores, then porosity is improved, but mechanical strength decreases making electrodes brittle
Solution Approach 1:
The use of porous silicon particles with controlled pore structures provides both the necessary porosity for mass transport and sufficient mechanical strength to prevent brittleness. The porous structure is optimized to maintain structural integrity while enabling efficient electrolyte penetration and gas transport during operation.
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 resulting porous electrodes are flexible, have improved electrochemical performance and efficiency, and exhibit enhanced mass transport and ionic diffusion, leading to increased durability and reduced production costs.
Implementation Method 1
shaping it into a green body, and subjecting it to phase inversion
Data Source
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AI summary
The present invention relates to a method (1) for producing a porous electrode comprising: preparing (2) a slurry comprising a solvent, between 1 % and 25 % by weight of a polymeric binder material and between 10 % and 80 % by weight of particles comprising an electrochemically active material, based on the total weight of the slurry, wherein the polymeric binder material is at least partially dissolved in the solvent; shaping (3) the slurry, thereby obtaining a green body; subjecting the green body to phase inversion (4), thereby forming the porous electrode, which comprises a porous matrix and the particles comprising the electrochemically active material, wherein the porous matrix comprises the polymeric binder material; wherein the weight ratio of the polymeric binder material to the particles in the slurry is between 2:98 and 50:50, and a total amount of the polymeric binder material and the particles in the slurry is between 32 % and 80 % by weight, based on the total weight of the slurry. The invention further relates to a porous electrode comprising a porous matrix comprising a polymeric binder material, and particles comprising an electrochemically active material.