# US 11,909,025 B2 · Air electrode assemblies incorporating ion exchange materials > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,909,025 B2 - Document ID: US11909025B2 - Status: Granted - Kind: B2 - Application number: 17/326,227 - Filed: 2021-05-20 - Published: 2021-11-25 - Granted: 2024-02-20 - Earliest claimed: 2020-05-22 - Assignees: Zelos Energy Ltd. - Applicants: Zelos Energy Ltd. - Inventors: Pavel Khokhlov; Alexander Gorer - Web page: https://patentgrep.com/patent/US11909025B2 ## CPC - H01M 12/08: composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type - C25B 1/46: in diaphragm cells - C25B 9/23: comprising ion-exchange membranes in or on which electrode material is embedded - C25B 11/04: characterised by the material - C25B 13/02: characterised by shape or form - H01M 4/38: of elements or alloys - H01M 12/06: with one metallic and one gaseous electrode - H01M 2220/20: Batteries in motive systems, e.g. vehicle, ship, plane - H01M 2300/0068: inorganic - Y02E 60/10: Energy storage using batteries - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - C25B: ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR (anodic or cathodic protection C23F13/00; single-crystal growth C30B) - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract An electrochemical cell includes a first electrode which is an air electrode and a second electrode. An ion transport material can be positioned between and contacting both electrodes. An ion exchange material is arranged to contact the air electrode and the ion transport material. In some embodiments the second electrode can include zinc. ## Claims ### Claim 1 An electrochemical cell, comprising a first electrode comprising an air electrode; a second electrode; an ion transport material positioned between and contacting both the air electrode and the second electrode; a catalyst layer configured to catalyze an electrochemical reaction in a triple phase zone that includes a gaseous phase, a solid phase, and a liquid phase; and an ion exchange material arranged to contact the air electrode and the ion transport material, wherein the ion exchange material is configured to conduct one or more ions associated with the electrochemical reaction, wherein the ion exchange material incorporates a wettability property that results in the ion exchange material being only partly wetted by the liquid phase, and wherein the partial wetting further prevents a flooding of the catalyst layer by the liquid phase. ### Claim 2 (depends on 1) The electrochemical cell of claim 1, wherein the electrochemical cell is a battery cell. ### Claim 3 (depends on 1) The electrochemical cell of claim 1, wherein the electrochemical cell is an electrolyzer cell. ### Claim 4 (depends on 1) The electrochemical cell of claim 1, wherein the air electrode comprises a gas diffusion layer. ### Claim 5 (depends on 1) The electrochemical cell of claim 1, wherein the air electrode comprises a current collector. ### Claim 6 (depends on 1) The electrochemical cell of claim 1, wherein the wettability is defined as a balance between hydrophobicity and hydrophilicity. ### Claim 7 (depends on 1) The electrochemical cell of claim 1, wherein the air electrode comprises a current collector positioned between a gas diffusion layer and an active layer. ### Claim 8 (depends on 1) The electrochemical cell of claim 1, wherein the ion transport material is a liquid electrolyte. ### Claim 9 (depends on 1) The electrochemical cell of claim 1, wherein the ion transport material comprises an ion exchange material. ### Claim 10 (depends on 1) The electrochemical cell of claim 1, wherein the electrochemical cell is a battery cell and the second electrode further comprises a zinc (Zn) containing anode. ### Claim 11 (depends on 1) The electrochemical cell of claim 1, wherein the ion exchange material further comprises a polymeric material. ### Claim 12 (depends on 1) The electrochemical cell of claim 1, wherein the ion exchange material further comprises a polymeric material having attached positively charged functional groups. ### Claim 13 An air electrode, comprising an active layer; a catalyst layer configured to catalyze an electrochemical reaction in a triple phase zone that includes a gaseous phase, a solid phase, and a liquid phase; and an ion exchange material arranged to contact the active layer, wherein the ion exchange material incorporates a wettability property that results in the ion exchange material being only partly wetted by the liquid phase, and wherein the partial wetting further prevents a flooding of the catalyst layer by the liquid phase. ### Claim 14 (depends on 13) The air electrode of claim 13, wherein the air electrode comprises a gas diffusion layer positioned to contact air. ### Claim 15 (depends on 13) The air electrode of claim 13, wherein the air electrode comprises a current collector positioned to contact the active layer. ### Claim 16 (depends on 13) The air electrode of claim 13, wherein the active layer comprises a porous carbon substrate. ### Claim 17 (depends on 13) The air electrode of claim 13, wherein the air electrode comprises a current collector positioned between a gas diffusion layer and an active layer. ### Claim 18 A method of manufacturing an electrochemical cell, comprising providing a first electrode comprising an air electrode; providing a second electrode; arranging an ion exchange material to contact the air electrode, wherein the ion exchange material is configured to conduct one or more ions associated with an electrochemical reaction associated with the electrochemical cell; providing an ion transport material to contact both the ion exchange material of the air electrode and the second electrode; providing a catalyst layer configured to catalyze an electrochemical reaction in a triple phase zone that includes a gaseous phase, a solid phase, and a liquid phase; and incorporating a wettability property into the ion exchange material, wherein the wettability results in the ion exchange material being only partly wetted by the liquid phase, and wherein the partial wetting further prevents a flooding of the catalyst layer by the liquid phase. ### Claim 19 (depends on 1) The electrochemical cell of claim 1, wherein the wettability is determined by a proportion of one or more carbon supports and a polymer binder in the ion exchange material. ### Claim 20 (depends on 13) The air electrode of claim 13, wherein the wettability is determined by a proportion of one or more carbon supports and a polymer binder in the ion exchange material. ### Claim 21 (depends on 18) The method of claim 18, wherein the wettability is determined by a proportion of one or more carbon supports and a polymer binder in the ion exchange material.