Aqueous electrode binder and electrodes and fuel cells including same
AssigneeGenCell Corporation
InventorsDavid A. Schoonmaker, Jeffrey P. Allen, Randolph M. Bernard
Life of this patent
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Abstract
An aqueous binder for making an electrode is provided. The aqueous binder includes water, a polymeric alcohol, a non-polymeric alcohol, a water-soluble resin, a drying moderator, and optionally an anti-foaming agent. The aqueous binder typically includes mostly water such that minimal toxic substances are evolved when the aqueous binder is used to produce electrodes. Electrodes and fuel cells assembled using the aqueous binder are also described.
Claims72
An aqueous binder for making an electrode, the aqueous binder comprising:
- a polymeric alcohol;
- a non-polymeric alcohol;
- a water-soluble resin;
- a drying moderator;
- and
- water.
An electrode slurry comprising:
- an aqueous binder comprising a polymeric alcohol, a non-polymeric alcohol, a water-soluble resin, a drying moderator, and water;
- and
- at least one metal admixed with the aqueous binder.
A method of producing an aqueous binder for making an electrode, the method comprising
- forming a first solution by combining water with at least one polymeric alcohol;
- forming a second solution by combining at least one non-polymeric alcohol with at least one water-soluble resin;
- and
- forming a slurry by combining the first and second solutions with a drying moderator and water.
A method of manufacturing an electrode slurry, the method comprising
- forming an aqueous binder by:
- combining water, at least one polymeric alcohol, at least one non-polymeric alcohol, at least one water-soluble resin, and a drying moderator,
- combining the aqueous binder with at least one metal to the slurry to form the electrode slurry.
A method of manufacturing an electrode, the method comprising:
- combining an aqueous binder and at least one metal to form an electrode slurry, the aqueous binder comprising water, at least one polymeric alcohol, at least one non-polymeric alcohol, at least one water-soluble resin, and a drying moderator;
- casting an electrode by transferring the electrode slurry to a casting device;
- and
- drying the cast electrode.
A fuel cell comprising:
- an anode electrode;
- an electrolyte in communication with the anode;
- a cathode electrode in communication with the electrolyte wherein at least one of the anode electrode and the cathode electrode is produced by
- forming an electrode slurry by combining an aqueous binder and at least one metal, the aqueous binder comprising water, at least one polymeric alcohol, at least one non-polymeric alcohol, at least one water-soluble resin, and a drying moderator;
- forming an electrode by transferring the electrode slurry to a casting device;
- and
- drying the cast electrode.
A method of making a fuel cell, the method comprising:
- providing an anode electrode, an electrolyte and a cathode electrode, at least one of the anode electrode and the cathode electrode produced by:
- combining an aqueous binder and at least one metal to form an electrode slurry, the aqueous binder comprising water, at least one polymeric alcohol, at least one non-polymeric alcohol, at least one water-soluble resin, and a drying moderator,
- casting an electrode by transferring the electrode slurry to a casting device to form a cast electrode, and
- drying the cast electrode;
- and
- heating the fuel cell to a suitable temperature to combust substantially and to vaporize substantially the anti-foaming agent, the polymeric alcohol, the non-polymeric alcohol, the water-soluble resin and the drying moderator of the cast cathode electrode.
Dependencies are inferred from the claim text.