Nanostructural Electrode and Method of Forming the Same
OwnerYevgen Kalynushkin, Peter Novakinventors
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Abstract
An electrode and method of forming the same of the present invention is used for the high-rate deposition of materials, such as carbon, silicon, metals, metal oxides, and the like, onto a metal substrate defined by a metal tape used as cathode or anode combined with a separator to form a fuel cell of a secondary battery, metal-ceramic membranes, film composite metal-ceramaic materials for electronic devices. The method is cost effective and is directed to form the electrode with improved and high porosity.
Claims31
An electrode for a cell for producing electric power comprising;
- a substrate for collecting current, and
- an active layer of said electrode defined by a plurality of first elements with each of said first elements presenting at least one second element being integral with each of said first elements extending outwardly therefrom in a first direction and at least one third element being integral with and extending from each second element in a second direction with said second and third elements being fusible connected to one another thereby forming a porous structure of said active layer.
A cell for producing electric power comprising;
- a first electrode and a second electrode formed from a metal substrate for collecting current,
- an electrolyte disposed between said first and second electrodes,
- an active layer of at least one of said first and second electrodes defined by a plurality of granules fusible connected to said metal substrate, said granule presenting at least one of circular and rectangular configuration and a size of 1-15 μm,
- at least one rod being integral with each of said granules extending outwardly therefrom in a first direction outwardly from said metal substrate wherein said rod presents a circular cross-section wherein said rod presents a diameter of at least 250 and up to 2000 nm and the length of said rod is at least 1.5 and up to 5.0 times longer than the diameter of said rod,
- at least one fiber being integral with and extending from each rod in a second direction generally perpendicular to said first direction of said rods wherein said fiber presents a circular cross section wherein said fiber includes a diameter of at least 5 nm and up to 100 nm and the length of said fiber is at least 1.2 and up to 15.0 times longer than the diameter of said fiber,
- said fibers have a laminar constitution with predominant orientation of lamellas perpendicularly to the axis of said fiber and having a spiral morphology, and
- said fibers of each of said rods being fusible connected to one another thereby forming a porous structure of said active layer wherein said rods and said fibers form a grid of a three dimensional configuration to define pores therebetween thereby forming said porosity of said active layer ranging from 0% at a metal tape for collecting current to up to 80% as said active layer extends further away from said metal tape.
A method of forming at least one electrode for cell to collect electric current and an electrolyte disposed therebetween, said method comprising the steps of:
- moving a metal tape of the electrodes;
- forming an aerosol drops from liquid carbonic material under pressure;
- partially solidifying the aerosol drops by forming of a crust surrounding a liquid core of each aerosol drop;
- and
- forming an active layer of the metal tape of the electrode with the active layer having a plurality of at least two elements being integral with and extending outwardly from one another in different directions with the at least two elements received in response to boiling of the liquid core inside the crust and solidification of the liquid core boiled out of the crust.
Dependencies are inferred from the claim text.