Electrode for use in a deionization apparatus and method of making the same

A process for forming an electrode comprising the steps of:

• dissolving at least one polymerization monomer in a first crosslinker to form a first liquor;
• maintaining the first liquor for a sufficient time and at a sufficient temperature until the first liquor forms a partially reacted liquor;
• mixing the partially reacted liquor with a second crosslinker to form a mixed first liquor and maintaining the mixed first liquor for a sufficient time and at a sufficient temperature until the mixed first liquor polymerizes into a first solid blank;
• firing the first solid blank at a sufficient temperature and for a sufficient time such that the first solid blank carbonizes into an electrically conductive member;
• processing the first solid blank, after the first block cools, so as to break up the carbonized blank into a granular carbon material;
• wetting the granular carbon material with a wetting fluid that is a mixture of the first liquor and a wetting solvent;
• mixing the wetted granular carbon material for a time and at a sufficient temperature to sufficiently de-air the granular carbon material;
• adding a second crosslinker to the granular carbon material, solvent and first liquor mixture to form a second mixture;
• maintaining the second mixture at a sufficient temperature and for a sufficient time until the second mixture polymerizes into a second solid blank;
• and
• firing the second solid blank for a sufficient time and at a sufficient temperature such that the second solid blank carbonizes into an electrically conductive substrate.

A process for forming an electrode comprising the steps of:

• wetting a granular conductive carbon material with a first wetting fluid, solvent and first crosslinker and mixing the wetted granular conductive carbon material with an amount of a second crosslinker to form a first mixture;
• maintaining the first mixture for a sufficient time and at a sufficient temperature until the first mixture polymerizes into a block;
• firing the block for a sufficient time and at a sufficient temperature such that the block carbonizes into an electrically conductive substrate;
• securely coupling an electrical connector component in place along a length of the block;
• and
• sealing the electrical connector component.

An electrode for use in a deionization apparatus comprising:

• a polymerization monomer;
• a crosslinker;
• and
• a catalyst;
• and
• or reaction products thereof, together in a carbonized form that is free of a carbon fiber reinforcing agent that is added to a mixture of the polymerization monomer and the crosslinker.

An electrode for use in a deionization apparatus comprising:

• a polymerization monomer;
• a crosslinker;
• and
• a catalyst;
• or reaction products thereof, together in a carbonized form that is formed from a homogenous reinforcement material formed of a granular conductive carbon material that has substantially the same chemical composition as the electrode.

A process for forming an electrode comprising the steps of:

• wetting a granular conductive carbon material with a wetting fluid, solvent, and first crosslinker to form a first mixture;
• mixing the first mixture with a second crosslinker;
• maintaining the first mixture for a sufficient time and at a sufficient temperature until the first mixture polymerizes into a block;
• and
• firing the block for a sufficient time and at a sufficient temperature such that the block carbonizes into an electrically conductive substrate by subjecting the block to infrared energy emitted by an infrared oven.