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AssigneeUTC Power Corporation
InventorRichard D. Breault
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A method of making an electrochemical cell electrode substrate includes creating an aqueous or dry mixture of chopped carbon fibers, chopped cross-linkable resin fibers that are still fuseable after being formed into a felt, such as novolac, a temporary binder, such as polyvinyl alcohol fiber or powder, forming a non-woven felt from either an aqueous suspension of the aqueous mixture or an air suspension of the dry mixture, by a non-woven, wet-lay or dry-lay, respectively, felt forming process, a resin curing agent, such as hexamethylene tetramine may be included in the aqueous or dry mixture, or it may be coated onto the formed felt; pressing one or more layers of the formed felt for 1-5 minutes to a controlled thickness and a controlled porosity at a temperature at which the resin melts, cross-links and then cures, such as 150° C.-200° C.; and heat treating the pressed felt in a substantially inert atmosphere, first to 750° C.-1000° C. and then to 1000° C.-3000° C.
An electrochemical cell electrode substrate characterized by being formed of fibers of uncured resin and fibers of carbon.
An electrochemical cell electrode substrate including carbon fibers, characterized by resin fibers which have become cured, cross-linked and bind the carbon fibers, and which are partially carbonized.
An electrochemical cell electrode substrate comprising a pressed non-woven felt including carbon fibers;
A method of making an electrochemical cell electrode substrate characterized by:
A method of making an electrochemical cell electrode substrate characterized by:
Dependencies are inferred from the claim text.