# US 2013/0280415 A1 · Vacuum chamber method to form polymer coatings on porous support

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- Number: US 2013/0280415 A1
- Document ID: US20130280415A1
- Status: Published application
- Kind: A1
- Application number: 13/996,721
- Filed: 2010-12-31
- Published: 2013-10-24
- Earliest claimed: 2010-12-31
- Assignees: General Electric Company
- Inventors: John Barber; Hai Yang; Su Lu; Russell James MacDonald; Zhigang Deng; Xin Gao
- Web page: https://patentgrep.com/patent/US20130280415A1

## CPC

- H01M 4/0402: {Methods of deposition of the material}
- C02F 1/4695: {electrodeionisation}
- H01M 4/8657: {layered}
- H01M 4/8892: {Impregnation or coating of the catalyst layer, e.g. by an ionomer}
- H01M 4/96: Carbon-based electrodes
- B05D 1/32: using means for protecting parts of a surface not to be coated, e.g. using stencils, resists
- B05D 5/12: to obtain a coating with specific electrical properties
- C02F 1/4693: {electrodialysis}
- C02F 2001/46128: {Bipolar electrodes}
- C23C 18/06: Coating on selected surface areas, e.g. using masks
- H01M 2004/8694: {Bipolar electrodes}
- Y02E 60/10: Energy storage using batteries
- Y02E 60/50: Fuel cells
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- C02F: TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE (separation in general B01D; special arrangements on waterborne vessels of installations for treating water, waste water or sewage, e.g. for producing fresh water, B63J; adding materials to water to prevent corrosion C23F; treating radioactively-contaminated liquids G21F9/04; regeneration of reactants for recirculation into processes, see the relevant places for the processes)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A bi-polar electrode having ion exchange polymers on opposite faces of a porous substrate is formed using a method that includes providing an electrode substrate with activated carbon layers on opposite faces of the electrode substrate, wherein said faces have an outer perimeter band void of the activated carbon layers. Gaskets are placed against the outer perimeter band of the electrode substrate void of activated carbon and the electrode substrate is clamped between two rigid plates to form a first airtight chamber on one side of the electrode substrate and a second airtight chamber on the opposite side of the electrode substrate. A first polymerizable monomer mixture having an anion exchange group is added into the first chamber and a second polymerizable monomer mixture having a cation exchange group is added into the second chamber. The first and second polymerizable monomer mixtures are then polymerized in an oven.

## Claims

### Claim 1

A method of forming a bi-polar electrode having ion exchange polymers on opposite faces of a porous substrate, the method comprising:
providing an electrode substrate with activated carbon layers, said electrode substrate having a first side and a second side, said first side having a first face and said second side having a second face, said first side and second side are opposite;
wherein said first face and said second face each have an outer perimeter band void of the activated carbon layers;
providing a first gasket to the outer perimeter band of the first face, and a second gasket to the outer perimeter band of the second face;
clamping the electrode substrate between two rigid plates to form a first air-tight chamber on the first side of the electrode substrate and a second air-tight chamber on the second side of the electrode substrate;
adding a first polymerizable monomer mixture into the first air-tight chamber, the first polymerizable monomer mixture comprising a polymerizable monomer having an anion exchange group or a group that can be converted to an anion exchange group;
adding a second polymerizable monomer mixture into the second air-tight chamber, the second polymerizable monomer mixture comprising a polymerizable monomer having a cation exchange group or a group that can be converted to the cation exchange group; and
polymerizing the first and second polymerizable monomer mixtures.

### Claim 2 (depends on 1)

The method of claim 1, wherein the first and second polymerizable monomer mixtures are polymerized by thermal polymerization.

### Claim 3 (depends on 2)

The method of claim 2, wherein the first and second polymerizable monomer mixtures are polymerized by placing the electrode substrate into an oven at about 50° C. to about 150° C.

### Claim 4 (depends on 3)

The method of claim 3, wherein the first and second polymerizable monomer mixtures are placed in the oven for about 10-120 minutes.

### Claim 5 (depends on 2)

The method of claim 2, wherein the polymerizable monomer having an anion exchange group or a group that can be converted to an anion exchange group is selected from the group consisting of trimethylammoniumethylmethacrylate chloride, methacryloxypropyltrimethylammonium chloride, vinylbenzyltrimethylammonium chloride, diallyldimethylammonium chloride, and salts and derivatives thereof

### Claim 6 (depends on 2)

The method of claim 2, wherein the polymerizable monomer having a cation exchange group or a group that can be converted to the cation exchange group is selected from the group consisting of sulfoethylmethacrylate, acrylamidomethylpropane sulfonic acid, sodiumstyrenesulfonate, sulfopropylmethacrylate, potassium salt, and salts and derivatives thereof.

### Claim 7 (depends on 1)

The method of claim 1, further comprising inserting a first syringe into the first chamber through the first gasket and a second syringe into the second chamber through the second gasket and adding the first and second polymerizable monomer mixture into the first and second chambers through the first and second syringes, respectively.

### Claim 8 (depends on 1)

The method of claim 1, wherein the first polymerizable monomer mixture is further comprised of a crosslinking agent.

### Claim 9 (depends on 8)

The method of claim 8, wherein said crosslinking agent is a divinyl compound or a latent crosslinking system.

### Claim 10 (depends on 9)

The method of claim 9, wherein the divinyl compound is selected from the group consisting of divinylbenzene, divinylsulfone, butadiene, chloroprene, divinylbiphenyl, trivinylbenzene, divinylnaphthalene, diallylamine, divinylpyridine, ethyleneglycol dimethacrylate, di acrylates, multi acrylates, di methacrylates of polyols, or multi methacrylates of polyols.

### Claim 11 (depends on 9)

The method of claim 9, wherein the latent crosslinking system is selected from the group consisting of hydroymethylacrylamide plus acrylamide or hydroymethylacrylamide plus phenol.

### Claim 12 (depends on 8)

The method of claim 8, wherein the first polymerizable monomer mixture is further comprised of a polymerization initiator.

### Claim 13 (depends on 12)

The method of claim 12, wherein said polymerization initiator is an organic peroxide or an organic azo compound.

### Claim 14 (depends on 13)

The method of claim 13, wherein said polymerization initiator is selected from the group consisting of octanoyl peroxide, lauroyl peroxide, tert-butyl peroxy-2-ethylhexanoate, benzoyl peroxide, tert-butyl peroxyisobutylate, tert-butyl peroxylaurate, tert-hexyl peroxybenzoate, di-tert-butyl peroxide, or azobis isobutyronitrile.

### Claim 15 (depends on 1)

The method of claim 1, wherein the second polymerizable monomer mixture is further comprised of a crosslinking agent.

### Claim 16 (depends on 15)

The method of claim 15, wherein said crosslinking agent is a divinyl compound or a latent crosslinking system.

### Claim 17 (depends on 16)

The method of claim 16, wherein the divinyl compound is selected from the group consisting of divinylbenzene, divinylsulfone, butadiene, chloroprene, divinylbiphenyl, trivinylbenzene, divinylnaphthalene, diallylamine, divinylpyridine, ethyleneglycol dimethacrylate, di acrylates, multi acrylates, di methacrylates of polyols, or multi methacrylates of polyols.

### Claim 18 (depends on 16)

The method of claim 16, wherein the latent crosslinking system is selected from the group consisting of hydroymethylacrylamide plus acrylamide or hydroymethylacrylamide plus phenol.

### Claim 19 (depends on 15)

The method of claim 15, wherein the second polymerizable monomer mixture is further comprised of a polymerization initiator.

### Claim 20 (depends on 19)

The method of claim 19, wherein said polymerization initiator is an organic peroxide or an organic azo compound.