# US 2020/0286643 A1 · Thermoplastic carbon composite electrodes > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2020/0286643 A1 - Document ID: US20200286643A1 - Status: Published application - Kind: A1 - Application number: 16/881,824 - Filed: 2020-05-22 - Published: 2020-09-10 - Earliest claimed: 2017-02-07 - Assignees: Colorado State University Research Foundation - Applicants: Colorado State University Research Foundation - Inventors: Charles S. Henry; Kevin Klunder - Web page: https://patentgrep.com/patent/US20200286643A1 ## CPC - H01B 1/24: the conductive material comprising carbon-silicon compounds, carbon or silicon - B82Y 30/00: Nanotechnology for materials or surface science, e.g. nanocomposites - B82Y 40/00: Manufacture or treatment of nanostructures - C08K 3/041: {Carbon nanotubes} - C08K 3/042: {Graphene or derivatives, e.g. graphene oxides} - C08K 3/38: Boron-containing compounds - C08L 33/12: Homopolymers or copolymers of methyl methacrylate - H01B 13/0036: {Details} - H01G 11/32: Carbon-based - H01G 11/38: Carbon pastes or blends; Binders or additives therein - H01M 4/0404: {by coating on electrode collectors} - H01M 4/0414: {by screen printing} - H01M 4/133: Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx - H01M 4/1393: of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx - H01M 4/583: Carbonaceous material, e.g. graphite-intercalation compounds or CFx - H01M 4/621: {Binders} - H01M 4/622: {being polymers} - H01M 4/625: {Carbon or graphite} - H01M 4/886: {Powder spraying, e.g. wet or dry powder spraying, plasma spraying} - H01M 4/96: Carbon-based electrodes - C08K 2201/001: Conductive additives - C08K 2201/003: Additives being defined by their diameter - C08K 2201/005: Additives being defined by their particle size in general - C08L 25/06: Polystyrene - C08L 55/02: ABS [Acrylonitrile-Butadiene-Styrene] polymers - Y02E 60/10: Energy storage using batteries - Y02E 60/50: Fuel cells - Y10S 977/753: with polymeric or organic binder - H01B: CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES (selection for magnetic properties H01F1/00; waveguides H01P {; printed circuits H05K}) - B82Y: SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES - C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09) - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) - H01G: CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE (selection of specified materials as dielectric H01B3/00; capacitors having potential barriers H10D1/62, H10K10/10) - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION - Y10S: TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS ## Abstract A new solvent-based method is presented for making low-cost composite graphite electrodes containing a thermoplastic binder. The electrodes, termed thermoplastic electrodes (TPEs), are easy to fabricate and pattern, give excellent electrochemical performance, and have high conductivity (1500 S m−1). The thermoplastic binder enables the electrodes to be hot embossed, molded, templated, and/or cut with a CO2 laser into a variety of intricate patterns. These electrodes show a marked improvement in peak current, peak separation, and resistance to charge transfer over traditional carbon electrodes. The impact of electrode composition, surface treatment (sanding, polishing, plasma treatment), and graphite source were found to impact fabrication, patterning, conductivity, and electrochemical performance. Under optimized conditions, electrodes generated responses similar to more expensive and difficult to fabricate graphene and highly oriented pyrolytic graphite electrodes. These TPE electrodes provide an approach for fabricating high-performance carbon electrodes with applications ranging from sensing to batteries. ## Claims ### Claim 1 A method of preparing a thermoplastic electrode comprising: a) dissolving a thermoplastic binder in a solvent to form a solution; b) combining a carbon allotrope and the solution to form a thermoplastic mixture; c) at least partially drying the thermoplastic mixture to form a thermoplastic composite; d) shaping the thermoplastic composite; and e) etching the thermoplastic binder at the surface of thermoplastic composite, thereby at least partially exposing the carbon allotrope; wherein the thermoplastic composite is in electrical contact with an electrical conductor to form a thermoplastic electrode having an active surface and a surface roughness of about 0.1 μm to about 5 μm. ### Claim 2 (depends on 1) The method of claim 1 wherein the thermoplastic binder comprises poly(methyl methacrylate), poly-caprolactone, polyethylene, polycarbonate, polylactic acid, polyamide, polyimide, acrylonitrile butadiene styrene, polybenzimidazole, polypropylene, polystyrene, polyvinyl chloride, polyphenylene sulfide, polyphenylene oxide, polyether sulfone, polyoxymethylene, polyetherether ketone, polyetherimide, polyurethanes, polyolefin, ionic liquids, or a combination thereof. ### Claim 3 (depends on 2) The method of claim 2 wherein the carbon allotrope comprises graphite, expanded graphite, graphite oxide, graphene, boron doped diamond, graphene oxide, glassy carbon, vitreous carbon, carbon nanotubes, carbon black, carbon fiber, fullerenes, or a combination thereof. ### Claim 4 (depends on 3) The method of claim 3 wherein the carbon allotrope comprises graphite, and the graphite has a particle diameter of about 0.1 μm to about 300 μm. ### Claim 5 (depends on 3) The method of claim 3 wherein a mass ratio of binder:graphite is about 1:0.5 to about 1:6. ### Claim 6 (depends on 2) The method of claim 2 wherein the thermoplastic composite is viscous or has gum-like consistency. ### Claim 7 (depends on 1) The method of claim 1 wherein shaping comprises molding, cutting, embossing, sanding, or a combination thereof. ### Claim 8 (depends on 1) The method of claim 1 wherein shaping is performed at about the glass transition temperature (Tg) of the thermoplastic composite, about less than 20° C. below Tg, or about less than 20° C. above Tg. ### Claim 9 (depends on 1) The method of claim 1 wherein the shaping comprises applying pressure to the thermoplastic composite, wherein a gasket is between a surface of the thermoplastic composite and a surface applying the pressure. ### Claim 10 (depends on 1) The method of claim 1 wherein the solvent comprises lower alkyl halogenated alkanes, lower alkyl ketones, lower alkyl ethers, lower alkyl esters, lower alkyl alcohols, lower alkyl amides, lower alkyl sulfoxides, toluene, xylene, or a combination thereof. ### Claim 11 (depends on 1) The method of claim 1 wherein etching is performed by sanding, polishing, plasma exposure, laser, sonication, electrochemical conditioning, solvent wiping, or a combination thereof. ### Claim 12 (depends on 11) The method of claim 11 wherein the thermoplastic electrode is characterized by a peak separation that is approximately Nernstian, or the thermoplastic electrode is characterized by a kinetic charge transfer value of about 0.1 ohm cm2 to about 4 ohm cm2. ### Claim 13 (depends on 1) The method of claim 1 wherein the thermoplastic electrode has a conductivity of about 10-fold to about 1500-fold higher than a screen-printed carbon electrode, or the thermoplastic electrode has a conductivity of about 100 S m−1 to about 5000 S m−1. ### Claim 14 (depends on 1) The method of claim 1 wherein the thermoplastic composite comprises a catalyst. ### Claim 15 (depends on 14) The method of claim 14 wherein the catalyst is a metal, metal oxide, metal coordination complex, alloy, enzyme, or organic molecule. ### Claim 16 (depends on 1) The method of claim 1 wherein the thermoplastic composite has negligible porosity. ### Claim 17 (depends on 1) The method of claim 1 wherein shaping the thermoplastic composite comprises a substrate that has a 2-dimensional pattern, a 3-dimensional pattern, or a combination thereof. ### Claim 18 (depends on 1) The method of claim 1 wherein the thermoplastic composite is shaped to have a pattern diameter or width of about 0.1 μm to about 500 μm. ### Claim 19 A method of preparing a thermoplastic electrode comprising: a) dissolving a poly(methyl methacrylate) binder in a solvent to form a solution; b) combining a carbon allotrope and the solution to form a thermoplastic mixture; c) at least partially drying the thermoplastic mixture to form a thermoplastic composite; d) shaping the thermoplastic composite into a pattern having a pattern diameter or width of about 0.1 μm to about 500 μm; and e) etching the thermoplastic binder at the surface of thermoplastic composite, thereby at least partially exposing the carbon allotrope; wherein the thermoplastic composite is in electrical contact with an electrical conductor to form a thermoplastic electrode having an active surface and a surface roughness of less than 5 μm. ### Claim 20 (depends on 19) The method of claim 19 wherein a mass ratio of binder:allotrope is about 1:0.5 to about 1:6. ### Claim 21 (depends on 19) The method of claim 19 wherein the carbon allotrope has a particle diameter of about 0.1 μm to about 300 μm.