High surface area electrode structures for electrochemical processes

Abstract

A porous, high surface area electrode comprising a fine fibrous conductive substrate having a density less than about 50% and a specific surface area to volume ratio of greater than about 30 cm.sup.2 /cm.sup.3. The individual fibers of the substrate have a length to diameter aspect ratio greater than 1000:1. An electrocatalyst covers at least a portion of the substrate. A current distributor is electrically connected to the coated substrate. The method of fabricating the electrode includes fabricating a fine fibrous conductive substrate, preparing the surface of the substrate for receiving an electrocatalyst covering thereon, preparing the electrocatalyst for application to the substrate and applying the electrocatalyst to the substrate. Optionally, the electrode may be further treated to promote adhesion of the electrocatalyst to the substrate.

Dependencies are inferred from the claim text.