# US 8,541,135 B2 · Current collector for catalytic electrode > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,541,135 B2 - Document ID: US8541135B2 - Status: Granted - Kind: B2 - Application number: 12/791,042 - Filed: 2010-06-01 - Published: 2010-12-02 - Granted: 2013-09-24 - Earliest claimed: 2009-05-29 - Assignees: Eveready Battery Company, Inc. - Applicants: Wayne B. Bennett; Jingdong Guo - Inventors: Wayne B. Bennett; Jingdong Guo - Web page: https://patentgrep.com/patent/US8541135B2 ## CPC - H01M 12/06: with one metallic and one gaseous electrode - H01M 4/8605: {Porous electrodes} - H01M 4/8817: {Treatment of supports before application of the catalytic active composition (coated porous composites H01M8/0245)} - H01M 8/0245: in the form of layered or coated products - H01M 4/661: {Metal or alloys, e.g. alloy coatings (H01M4/669 take precedence)} - H01M 4/663: {containing carbon or carbonaceous materials as conductive part, e.g. graphite, carbon fibres} - H01M 4/8803: {Supports for the deposition of the catalytic active composition (H01M4/90 takes precedence)} - H01M 4/9016: {Oxides, hydroxides or oxygenated metallic salts} - H01M 8/083: Alkaline fuel cells - Y02E 60/10: Energy storage using batteries - Y02E 60/50: Fuel cells - Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product - 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 - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract The invention is an electrochemical cell with a catalytic electrode and an aqueous alkaline electrolyte within a cell housing having one or more ports for the passage of a gas to or from the catalytic electrode and a process for making the cell. The catalytic electrode includes a catalytic layer, containing a catalytic material, and a porous current collector, at least partially embedded in the catalytic layer. The current collector includes a substrate with an electrically conductive metal layer, in contact with the catalytic material on the side of the current collector facing the ports, and a coating including electrically conductive particles, in contact with the catalytic layer on the side facing the separator. ## Claims ### Claim 1 An electrochemical cell comprising a catalytic electrode, a counter electrode, a separator disposed between the catalytic electrode and the counter electrode, and an aqueous alkaline electrolyte, all contained within a cell housing having one or more ports for the passage of a gas through the housing to or from the catalytic electrode, wherein: the catalytic electrode comprises a first side facing the separator, a second side opposite the first side and in fluid communication with the one or more ports, a catalytic layer comprising a catalytic material capable of reducing oxygen, and a porous current collector at least partially embedded in the catalytic material; the current collector has a first side corresponding to the first side of the catalytic electrode and a second side corresponding to the second side of the catalytic electrode; and the current collector comprises a substrate with an electrically conductive protective metal surface layer in contact with the catalytic material on one of the first side and the second side and a coating including a binder and electrically conductive particles in contact with the catalytic material on the other of the first side and the second side. ### Claim 2 (depends on 1) The electrochemical cell according to claim 1, wherein the current collector is at least partially embedded in the catalytic material on the first surface of the catalytic electrode. ### Claim 3 (depends on 1) The electrochemical cell according to claim 1, wherein the protective metal surface layer is in contact with the catalytic material on the second side of the current collector and the coating is in contact with the catalytic material on the first side of the current collector. ### Claim 4 (depends on 1) The electrochemical cell according to claim 1, wherein the protective metal surface layer is present on essentially the entire first side and essentially the entire second side of the current collector. ### Claim 5 (depends on 2) The electrochemical cell according to claim 2, wherein the protective metal surface layer is a distinct layer with a different composition than a portion of the substrate beneath the metal surface layer. ### Claim 6 (depends on 1) The electrochemical cell according to claim 1, wherein the protective metal surface layer comprises at least one member of the group consisting of gold, platinum, palladium and silver. ### Claim 7 (depends on 1) The electrochemical cell according to claim 1, wherein the protective metal surface layer comprises gold. ### Claim 8 (depends on 1) The electrochemical cell according to claim 1, wherein the binder comprises a polymeric material. ### Claim 9 (depends on 8) The electrochemical cell according to claim 8, wherein the polymeric material is at least one member of the group consisting of a fluoropolymer and a polyvinyl alcohol. ### Claim 10 (depends on 1) The electrochemical cell according to claim 1, wherein the electrically conductive particles comprise at least one member of the group consisting of carbon particles, gold particles, nickel particles and silver particles. ### Claim 11 (depends on 10) The electrochemical cell according to claim 10, wherein the electrically conductive particles comprise at least one member of the group consisting of graphite particles and carbon black particles. ### Claim 12 (depends on 1) The electrochemical cell according to claim 1, wherein the catalytic material comprises at least one member selected from the group consisting of a manganese oxide, an activated carbon, platinum, palladium, a cobalt oxide, a nickel oxide and an organic macrocyclic compound. ### Claim 13 (depends on 12) The electrochemical cell according to claim 12, wherein the catalytic material comprises at least one member selected from the group consisting of a manganese oxide and an activated carbon. ### Claim 14 (depends on 1) The electrochemical cell according to claim 1, wherein the electrolyte comprises one or both of potassium hydroxide and sodium hydroxide. ### Claim 15 (depends on 1) The electrochemical cell according to claim 1, wherein the catalytic electrode is an oxygen reduction electrode for reducing oxygen from outside the cell housing. ### Claim 16 (depends on 15) The electrochemical cell according to claim 15, wherein the cell is a metal-air cell, the catalytic electrode is a positive electrode, and the counter electrode is a negative electrode comprising a metal as an active material. ### Claim 17 (depends on 16) The electrochemical cell according to claim 16, wherein the active material of the negative electrode comprises zinc or an alloy of zinc. ### Claim 18 (depends on 15) The electrochemical cell according to claim 15, wherein the cell is a fuel cell.