High differential pressure electrochemical cell
View Patent ↗An electrochemical cell capable of operating in pressure differentials exceeding about 2,000 psi, using a porous electrode. The porous electrode comprises a catalyst adsorbed on or in a porous support that is disposed in intimate contact and fluid communication with the electrolyte membrane.
1. A method for making a porous electrode, comprising:
sintering a layer of electrically conductive material to form a sintered porous support having a porosity of greater than about 10%, wherein said electrically conductive material is cobalt, zirconium, hafnium, niobium, tungsten, carbon, or mixtures or alloys thereof; and
infiltrating said sintered porous support with a catalyst.
2. A method for making a porous electrode as in claim 1 , wherein the porous electrode has a mean pore size of about 2 to about 13 microns.
3. A method for making a porous electrode as in claim 1 , wherein said sintered porous support has a porosity greater than about 40%.
4. A method for making a porous electrode, comprising:
coating an electrically conductive material with a catalyst, wherein said electrically conductive material is cobalt, zirconium, hafnium, niobium, tungsten, carbon, iron, or mixtures or alloys thereof;
forming a layer of said coated material; and
sintering said layer to form the porous electrode, wherein said porous electrode has a porosity greater than about 20%.
5. A method for making a porous electrode as in claim 4 , wherein said porous electrode has a porosity greater than about 40%.
6. A method for making a porous electrode, comprising:
coating an electrically conductive material with a catalyst;
forming a layer of said coated material; and
sintering said layer to form the porous electrode, wherein said porous electrode has a porosity greater than about 20%; and
wherein said porous electrode has a mean pore size of about 2 to about 13 microns.
7. A method for making a porous electrode, comprising
coating an electrically conductive, porous support with a solution of catalyst precursor; and
converting said catalyst precursor to a catalyst;
wherein said pourous support comprises an electrically conductive material, and wherein said material is cobalt, zirconium, hafnium, niobium, tungsten, carbon, iron, or mixtures or alloys thereof.
8. A method for making a porous electrode as in claim 7 , wherein the electrode has a porosity greater than about 20% by volume.
9. A method for making a porous electrode as in claim 7 , wherein the porous electrode has a mean pore size of about 2 to about 13 microns.
10. A method for making a porous electrode as in claim 7 , wherein said sintered porous support has a porosity greater than about 40% by volume.
11. A method for making a porous electrode as in claim 6 , wherein said material is nickel, cobalt, titanium, zirconium, hafnium, niobium, tungsten, carbon, iron, or mixtures or alloys thereof.
12. A method for making a porous electrode as in claim 11 , wherein said electrically conductive material is cobalt, zirconium, hafnium, niobium, tungsten, carbon, or mixtures or alloys thereof.
13. A method for making a porous electrode as in claim 11 , wherein said material is nickel, titanium, iron, or mixtures or alloys thereof.