Process for making a catalytic electrode and electrochemical cell using the electrode

1. A process for making a catalytic electrode for an electrochemical cell, comprising the steps:

(a) mixing a catalytic material for oxidizing or reducing an active material with an electrically conductive material and a binder;

(b) forming the mixture from step (a) into an active layer sheet having a first surface and a second surface opposite the first surface;

(c) disposing a gas diffusion layer sheet having a first surface and a second surface opposite the first surface adjacent to the active layer sheet, with the first surface of the gas diffusion layer sheet against the first surface of the active layer sheet;

(d) forming a bonded sheet by applying pressure to the second surface of the gas diffusion layer sheet via a textured roller or removable interleaf sheet having a woven pattern to bond the gas diffusion layer sheet to the active layer sheet with a pattern of relatively high adhesion areas and relatively low adhesion areas corresponding to the woven pattern of the textured roller or interleaf sheet; wherein the relatively high adhesion areas have lower gas permeability than the relatively low adhesion areas;

(e) forming the bonded sheet into an electrode.

2. The process according to claim 1 , wherein the pressure in step (d) is applied via a textured interleaf sheet that is removed after forming the bonded sheet.

3. The process according to claim 2 , wherein the textured interleaf sheet comprises woven threads, fibers, filaments, hairs, or wires.

4. The process according to claim 3 , wherein the interleaf sheet comprises a woven silk fabric.

5. The process according to claim 1 , wherein the pressure in step (d) is applied via a textured roller with a woven pattern having raised portions 0.03 to 0.1 mm wide, separated by areas 0.15 to 0.25 mm wide.

6. The process according to claim 1 , wherein the pressure is applied by a combination of plates, platens or rollers.

7. The process according to claim 1 , wherein the adhesion of the gas diffusion area to the active layer is characterized by an overall bond strength of from 65 grams per 25.4 mm to 250 grams per 25.4 mm and the catalytic.

8. The process according to claim 1 , wherein the gas diffusion layer sheet comprises a hydrophobic material.

9. The process according to claim 8 , wherein the hydrophobic material comprises a fluorinated polymer.

10. The process according to claim 9 , wherein the gas diffusion layer sheet comprises a polytetrafluoroethylene sheet.

11. The process according to claim 10 , wherein the polytetrafluoroethylene sheet, prior to bonding the gas diffusion layer sheet to the active layer sheet, has an air permeability value of from 1 to 300 seconds and an apparent density of 1.5 to 1.7 g/cm 2 .

12. The process according to claim 1 , wherein the process further comprises the step of incorporating an electrically conductive current collector.

13. The process according to claim 12 , wherein the current collector is made from an expanded metal comprising nickel and has a coating comprising graphite.

14. The process according to claim 12 , wherein the current collector is embedded into the second surface of the active layer sheet.

15. A process for making an electrochemical cell comprising the steps:

(a) providing a catalytic electrode made according to the process according to claim 1 ;

(b) assembling the catalytic electrode with a counter electrode, an electrolyte and a separator, with the separator disposed between the catalytic electrode and the counter electrode, into a housing comprising an anode casing and a cathode casing; and

(c) sealing the cell.

16. The process according to claim 15 , wherein the cell is a metal-air battery cell.

17. The process according to claim 16 , wherein the counter electrode comprises zinc and the electrolyte comprises an aqueous alkaline electrolyte.

18. The process according to claim 15 , wherein the catalytic material comprises a manganese oxide.