Methods for forming magnetically modified electrodes and articles produced thereby

• US 20030232223A1
• Filed: 02/03/2003
• Published: 12/18/2003
• Est. Priority Date: 08/25/1994
• Status: Active Grant

• Current Assignee: University of Iowa Research Foundation
• Original Assignee: University of Iowa Research Foundation
• Inventors: Leddy, Johna, Zou, Pengcheng
• Granted Patent: US 7,709,115 B2
• Time in Patent Office: Days
• US Class Current: 429/10
• CPC Class Codes: B01D 39/04 Organic material, e.g. cellulose, cotton
• CPC Class Codes: B01D 39/06 Inorganic material, e.g. asbestos fibres, glass beads or fibres
• CPC Class Codes: B03C 1/01 by addition of magnetic adjuvants
• CPC Class Codes: B03C 1/02 acting directly on the substance being separated
• CPC Class Codes: B82Y 25/00 Nanomagnetism, e.g. magnetoimpedance, anisotropic magnetoresistance, giant magnetoresistance or tunneling magnetoresistance
• CPC Class Codes: C23C 30/00 Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process C23C26/00, C23C28/00 take precedence
• CPC Class Codes: C25B 11/00 Electrodes; Manufacture thereof not otherwise provided for
• CPC Class Codes: H01M 4/86 Inert electrodes with catalytic activity, e.g. for fuel cells
• CPC Class Codes: H01M 4/8605 Porous electrodes
• CPC Class Codes: H01M 8/00 Fuel cells; Manufacture thereof
• CPC Class Codes: H01M 8/1004 characterised by membrane-electrode assemblies [MEA] H01M8/12 takes precedence
• CPC Class Codes: H04W 84/08 Trunked mobile radio systems
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

The present invention is directed to methods for making magnetically modified electrodes and electrodes made according to the method. Such electrode are useful as electrodes in batteries, such as Ni-MH batteries, Ni—Cd batteries, Ni—Zn batteries and Ni—Fe batteries.

Claims

1. A method for forming a magnetically modified electrode, which comprises:

providing a substrate comprising a magnetic material; and

forming a coating layer on said substrate, wherein said coating layer comprises particles capable of generating electrochemical energy in the presence of a magnetic field.

2. The method according to claim 1, wherein said substrate comprises a member selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron and combinations thereof.

3. The method according to 1, wherein said particles capable of generating electrochemical energy in the presence of a magnetic field are selected from the group consisting of nickel hydroxide, zinc hydroxide, cobalt oxide, manganese oxide, lithium, lithium hydroxide and combinations thereof.

4. The method according to claim 1, wherein said forming a coating layer comprises:

preparing a mixture comprising particles capable of generating electrochemical energy in the presence of a magnetic field, a solvent and, optionally, a binder; and

applying said mixture to at least a portion of said substrate; and

, optionally, drying said mixture for a time effective to remove at least a portion of said solvent therefrom.

5. The method according to claim 4, wherein said mixture is applied by spray coating, spin coating, painting, drop depositing, decal transfer, laminating or rolling.

6. The method according to claim 4, wherein said solvent is selected from the group consisting of water, ethanol, methanol, benzene, toluene and combinations thereof.

7. The method according to claim 4, wherein said solvent is water.

8. The method according to claim 4, wherein said mixture comprises a binder.

9. The method according to claim 8, wherein said binder is selected from the group consisting of polymers, KOH, NaOH, LiOH, fatty acids, liposomes and combinations thereof.

10. The method according to claim 8, wherein said binder comprises a polymer.

11. The method according to claim 10, wherein said polymer is selected from the group consisting of hydroxypropyl methylcellulose, carboxymethyl cellulose, hydroxy methylcellulose, methyl cellulose and combinations thereof.

12. The method according to claim 1, wherein said coating layer further comprises magnetic particles.

13. The method according to claim 10, wherein said magnetic particles comprise a member selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron and combinations thereof.

14. The method according to claim 1, further comprising coating at least a portion of said magnetic particles with an inert material prior to forming said coating layer.

15. The method according to claim 14, wherein said inert material is selected from the group consisting of silanes, polystyrene and combinations thereof.

16. A method for forming a magnetically modified electrode, which comprises:

providing a substrate; and

forming a coating layer on said substrate, wherein said coating layer comprises particles capable of generating electrochemical energy in the presence of a magnetic field and magnetic particles.

17. The method according to claim 16, wherein said substrate comprises a member selected from the group consisting of metals, carbon, zinc, semiconductors, semimetals, magnetic materials and combinations thereof.

18. The method according to claim 16, wherein said substrate comprises nickel.

19. The method according to claim 16, wherein said particles capable of generating electrochemical energy in the presence of a magnetic field are selected from the group consisting of nickel hydroxide, zinc hydroxide, cobalt oxide, manganese oxide, lithium, lithium hydroxide and combinations thereof.

20. The method according to claim 16, wherein said magnetic particles are selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron or combinations thereof.

21. The method according to claim 19, wherein said magnetic particles are selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron or combinations thereof.

22. The method according to claim 16, wherein said forming a coating layer comprises:

preparing a mixture comprising particles capable of generating electrochemical energy in the presence of a magnetic field, a solvent and, optionally, a binder; and

applying said mixture to at least a portion of said substrate; and

, optionally, drying said mixture for a time effective to remove at least a portion of said solvent therefrom.

23. The method according to claim 22, wherein said mixture is applied by spray coating, spin coating, painting, drop depositing, decal transfer, laminating or rolling.

24. The method according to claim 22, wherein said solvent is selected from the group consisting of water, ethanol, methanol, benzene, toluene and combinations thereof.

25. The method according to claim 22, wherein said solvent is water.

26. The method according to claim 22, wherein said mixture comprises a binder.

27. The method according to claim 26, wherein said binder is selected from the group consisting of polymers, KOH, NaOH, LiOH, fatty acids, liposomes and combinations thereof.

28. The method according to claim 26, wherein said binder comprises a polymer.

29. The method according to claim 28, wherein said polymer is selected from the group consisting of hydroxypropyl methylcellulose, carboxymethyl cellulose, hydroxy methylcellulose, methyl cellulose and combinations thereof.

30. The method according to claim 16, further comprising coating at least a portion of said magnetic particles with an inert material prior to forming said coating layer.

31. The method according to claim 30, wherein said inert material is selected from the group consisting of silanes, polystyrene and combinations thereof.

32. A method for forming a magnetically modified electrode, which comprises:

providing a substrate; and

forming a coating layer comprising particles capable of generating electrochemical energy in the presence of a magnetic field on said substrate, wherein said method further comprises subjecting said particles to an external magnetic field before, during or after forming said coating layer.

33. The method according to claim 32, wherein said external magnetic field has a field strength of from about 0.1 T to about 2.0 T.

34. The method according to claim 32, wherein said external magnetic field has a field strength of about 0.2 T.

35. The method according to claim 32, wherein said particles capable of generating electrochemical energy in the presence of a magnetic field are subjected to an external magnetic field before forming said coating layer.

36. The method according to claim 32, wherein said particles capable of generating electrochemical energy in the presence of a magnetic field are subjected to an external magnetic field after forming said coating layer.

37. The method according to claim 32, wherein said substrate comprises a member selected from the group consisting of metals, carbon, zinc, semiconductors, semimetals, magnetic materials and combinations thereof

38. The method according to claim 32, wherein said substrate comprises nickel.

39. The method according to claim 32, wherein said particles capable of generating electrochemical energy in the presence of a magnetic field are selected from the group consisting of nickel hydroxide, zinc hydroxide, cobalt oxide, manganese oxide, lithium, lithium hydroxide and combinations thereof.

40. The met hod according t o claim 32, wherein said forming a coating layer comprises:

preparing a mixture comprising said capable of generating electrochemical energy in the presence of a magnetic field, a solvent and, optionally, a binder; and

applying said mixture to at least a portion of said substrate; and

, optionally, drying said mixture for a time effective to remove at least a portion of said solvent therefrom.

41. The method according to claim 40, further comprising subjecting said particles capable of generating electrochemical energy in the presence of a magnetic field to an external magnetic during at least a portion of one of said preparing, applying or drying.

42. The method according to claim 40, wherein said mixture is applied by spray coating, spin coating, painting, drop depositing, decal transfer, laminating or rolling.

43. The method according to claim 40, wherein said solvent is selected from the group consisting of water, ethanol, methanol, benzene, toluene and combinations thereof.

44. The method according to claim 40, wherein said solvent is water.

45. The method according to claim 40, wherein said mixture comprises a binder.

46. The method according to claim 45, wherein said binder is selected from the group consisting of polymers, KOH, NaOH, LiOH, fatty acids, liposomes and combinations thereof.

47. The method according to claim 45, wherein said binder comprises a polymer.

48. The method according to claim 47, wherein said polymer is selected from the group consisting of hydroxypropyl methylcellulose, carboxymethyl cellulose, hydroxy methylcellulose, methyl cellulose and combinations thereof.

49. The method according to claim 32, wherein coating layer further comprises magnetic particles.

50. The method according to claim 49, wherein magnetic particles are selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron or combinations thereof.

51. The method according to claim 32, further comprising coating at least a portion of said magnetic particles with an inert material prior to forming said coating layer.

52. The method according to claim 51, wherein said inert material is selected from the group consisting of silanes, polystyrene and combinations thereof.

53. A magnetically modified electrode, which comprises:

a substrate and a coating layer formed on said substrate, wherein said coating layer comprises particles capable of generating electrochemical energy in the presence of a magnetic field and magnetic particles.

54. The magnetically modified electrode according to claim 53, wherein said substrate comprises a member selected from the group consisting of metals, carbon, zinc, semiconductors, semimetals, magnetic materials and combinations thereof.

55. The magnetically modified electrode according to claim 53, wherein said substrate comprises nickel.

56. The magnetically modified electrode according to claim 53, wherein said particles capable of generating electrochemical energy in the presence of a magnetic field are selected from the group consisting of nickel hydroxide, zinc hydroxide, cobalt oxide, manganese oxide, lithium, lithium hydroxide and combinations thereof.

57. The magnetically modified electrode according to claim 53, wherein said magnetic particles are selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron or combinations thereof.

58. The magnetically modified electrode according to claim 56, wherein said magnetic particles are selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron or combinations thereof.

59. The magnetically modified electrode according to claim 58, wherein said substrate comprises a member selected from the group consisting of metals, carbon, zinc, semiconductors, semimetals, magnetic materials and combinations thereof.

60. The magnetically modified electrode according to claim 53, wherein said coating layer further comprises a binder.

61. The magnetically modified electrode according to claim 60, wherein said binder is selected from the group consisting of polymers, KOH, NaOH, LiOH, fatty acids, liposomes and combinations thereof.

62. The magnetically modified electrode according to claim 60, wherein said binder is selected from the group consisting of hydroxypropyl methylcellulose, carboxymethyl cellulose, hydroxy methylcellulose, methyl cellulose and combinations thereof.

63. The magnetically modified electrode according to claim 53, wherein at least a portion of said magnetic particles comprises a coating of an inert material.

64. The method according to claim 63, wherein said inert material is selected from the group consisting of silanes, polystyrene and combinations thereof.

65. A battery comprising a magnetically modified electrode according to claim 53.

66. A battery according to claim 65, wherein said battery is a Ni-MH battery, a Ni—

Cd battery, a Ni—

Zn battery or a Ni—

Fe battery.

67. A Ni-MH battery comprising an electrode according to claim 53.

75. The magnetically modified electrode according to claim 63, wherein said coating layer further comprises a binder.

76. The magnetically modified electrode according to claim 75, wherein said binder is selected from the group consisting of polymers, polymers, KOH, NaOH, LiOH, fatty acids, liposomes and combinations thereof.

77. The magnetically modified electrode according to claim 75, wherein said binder is selected from the group consisting of hydroxypropyl methylcellulose, carboxymethyl cellulose, hydroxy methylcellulose, methyl cellulose and combinations thereof.

78. A battery comprising a magnetically modified electrode according to claim 58.

79. A battery according to claim 78, wherein said battery is a Ni-MH battery, a Ni—

Cd battery, a Ni—

Zn battery or a Ni—

Fe battery.

68. A magnetically modified electrode, which comprises:

a magnetic substrate and a coating layer formed on said substrate, wherein said coating layer comprises particles capable of generating electrochemical energy in the presence of a magnetic field.

69. The magnetically modified electrode according to claim 68, wherein said substrate comprises a member selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron and combinations thereof.

70. The magnetically modified electrode according to claim 68, wherein said particles capable of generating electrochemical energy in the presence of a magnetic field are selected from the group consisting of nickel hydroxide, zinc hydroxide, cobalt oxide, manganese oxide, lithium, lithium hydroxide and combinations thereof

71. The magnetically modified electrode according to claim 68, wherein said coating layer further comprises magnetic particles.

72. The magnetically modified electrode according to claim 74, wherein said magnetic particles are selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron or combinations thereof.

73. The magnetically modified electrode according to claim 71, wherein at least a portion of said magnetic particles comprise a coating of an inert material.

74. The method according to claim 73, wherein said inert material is selected from the group consisting of silanes, polystyrene and combinations thereof.

80. A Ni-MH battery comprising an electrode according to claim 68.

81. A magnetically modified electrode, which comprises:

a substrate and a coating layer formed on said substrate, wherein said coating layer comprises particles capable of generating electrochemical energy in the presence of a magnetic field and further wherein said particles capable of generating electrochemical energy in the presence of a magnetic field are subjected to an external magnetic field before, during or after said coating layer is formed on said substrate.

82. The magnetically modified electrode according to claim 81, wherein said substrate comprises a member selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron and combinations thereof

83. The magnetically modified electrode according to claim 81, wherein said substrate comprises a member selected from the group consisting of nickel, carbon, zinc, semiconductors, semimetals, magnetic materials and combinations thereof.

84. The magnetically modified electrode according to claim 81, wherein said particles capable of generating electrochemical energy in the presence of a magnetic field are selected from the group consisting of nickel hydroxide, zinc hydroxide, cobalt oxide, manganese oxide, lithium, lithium hydroxide and combinations thereof.

85. The magnetically modified electrode according to claim 81, wherein said coating layer further comprises magnetic particles.

86. The magnetically modified electrodes according to claim 85, wherein said magnetic particles are selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodynium-iron-boron and combinations thereof.

87. The magnetically modified electrode according to claim 85, wherein at least a portion of said magnetic particles comprise a coating of an inert material.

88. The method according to claim 87, wherein said inert material is selected from the group consisting of silanes, polystyrene and combinations thereof

89. The magnetically modified electrode according to claim 81, wherein said coating layer further comprises a binder.

90. The magnetically modified electrode according to claim 89, wherein said binder is selected from the group consisting of polymers, KOH, NaOH, LiOH, fatty acids, liposomes and combinations thereof.

91. The magnetically modified electrode according to claim 89, wherein said binder is selected from the group consisting of hydroxypropyl methylcellulose, carboxymethyl cellulose, hydroxy methylcellulose, methyl cellulose and combinations thereof.

92. A battery comprising a magnetically modified electrode according to claim 81.

93. A battery according to claim 92, wherein said battery is a Ni-MH battery, a Ni—

Cd battery, a Ni—

Zn battery or a Ni—

Fe battery.

94. A Ni-MH battery comprising an electrode according to claim 81.