Conductive polymer, conductive polymer compositions and their use

• US 20060247364A1
• Filed: 04/08/2004
• Published: 11/02/2006
• Est. Priority Date: 04/09/2003
• Status: Active Grant

• Current Assignee: Bac2 Limited
• Original Assignee: Bac2 Limited
• Inventors: Campbell, Sheelagh Anne, Gillard, Stephen Paul, Murray, Graham Simpson
• Granted Patent: US 7,655,159 B2
• Time in Patent Office: Days
• US Class Current: 524/495
• CPC Class Codes: C02F 1/46109 Electrodes
• CPC Class Codes: C02F 2001/46128 Bipolar electrodes
• CPC Class Codes: C02F 2001/46133 characterised by the material
• CPC Class Codes: H01G 11/26 characterised by their structure, e.g. multi-layered, porosity or surface features
• CPC Class Codes: H01G 11/48 Conductive polymers
• CPC Class Codes: H01G 11/50 specially adapted for lithium-ion capacitors, e.g. for lithium-doping or for intercalation
• CPC Class Codes: H01G 11/52 Separators
• CPC Class Codes: H01G 11/56 Solid electrolytes, e.g. gels; Additives therein
• CPC Class Codes: H01G 9/02 Diaphragms; Separators
• CPC Class Codes: H01M 4/137 Electrodes based on electro-active polymers
• CPC Class Codes: H01M 4/60 of organic compounds
• CPC Class Codes: H01M 4/622 being polymers
• CPC Class Codes: H01M 4/625 Carbon or graphite
• CPC Class Codes: H01M 4/96 Carbon-based electrodes
• CPC Class Codes: H01M 50/409 Separators, membranes or diaphragms characterised by the material
• CPC Class Codes: H01M 50/46 Separators, membranes or diaphragms characterised by their combination with electrodes
• CPC Class Codes: H01M 8/0206 Metals or alloys
• CPC Class Codes: H01M 8/0213 Gas-impermeable carbon-containing materials
• CPC Class Codes: H01M 8/0221 Organic resins; Organic polymers
• CPC Class Codes: H01M 8/0226 in the form of mixtures
• CPC Class Codes: H01M 8/0232 : Metals or alloys
• CPC Class Codes: H01M 8/0234 : Carbonaceous material
• CPC Class Codes: H01M 8/0239 : Organic resins; Organic polymers
• CPC Class Codes: H01M 8/0243 : in the form of mixtures
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/13 : Energy storage using capacitors
• CPC Class Codes: Y02E 60/50 : Fuel cells

Abstract

The invention provides an electrode, electrolyte and/or a separator plate comprising a conductive material-doped ester-cured alkaline phenolic resole resin containing conducting alkaline salts.

Claims

1. An electrode comprising a conductive material-doped ester-cured alkaline phenolic resole resin containing conducting alkaline salts.

2. An electrode as claimed in claim 1 wherein the resin to conducting material weight ratio is from 0.001 to 100:

1.

3. An electrode as claimed in claim 1 wherein the conducting material comprises carbon and/or a non-carbon conductive filler.

4. An electrode as claimed in claim 3 wherein the carbon is in the form of graphite or an amorphous carbon and/or the non-carbon conductive filler is in the form of a metal, metal oxide, and/or metal-coated graphite and/or glass.

5. An electrode as claimed in claim 1 wherein the resin is a reaction product of an ester curing agent with a phenolic resole and a base.

6. An electrode as claimed in claim 5 wherein the phenolic resole is a reaction product of a phenol-reactive aldehyde with an alkaline compound of formula

7. An electrode as claimed in claim 6 wherein the phenol-reactive aldehyde is a compound of formula

RCHO  

 

(II)

wherein R represents hydrogen atom or a straight or branched chain alkyl group having from 1 to 8 (preferably from 1 to 4, more preferably from 1 to 2, most preferably

     1) carbon atoms;

or a precursor of a compound of formula (II).

8. An electrode as claimed in claim 6 wherein the phenol-reactive aldehyde is reacted with the compound of formula (I) in a ratio of from 1:

1 to 1;

3, preferably from 1;

1.2 to 1;

3, more preferably from 1;

1.5 to 1;

3.

9. An electrode as claimed in claim 5 wherein the ester curing agent is of formula

R³COOR⁴  

 

(III)

wherein R³ represents a hydrogen atom or a straight or branched chain alkyl group containing from 1 to 8 carbon atoms (preferably from 1 to 4, more preferably from 1 to 2 carbon atoms) optionally substituted by a halogen atom; and

R⁴ represents a straight or branched chain alkyl group containing from 1 to 8 carbon atoms (preferably from 1 to 4, more preferably from 1 to 2 carbon atoms) optionally substituted by one or more hydroxy and/or R³COO—

groups, or

a phenyl group optionally substituted by a straight or branched chain optionally unsaturated alkyl group containing from 1 to 8 carbon atoms (preferably from 1 to 4 carbon atoms, more preferably from 1 to 2 carbon atoms) optionally substituted by a hydroxy group, a halogen atom (preferably chlorine), a hydroxy group, and/or a phenyl or benzyl group (optionally substituted by a hydroxy group and/or a straight or branched chain alkyl group containing from 1 to 8 carbon atoms (preferably from 1 to 4 carbon atoms, more preferably from 1 to 2 carbon atoms));

or

R³ represents a chemical bond to R⁴ and R⁴ represents a straight or branched chain alkyl group containing from 2 to 10 carbon atoms (preferably from 2 to 4 carbon atoms).

10. An electrode as claimed in claim 1 wherein the resin includes a plasticiser to increase flexibility of the resin.

17. An electrolyte as claimed in claim 16 wherein the resin is as defined in claim 1.

19. An electrical device as claimed in claim 18 wherein the resin is as defined in claim 1.

11. An electrode substantially as hereinbefore described and/or as illustrated with reference to FIGS. 3 and/or 4 of the drawings.

12. A separator plate suitable for use in a fuel cell having one or more flow field for directing gas flow wherein the plate comprises an ester-cured alkaline phenolic resole resin containing conducting alkaline salts.

13. A separator plate as claimed in claim 12 wherein the resin is as defined in claim 2.

14. A separator plate as claimed in claim 12 or claim 13 which has two flow fields.

20. An electrical device as claimed in claim 18 wherein the separator plate is as defined in claim 12.

15. A separator plate substantially as hereinbefore described and/or as illustrated with reference to FIGS. 4 and/or 5 of the drawings.

16. An electrolyte suitable for use in an electrical device which comprises an ester-cured alkaline phenolic resole resin containing conducting alkaline salts.

18. An electrical device comprising:

(a) a negative electrode;

(b) a positive electrode; and

(c) an electrolyte means; and

optionally

(d) a separator and/or bipolar plate;

wherein one or more electrode, electrolyte and/or separator or bipolar plate comprises an ester-cured alkaline phenolic resole resin containing conducting alkaline salts.

21. An electrical device as claimed in claim 18 which is a cell, a battery including two or more cells, or a capacitor.

22. The electrical device as claimed in claim 18 wherein the electrolyte means is in the form of an electrolyte or it is arranged to receive an electrolyte.

23. The electrical device as claimed in claim 22 wherein the electrolyte means is in the form of a conduit through which an electrolyte could flow during operation of the cell or in the form of a container into which an electrolyte could be placed at least during operation of the cell.

24. (canceled)

25. (canceled)

26. (canceled)

27. (canceled)

28. (canceled)

29. (canceled)

30. (canceled)

31. (canceled)

32. (canceled)

33. (canceled)

34. (canceled)