Ion exchange system structure with a microtextured surface, method of manufacture, and method of use thereof

• US 6,869,712 B2
• Filed: 03/07/2002
• Issued: 03/22/2005
• Est. Priority Date: 03/07/2002
• Status: Expired due to Term

• Current Assignee: Intelligent Energy Limited (Lb-shell Plc)
• Original Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Inventors: Mittelstadt, Laurie S., Smith, Joshua W.
• Primary Examiner(s): YUAN, DAH WEI D
• Application Number:
  US10/091,485
• Publication Number:
  US 20030170519A1
• Time in Patent Office: 1,111 Days
• Field of Search: 429/30, 429/33, 429/40
• US Class Current: 429/479
• CPC Class Codes: C08J 5/2218 Synthetic macromolecular compounds
• CPC Class Codes: H01M 2300/0082 Organic polymers
• CPC Class Codes: H01M 4/0407 by coating on an electrolyte layer
• CPC Class Codes: H01M 4/8605 Porous electrodes
• CPC Class Codes: H01M 4/881 Electrolytic membranes
• CPC Class Codes: H01M 4/8853 Electrodeposition
• CPC Class Codes: H01M 4/8867 Vapour deposition
• CPC Class Codes: H01M 4/92 Metals of platinum group H01M4/94 , H01M4/9058 take precedence
• CPC Class Codes: H01M 8/0206 Metals or alloys
• CPC Class Codes: H01M 8/083 Alkaline fuel cells
• CPC Class Codes: H01M 8/1004 characterised by membrane-electrode assemblies [MEA] H01M8/12 takes precedence
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A method for roughening a surface of an ion exchange system structure using laser interaction with a surface. The laser surface roughening process allows the use of a wide range of substrates such as metals, ceramics, silicates, polymers and the like, including varieties which can not be fabricated in a fine fibrous structure. The surface roughened ion exchange system structure may be used as an ion-exchange media in applications such as fuel cells, batteries, and other catalysis systems where a high surface exchange area is desirable.

Claims

1. A substrate for an ion-exchange electrode structure, said substrate comprising an exterior surface wherein at least a portion of the exterior surface is irradiated by a laser radiation to enlarge a reactive surface area on the exterior surface, wherein the reactive surface area has two-scales of roughness, a first scale of roughness at least three orders of magnitude different than a second scale of roughness.

2. The substrate of claim 1, wherein the portion of the surface is irradiated by exposing the surface to the laser radiation near an ablation threshold of the substrate.

3. The substrate of claim 1, wherein the portion of the surface is irradiated by melting, boiling, or quenching part of the surface with laser radiation.

4. The substrate of claim 1, wherein the laser irradiated surface is coated with a layer of conductive material.

5. The substrate of claim 4, wherein the conductive material is a metal or an alloy.

6. The substrate of claim 4, wherein the layer of conductive material is further coated with a continuous or discontinuous layer of catalytic material.

7. The substrate of claim 6, wherein the catalytic material is selected from a group consisting of Pt, Pt alloys, V, V alloys, titanium dioxide, iron, nickel, lithium and gold.

8. The substrate of claim 1, wherein the laser irradiated surface is coated with a continuous or discontinuous layer of catalytic material.

9. The substrate of claim 8, wherein the catalytic material is selected from a group consisting of Pt, Pt alloys, V, V alloys, titanium dioxide, iron, nickel, lithium and gold.

10. The substrate of claim 8, further comprising micro openings wherein a fuel flows through the micro openings to reach the catalytic material.

11. The substrate of claim 1, wherein the reactive surface area includes a projecting surface feature.

12. The substrate of claim 11, wherein the projecting surface feature is cone-shaped.

13. The substrate of claim 1, wherein the first scale of roughness is about 10⁻

6 meters.