Gas Diffusion Electrode Based on Porous Hydrophobic Substrates with a Current Collector and Production Thereof

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This invention describes a gas diffusion electrode (GDE) with a novel layered structure for use in electrochemical reactions, particularly electrolysis. It features a hydrophobic, non-conductive, porous substrate supporting a catalyst layer. A current collector with a selectively coated polymer surface is positioned so electrical contact is optimized, but side reactions are minimized. The design improves the electrode's stability, efficiency, and scalability, especially for industrial applications like CO2 reduction.

Use CasesContent extracted from patent full text and abstract with AI.

• Industrial electrochemical CO2 reduction to valuable chemicals (e.g., ethylene, ethanol, propanol).
• Electrolysis cells for clean energy and chemical production.
• Conversion of industrial waste gases into useful feedstocks.
• Electrolyzers for green hydrogen or syngas production.
• Fuel cell and battery technology enhancements.

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly enhanced long-term stability of the electrode in electrolytic environments, allowing reliable industrial operation.
• Minimizes undesirable flooding of the electrode due to the hydrophobic substrate, maintaining high selectivity and efficiency.
• Suppresses unwanted side reactions (like hydrogen evolution) thanks to the polymer-coated current collector, improving Faradaic efficiency for target products.
• Easily scalable design for applications ranging from laboratory to industrial scale.
• Simplified and adaptable manufacturing process using established coating and assembly techniques, facilitating mass production and cost-effectiveness.
• Supports high current densities and product formation rates, crucial for economically viable electrochemical production.

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Patent Abstract

The invention relates to a gas diffusion electrode comprising a substrate, a catalyst layer and a current collector. The substrate is electrically non-conductive, hydrophobic and has a pore structure. The catalyst layer is applied to the substrate. The current collector has a first side and a second side, the first side having a polymer layer portion and an electrical potential application region. The polymer layer portion is coated with a polymer layer, while the electrical potential application region does not have a polymer layer. Further, the second side has an electrical contact-making portion. The electrical contact-making portion faces the catalyst layer so that electrical contacting with it is possible. The catalyst layer enables an electrical current to flow through the electrical contact-making portion and the electrical potential application region. The invention further relates to a system comprising an electrolytic cell which has the gas diffusion electrode according to the invention and to a method for producing the gas diffusion electrode according to the invention.