Manufacturing Strategies for Engineering Carbon Electrodes Via Non-Solvent Induced Phase Separation

Abstract

Porous electrodes are at the core of emerging electrochemical systems and tuning the electrode properties is critical to overcome system-specific limitations. To meet the stringent performance and cost requirements, there is a need for tailored microstructures generated through inexpensive and scalable synthesis methods with precursors originating from reliably-sourced, globally-abundant feedstocks. To this end, we recently introduced a manufacturing route using non-solvent induced phase separation (NIPS), yielding porous carbon electrodes with multimodal and interconnected porosity. The synthesized NIPS electrodes demonstrated a beneficial trade-off between transport properties (permeability, mass transfer) and electrochemically active surface area (ECSA) resulting in high performance in iron and all-vanadium redox flow batteries (RFBs)[1,2]. Moreover, NIPS manufacturing offered control over electrode characteristics (pore size, surface area) which are critical parameters for broader electrochemical devices. Besides its use for RFB application, we hypothesize that the electrode morphologies resulting from NIPS could be applied to a broader range of electrochemical systems employing porous electrodes. Consequently, here we focus on extending the library of electrode microstructures achievable via NIPS through the alteration of simple process parameters.In this presentation, I will discuss our latest advances on the bottom-up manufacturing of porous electrodes using NIPS targeting porosity gradients and high ECSA materials. For the former, we introduce the use of a control layer, casted on top of the NIPS polymer solution at the interface with the coagulation bath, thereby altering the rate of the phase separation process. We investigate various process parameters such as the composition, viscosity, and thickness of the control layer and assess their effect onto the resulting microstructures. The NIPS method assisted by a control layer generates porosity gradients, resulting in a slight increase of the electrode ECSA at the cost of a higher pressure drop. To further increase the ECSA of the prepared electrodes, we also propose nano-patterning approaches to significantly enhance ECSA through addition of nano-scale porosity without compromising the pressure drop through the porous structure. Finally, both porosity gradient and nano-patterned NIPS electrodes are tested in a all-vanadium redox flow cell to extract microstructure-performance relationships. Despite being in its early technological stage, this work illustrates the versatility of NIPS to manufacture porous electrodes through a very broad microstructural design space.