AU673003B2 - Flexible, conducting plastic electrode and process for its preparation - Google Patents

Description

I'

I

OPI DATE 29/03/94 APPLN, ID AOJP DATE 23/06/94 PCT NUMBER AU9349360 (51) International Patent classifncation 5 (1 nentoa ulcto ubr O9/66 4/88, 4/96, 8/20 (Al Itra~nlPb~ato ubr O9/66 140 1M 8/18, B29C 35/02 Al (43) International Publication Date: 17 March 1994 (17.03.94) C25B 11/12, C25C7/02 (21) International Application Number: PCT/AU93/00456 (74) Agent., SPRUSON FERGUSON; GPO B~ox 3898, Syd.

(22) International Filing Date: 6 September 1993 (06.09.93) ney, NSW 2001 (AU).

(81) Designated States: AT, AU, JBj JG, BR, BY, CA, CH-, Priority data: CZ, DE, DK, ES, Fl, Gil, H-U, JP, KP, KR, KZ, LK, PL 4504 4 September 1992 (04.09,92) AU LU, MG, MN, MW, NL, NO, NZ, PL, PT, RO, RU, SD, SE, SK, UA, US, VN, European patent (AT, BE, CH, DE, DK, ES, FR, G13, GR, IE, IT, LU, MC, NL, (71) Applicant (for all designated Statves cp US): UNISE. PT,,SE), GAPI patent (BIF, 133, CF, CG, Cl, CM, GA, ARCH- LIMITED 221 AacParade, Ken. GN, ML, MR, NE, SN, TD, TG).

sington, NSW 2033 (AU).

(72) Inventors; and Published Inventors/Applicants (for US on~jy) ZHONG, Shihuang 111lh International search report.

[CN/AUI; Unisearcl: Limited, 221 Anzac Parade, Ken.

sington, NSW 2033 KAZACOS, Michael (AU/ AU]; 54 Thc Esplanade, Sylvania Heights, NSW 2224 SKYLLAS KAZACOS, M aria 54 The Esplanade, Sylvania, N SW 2224 HADDADI.

ASL, Vahid [IJR/AU]; 12/36 llrittain Crescent, Hillsdale, NSW 2036 (AU).

(54)1Title: FLEXIB3LE. CONDUCTING PLASTIC ELECTRODE AND PROCESS FOR ITS PREPARATION (57) Abstract Conducting plastic electrodes and methods or preparing such electrodes are disclosed, The electrodes comprise a thermoplastic polymer, tin elastomeric polymer, and a conductive filler material, S WO 94/06164 PCT/AU93/00456 1 FLEXIBLE. CONDUCTING PLASTIC ELECTRODE AND PROCESS FOR ITS

PREPARATION

TECHNICAL FIELD The present invention is directed to a flexible, conducting plastic electrode and a process for the preparation of the same. The electrodes have application in redox flow batteries, particularly vanadium redox flow batteries, as well as in other electrochemical applications such as electrodepositing and electrowinning.

BACKGROUND ART The desired characteristics for electrode materials which are to be used in redox cells and other electrolytic processes include: low electrical resistivity, good mechanical properties and chemical stability and optionally low weight and low volume. The electrode material should not be attacked by reactants or products during cell operation. Thus there is a need for an electrode material which has good mechanical properties to withstand the hydraulic pressure and cell assembling operation without cracking and which is solution impermeable so that penetration and attack of the metal current collector (in end-electrodes) and loss in current efficiency (due to electrolytes crossing the bipolar electrodes) is low.

OBJECTS OF THE INVENTION Objects of the present invention are to provide a flexible, conducting plastic electrode and a process for the preparation of the same.

DISCLOSURE OF THE INVENTION The present inventors have surprisingly found that by combining a thermo-plastic polymer, an elastomeric polymer and a conductive filler material, a superior flexible, conducting plastic electrode is produced which has good physical strength, chemical stability and electrical conductivity. In particular, the inventors have found that by combining, for example, high density polyethylene (HDPE) resin, an elastomeric polymer such as, for example, styrene-ethene/butene-styrene (SEBS) block copolymer and conductive filler material such as carbon black particles or a mixture of carbon black particles and graphite fibres, a commercially useable plastic electrode is produced.

According to a first embodiment of this invention there is provided a flexible, conducting plastic electrode comprising: a conductive filler material; a thermo-plastic polymer; and an elastomeric polymer at least partially cross-linked with wherein the amount of is such that the electrode is electrically conducting and the degree of cross-linking of with is such that the electrode is flexible and has high tensile strength.

According to another embodiment of this invention there is provided a flexible, conducting plastic electrode comprising: a conductive filler material; a thermo-plastic polymer: and rt' -r 1' i 1- i i i. I' L* WO 94/06164 PCT/AU93/00456 2 an elastomeric polymer; wherein the amount of is such that the electrode is electrically conducting and the amounts of are such that the electrode is flexible and has high tensile strength.

The conducting plastic electrode of the first embodiment may be pressure and heat welded onto at least one metal mesh, a metal mesh and graphite felt or at least one graphite felt. Hence, in the case when the electrode is in the form of a sheet the following configurations may be employed, for example: a metal mesh may be pressure and heat welded onto at least one side of the sheet; a metal mesh may be pressure and heat welded onto one side of the sheet and a graphite felt pressure and heat welded onto the other side of the sheet; a graphite felt may be pressure and heat welded onto at least one side of the sheet; and a metal mesh sheet or foil may be pressure and heat welded between two of the flexible, conducting plastic electrodes.

Carbon and graphite felts are generally woven from yarns which are bundles of individual carbon monofilaments generally having a diameter in the range from about 1 to lm, usually in the range from about 5 to 10 .tm. The yarns will typically include from about 100 to 20,000 monofilaments, usually having from about 3,000 to 6,000 filaments. The denier of the yarns used as in fabricating the carbon felts will typically be in the range from about 500 to 5,000 mg/m, usually being in the range from about 1,000 to 2,000 mg/m.

Denier is equal to the number of grams which yield 9,000 meters of the yarn or filament. The yarns are woven by conventional weaving machines yielding large fabrics which may be cut into the desired dimensions for the electrode. Each electrode may employ a plurality of layers of the fabric, so that the final dimensions of the electrode may vary widely.

According to a second embodiment of this invention there is provided a process for making a flexible, conducting plastic electrode, the process comprising: mixing a thermo-plastic polymer, an elastomeric polymer and conductive filler material, the mixing being at a temperature(s) above the melting point temperatures of the thermo-plastic polymer and the elastomeric polymer.

pressure moulding (or extrusion moulding or injection moulding or calendering or veneering) the mixture of at a temperature(s) above the melting temperatures of the thermo-plastic polymer and the elastomeric polymer until the polymers are at least partially cross-linked wherein the degree of cross-linking of the thermo-plastic polymer with the elastomeric polymer is such that the electrode is flexible and has high tensile strength, and cooling the cross-linked polymerized mixture of to form the electrode; wherein the amount of the conductive filler material is such that the electrode is electrically conducting.

According to a further embodiment of this invention there is provided a process for making a flexible, conducting plastic electrode, the process comprising: -r j WO 94/06164 PCT/AU93/00456 3 mixing a thermo-plastic polymer, an elastomeric polymer and conductive filler material, the mixing being at a temperature(s) above the melting point temperatures of the thermo-plastic polymer and the elastomeric polymer, pressure moulding (or extrusion moulding or injection moulding or calendering or veneering) the mixture of at a temperature(s) above the melting temperatures of the thermo-plastic polymer and the elastomeric polymer until the mixture results in an electrode which is flexible and has high tensile strength, and cooling the cross-linked polymerized mixture of to form the electrode; wherein the amount of the conductive filler material is such that the electrode is electrically conducting.

Generally, during the pressure moulding (or other moulding) the pressure forces the mixture to fill the mould cavity.

Typically in step the polymerized mixture of is cooled rapidly, for example, typically 1 10 0 C per minute, more typically 2 to 5°C per minute.

The process may also include: adding a polymerization initiator to the mixture of to at least partially cross-link the thermo-plastic polymer with elastomeric polymer.

The process may also include: adding a plastics additive(s) to the mixture of The process of the second embodiment may further include the step of pressure and heat welded onto at least one metal mesh, a metal mesh and graphite felt or at least one graphite felt onto at least one conducting plastic electrode.

Also included within the scope of this invention is a conducting plastic electrode [i when prepared by the method of the second embodiment.

Generally during the pressure moulding the pressure forces the mixture to fill the mould cavity.

Generally, the moulding pressure-during elevated pressure step is from 2 2500 Kg/cm 2 more typically 2 500 Kg/cm 2 and even more typically, 2 300 Kg/cm 2 Generally, the temperature in step is in the range 100 750 0 C, typically 170 350°C, and more typically 150 260°C. Generally, the pressure and elevated temperatures are simultaneously applied for at least 15 to 30 minutes, more generally 25 minutes to 60 minutes and up to 6 hours or more. Alternatively, a 10 to 30 minute preheat (typically 20 minutes at 100 750°C, more typically 120 400°C) followed by a compression which is gradually increased up to 30 70 tons, more typically 40 50 tons where it is held typically for 15 minutes, more typically 30 minutes at a temperature at the above conditions. The mould is then cooled down to room temperature over 1.5 4 hours, typically over 2 hours. To prepare an end-electrode, a metal mesh (such as copper) or alternative as listed elsewhere in this specification is placed in the bottom of the mould. The carbon-plastic sheet is placed on top and the mould preheated up to 100 750 0 C, more typically 120 400°C. The temperature is maintained for 15 60 minutes, more typically 30 minutes, before applying =go" SWO 94/06164 PCT/AU93/00456 4 gradually increased pressure up to 30 70 tons, more typically 40 50 tons where it is held typically for 15 90 minutes, more typically 60 minutes. While keeping the hot carbonplastic sheet with the metal mesh backing in mould, a window of desired area e.g. 300 x 500 mm 2 is placed on the top of the hot sheet and a graphite felt is placed in the window. A pressure of 1 6 tons, typically 2 tons, is then applied to the mould with the window, and this is maintained for 20 90 minutes, typically 30 minutes. The mould is then cooled down to room temperature to obtain the carbon-plastic and graphite felt composite end-electrode.

The conductive filler material has high conductivity and is present in sufficient amounts to allow for interparticle contact between the filler species so that the electrode is electrically conducting. The filler material may comprise one or more of the following materials: carbon black, graphite, metal powder, metallized glass fibres, polypyrrole powder, pitch-derived carbon fibres, graphite fibres, polyacrylonitrile-derived carbon fibres and polyacrylonitrile-derived graphite fibres. Typically, the filler material is comprised of carbon black by itself or a mixture of carbon black and graphite fibres (in a range of 5-70 wt% of the total composition. The ratio of carbon black to graphite fibres is typically in a range of 5:95 to 99:1 wt% more typically in a range of 30:70 to 70:30 wt% and even more typically 95:5 wt%. Generally, at least two different types of carbon black are used, for example fine carbon black powder (2 35nm) and coarse carbon black powder (35nm 10,000nm) in a ratio of fine carbon:coarse carbon of from 1:99 to 99:1. In particular, a weight ratio of total carbon content to polymer of 2:3 in the electrode of the invention has good electrical conductivity while maintaining excellent physical strength and flexibility.

In the electrode, the thermo-plastic is the basic polymer which maintains the plastic properties of the composite and is generally 10-80 wt% more typically 20-70 wt% of the electrode. If the weight fraction of the thermo-plastic is too low there will be a resultant unacceptable loss of the plastic properties of the electrode. If the weight fraction of the thermo-plastic is too high there will be a resultant unacceptable decrease in electrical conductivity of the electrode.

Examples of thermo-plastic polymers include, by way of illustration only, endcapped polyacetals, such as poly(oxymethylene) or polyformaldehyde, poly(trichloroacetaldehyde), poly(a-valeraldehyde), poly(acetaldehyde), poly(propionaldehyde), and the like; acrylic polymers, such as polyacrylamide, poly(acrylic acid), poly(methacrylic acid), poly(ethyl acrylate), poly(methyl methacrylate), and the like; fluoro-carbon polymers, such as poly(tetrafluoroethylene), perfluorinated ethylene-propylene copolymers, ethylene-tetrafluoroethylene copolymers, poly(chlorotrifluoroethylene), ethylene-chlorotrifluoroethylene copolymers, poly(vinylidene fluoride), poly(vinyl fluoride), and the liKe; polyamides, such as poly(6-aminocaproic acid) or poly (e-capro-lactam), poly(hexamethylene adipamide), poly(hexamethylene sebacamide), poly( 1-aminoundecanoic acid), and the like; polyaramides, such as poly(imino-1,3-phenyleneiminoisophthaloyl) or poly(m-phenylene isophthalamide), and the like; parylenes. such as poly-p-xylylene.

poly(chloro-p-xylylene). and the like; polyaryl ethers, such as poly(oxy-2.6-dimethvl-l,4- 1 1 i.i WO 94/06164 PCT/AU93/00456 phenylene) or poly(p-phenylene oxide), and the like; polyaryl sulfones, such as poly(oxy-1,4phenylenesulfonyl-l,4-phenylene-oxy- 1,4-phenylene-isopropylidene-1,4-phenylene), poly(sulfonyl- ,4-phenyl-eneoxy-l,4-phenylenesulfonyl-4,4'-biphenylene), and the like; polycarbonates, such as poly(bisphenol A) or poly(carbonyldioxy- 1,4phenyleneisopropylidene-1,4-phenylene), and the like; polyesters, such as poly(ethylene terephthalate), poly(tetramethylene terephthalate), poly(cyclohexylene-1,4-dimethylene terephthalate) or poly(oxymethylene-l,4-cyclohexylenemethyleneoxyterephthaloyl), and the like; polyaryl sulfides, such as poly(p-phenylene sulfide) or poly(thio-1,4-phenylene), and the like; polyimides, such as poly(pyromellitimido-l,4-phenylene), and the like; C2 C12 polyolefins, such as polyethylene, polypropylene, poly(l-butene), poly(2-butene), poly(lpentene), poly(2-pentene), poly(3-methyl-l-pentene), poly(4-methyl-l-pentene), 1,2-poly- 1,3-butadiene, l,4-poly-l,3-butadiene, polyisoprene, polychloroprene, polyacrylonitrile, poly(vinyl acetate), poly(vinylidene chloride), polystyrene, and the like; copolymers of the foregoing, such as acrylonitrile-butadiene-styrene (ABS) copolymers, and the like. The molecular weight of the thermoplastic polymer is typically in the range 25,000 to 500,000, more typically 30,000 to 300,000. Further examples of thermoplastic polymers may be found in "Polymer Handbook", editors J. Brandrup and E.H. Immergut, 3rd edition, John Wiley Sons, New York, 1989, "Encyclopedia of Chemical Technology", Kirk-Othmer, 3rd Edition, John Wiley Sons, New York, "Compounding Materials for the Polymer Industries", "Handbook of Thermoset Plastics", S. H. Goodman, Noyes Publications, Park Ridge, New Jersey 1986, J. S. Dick, Noyes Publications, Park Ridge, New Jersey 1987, and "Handbook of Plastics Materials and Technology", editor Irvin I. Rubin, John Wiley Sons, New York, 1990, the contents of which are incorporated herein by cross reference.

A thermo-plastic is used herein to mean a thermo-plastic polymer which has moderate to high crystallinity or a glass temperature (Tg) above the operating conditions of the electrode. The Tg is the temperature below which the polymer exhibits glasslike behaviour. One or more of the following are typical thermo-plastics which may be used in the electrode: low density polyethylene, high density polyethylene, polypropylene, polybutylene or polystyrene. In particular, high density polyethylene, is a suitable thermoplastic for use in the electrode of the invention.

According to a further embodiment of this invention there is provided an all-vanadium redox battery having a positive compartment containing a catholyte in electrical contact with a positive electrode, the catholyte comprising an electrolyte containing tetravalent vanadium ions or pentavalent vanadium ions, a negative compartment containing an anolyte in electrical contact with a negative electrode, the anolyte comprising an electrolyte containing tetravalent vanadium ions, trivalent vanadium ions or divalent vanadium ions, and an ionic conducting separator disposed between the positive and negative compartments and in contact with the catholyte and anolyte to provide ionic communication therebetween and wherein the catholyte includes a salt of the formula VO(X)y where y is 2 and X is selected from F, Br or Cl or y is 1 and X is selected from SO 4 or O. V20 5 V203, V20 4 VO, VSO 4 VOS0 4 V2(S0 4 3 1 gir -r 1 -j WO 94/06164 PCT/AU93/00456 6

(VO

2 2 S0 4 and NH 4

VO

3 and the concentration of the salt is 0.1M to 8.0M, more particularly 0. M to 5.0M, and wherein at least one of the positive and negative electrodes is a conducting plastic electrode of the first embodiment or a conducting plastic electrode when prepared by the process of the second or third embodiments.

The electrochemical reactions of the redox cell can be conducted in any electrochemical cell which has an anode compartment and a cathode compartment through which the appropriate fluids can be transported. A particular redox cell in which the permeation selective membranes may be used to. advantage is an all-vanadium battery described in United States Patent No. 4,786,567, the contents of which are incorporated herein by cross reference.

Although the design of the electrode and cathode compartments of the redox cell are not critical to the practice of this invention, certain embodiments are preferred. For example, a parallel plate electrochemical cell in which anode and cathode compartments alternate in order to increase voltage and decrease current is a preferred embodiment. Generally, the electrodes will have a height in the range from about 1 cm to 100 cm, a width in the range from about 0.1 cm to 900 cm, more typically from about 5 cm to 300 cm, and a thickness in the range from about 0.02 cm to 3.0 cm, more typically 0.02 cm to 1.0 cm. The particular dimensions chosen will depend primarily on the capacity of the electrochemical cell.

The elastomeric polymer is the critical component for improving the flexibility of the composite under high pigment loading conditions higher than 40wt% loading with conducting filler). Examples of naturally occurring and synthetic elatomeric polymers are given in "Elastomers and Rubber Compounding Materials" Studies in Polymer Science I, I.

Franta (editor), Elsevier, New York 1989, "Compounding Materials for the Polymer Industries", J. S. Dick, Noyes Publications, Park Ridge, New Jersey 1987, "Handbook of Elastomers", A. K. Bhowmick and H. L. Stephens (editors), Marcel Dekker. Inc.. New York 1988 (see Chapter 9, in particular), and "Natural Rubber Science and Technology", A.

D. Roberts (editor), Oxford University Press, 1988, the contents of all of which are incorporated herein by cross-reference. Particularly useful elastomeric polymers are thermoplastic styrene block copolymers such as diblock triblock ("SBS" or "SIS"), saturated triblock radial trichain, radial tetrachain, and radial multichain polymers or any combination thereof. For example, the styrenic block copolymers employed may be a combination of one or more of styrene-isoprene-styrene, styrene-butadiene-styrene, or styrene-(ethylene-butylene)-styrene. Typically, styrene-butadiene-styrene or styrene- (ethylene-butylene)-styrene ("SEBS") or a mixture thereof in the ratio in the range 1:10 to 10:1 w/w) is used.

In an embodiment of the invention the elastomeric polymer concentration, for i example SB, SBS, SIS or SEBS block copolymer concentration or SBR, NR, XNBR, SBR- NR, PTPR, SBR latex, NR latex, EPR, n-butyl rubber, BMX4 2 santoprene, silicone rubber, IR, PP, PIP. PP. PU rubber, CSM, CR, BR, HSN, ACM, polybutadiene rubbers. IIR, polyisoprene rubbers, MFQ, PPVQ, butadiene-isoprene rubbers, CM, BIIR, CIIR. NIR, ,1 2 i i WO 94/06164 PCT/AU93/00456 7 butadiene-piperylene rubbers, EPM, MVQ, AFMU, AU, EU, acrylonitrile-butadiene rubbers, XNBR latex, SBR-NR latex. PTPR latex, carboxylated SBR, carboxylated NR, carboxylated SBR-NR, FKM, CFM, ANM, CO, carboxylated PTPR, ECO, T, natural rubbers, NBR/PVC, MQ, butadiene-propylene rubbers, MPQ, EPDM+EPM, EVA rubber, NBR or EPDM, is 0.1-50wt% of the total electrode composition. The molecular weight of the elastomeric polymer is typically in the range 25,000 to 500,000, more typically 30,000 to 300,000. A higher proportion of styrenic block copolymer will give the electrode a rubber appearance. A lower proportion does not significantly improve the flexibility of the composite. A concentration in the range of 10-30wt%, more particularly in the range of 25wt% and even more particularly about 20wt% of styrene-butadiene-styrene or is typically used.

A cross linking agent may be used to cross-link the thermoplastic polymer with the elastomeric polymer. The cross linking agent is generally chosen depending on the nature of the thermoplastic polymer and the elastomeric polymer. Examples include vinylidene chloride, vinyl acetate, styrene, acrylamide, 1,3 butadiene, methacrylic acid, vinyl chloride, acrylonitrile, 2-hydroxyethyl methacrylate, methyl methacrylate, may be chosen depending on the polyelectrolyte and ion exchange resin. Other examples of possible monomers for use as cross linking agents include: esters of acrylic and methacrylic acid such as methyl, ethyl, propyl, isobutyl, isopropyl, butyl, tert-butyl, sec-butyl, ethylhexyl, amyl, hexyl, octyl, decyl, dodecyl, cyclohexyl, isobornyl, benzyl, phenyl, alkylphenyl, ethoxymethyl, ethoxyethyl, ethoxypropyl, propoxymethyl, propoxyethyl, propoxypropyl, ethoxyphenyl, ethoxybenzyl, ethoxycyclohexyl, hydroxyethyl, hydroxypropyl, ethylene, propylene, isobutylene, diisobutylene, styrene, ethylvinylbenzene, vinylbenzylchloride, vinyltoluene, vinyl chloride, vinyl acetate, vinylidene chloride, dicyclopentadiene, acrylonitrile, methacrylonitrile, acrylamide, methacrylamide, diacetone acrylamide, neutral or half-acid half-esters or free diacids of the unsaturated dicarboxylic acids including itaconic, citraconic, aconitic, fumaric, and maleic acids, substituted acrylamides, such as N-monoalkyl, N,N-dialkyl and Ndialkylaminoalkylacrylamides or methacrylamides where the alkyl groups may have from one to eighteen carbon atoms, such as methyl, ethyl, isopropyl, butyl, hexyl, cyclohexyl, octyl, dodecyl, hexadecyl and octadecyl aminoalkyl esters of acrylic or methacrylic acid, such as bdimethylaminoethyl, b-diethylaminoethyl or 6-dimethylaminohexyl acrylates and methacrylates, alkylthioethyl methacrylates and acrylates such as ethylthioethyl methacrylate, functional monomers such as vinylbenzene, sulfonic acid, vinyl esters, including vinyl acetate, vinyl propionate, vinyl butyrate, vinyl laurate, vinyl ketones including vinyl methyl ketone, vinyl ethyl ketone, vinyl isopropyl ketone, vinyl n-butyl ketone, vinyl -hexyl ketone, vinyl octyl ketone, methyl isopropenyl ketone, vinyl aldehydes including acrolein, methacrolein, crotonaldehyde, vinyl ethers including vinyl methyl ether, vinyl ethyl ether, vinyl propyl ether, vinyl isobutyl ether, vinylidene compounds including vinylidene chloride, vinylidene bromide, or vinylidene bromochloride, vinylpyridines; such as 2-vinylpyridine. 4vinylpyridine, 2-methyl-5-vinylpyridine. Examples of polyethylenically unsaturated WO 94/06164 PCI/AU93/00456 8 monomers include: divinylbenzene, divinylpyridine, divinylnaphthalenes, diallylphthalate, ethylene glycol diacrylate, ethylene glycol dimethacrylate, trimethylolpropanetrimethacrylate, divinylsulfone, polyvinyl or polyallyl ethers of glycol, of glycerol, of pentaerythritol, of diallyl malonate, diallyl oxalate, diallyl adipate, diallyl sebacate, divinyl sebacate, diallyl tartrate, diallyl silicate, triallyl tricarballylate, diethyleneglycol, of monothio-derivatives of glycols, and of resorcinol divinylketone, divinylsulfide, allyl acrylate, diallyl maleate, diallyl fumarate, diallyl succinate, diallyl carbonate, diallyl malonate, diallyl oxalate, diallyl adipate, diallyl sebacate, divinyl sebacate, diallyl tartrate, diallyl silicate, triallyl tricarballylate, triallyl aconitate, triallyl citrate, and triallyl phosphate. N,N'-methylene-diacrylamide, N,N'methylene-dimethacrylamide, N,N'-ethylenediacrylamide, trivinylbenzene, trivinylnapthalenes, vinylanthracenes, including styrene, vinyl pyridine, vinyl naphthalene, vinyl toluene, phenyl acrylate, vinyl xylenes, ethylvinylbenzene, divinyl pyridine, divinyl naphthalene, divinylbenzene, trivinylbenzene, alkyldivinylbenzenes having from 1 to 4 alkyl groups of 1 to 6 carbon atoms substituted in the benzene nucleus, and alkyltrivinylbenzenes having 1 to 3 allyl groups of 1 to 3 carbon atoms substituted in the benzene nucleus. Further examples include aromatic diacids and their derivatives (the esters, anhydrides and acid chlorides) including phthalic acid, phthalic anhydride, terephthalic acid, isophthalic acid, dimethylphthalate, aliphatic dibasic acids such as maleic acid, fumaric acid, itaconic acid, 1,1-cyclobutane-dicarboxylic acid, aliphatic diamines such as piperazine, 2-methylpiperazine, cis, cis-bis (4-aminocyclohexyl) methane, metaxylylenediamine, glycols such as diethylene glycol, triethylene glycol, 1,2-butanediol, neopentyl glycol, bischloro-formates such as cis and trans-1,4-cyclohexylbis-cbloroformate, 2,2,2,4-tetra-methyl- 1,3-cyclobutyl bischloroformate and bischloroformates of other glycols above listed, hydroxy acids such as salicylic acid, m- and p-hydroxy-benzoic acid and lactones, derived therefrom such as the propiolactones, valerolactones, caprolactones, diisocyantes such as cis and transcyclopropane-1 ,2-diisocyanate, cis and trans-cyclobutane-1,2-diisocyanate, phenol and derivatives of phenol, including, alkylphenols, polyfunctional cross-linking agents such as trior poly basic acids such as trimellitic acid, tri- or polyols such as glycerol, tri- or polyamines such as diethylenetriamine; and other condensation monomers and mixtures of thereof, aromatic diamines such as benzidine, 4,4'-methylenediamine, bis(4-amino-phenyl)ether, bisphenols such as bisphenol A, bisphenol C, bisphenol F, phenolphthalein, resorcinol, -I bisphenol bis(chloroformates) such as bisphenol A bis(chloroformate), 4,4'dihydroxybenzophenone bis(chloroformate), carbonyl and thiocarbonyl compounds such as formaldehyde, acetaldehyde thioacetone acetone. Examples of further monomers that may be used as cross linking agents are given in J. Brandup and E. H. Immergut, "Polymer Handbook", 3rd Edition, John Wiley and Sons, New York, 1989, the contents of which are incorporated herein by cross reference. For given set of circumstances, the amount of crosslinking agent to be used (typically 0,01-25wt%, more typically 0.5-O10wt% and even more typically 0.75-5wt%) may be readily determined by trial an error without undue experimentation.

WO 94/06164 PCT/AU93/00456 9 To facilitate cross-linking an initiator such as dicumyl peroxide, for example, is used in concentrations of 0.01-10wt% of the elastomeric polymer. Further examples.of polymer initiators may be found in "Plastics Additives", E. W. Flick, Noyes Publications, Park Ridge, New Jersey 1986, "Compounding Materials for the Polymer Industries", J. S. Dick, Noyes Publications, Park Ridge, New Jersey 1987, "Chemical Additives for the Plastics Industry", Radian Corporation, Noyes Publications, Park Ridge, New Jersey 1987, "Polymer Handbook", editors J. Brandrup and E.H. Immergut, 3rd edition, John Wiley Sons, New York, 1989, "Encyclopedia of Chemical Technology", Kirk-Othmer, 3rd Edition, John Wiley Sons, New York, and "Handbook of Plastics Materials and Technology", editor to Irvin I. Rubin, John Wiley Sons, New York, 1990, the contents of which are incorporated herein by cross reference.

Other plastic additives such as fillers, lubricants, reinforcements, coupling agents, plasticiznrs,, heat stabilizers and antioxidants may be used in the carbon-plastic electrodes of the invention. Examples of such additives are described in "Plastics Additives", E. W. Flick, Noyes Publications, Park Ridge, New Jersey 1986, "Polymer Handbook", editors J.

Brandrup and E.H. Immergut, 3rd edition, John Wiley Sons, New York, 1989, "Compounding Materials for the Polymer Industries", J. S. Dick, Noyes Publications, Park Ridge, New Jersey 1987, "Handbook of Plastics Materials and Technology", editor Irvin I.

Rubin, John Wiley Sons, New York, 1990, and "Chemical Additives for the Plastics Industry", Radian Corporation, Noyes Publications, Park Ridge, New Jersey 1987, the contents of which are incorporated herein by cross reference.

Generally, the flexible, conducting plastic electrode material comprises: thermo-plastic polymer 30wt% elastomeric polymer cross-linked with thermoplastic polymer 10wt% conductive filler material 5-50wt%; and graphite felt (heat and pressure fused onto at least one surface of the electrode) metal mesh/foil (heat and pressure fused onto a surface of the electrode).

In one preferred form the flexible, conducting plastic electrode material comprises: thermo-plastic polymer 30wt% elastomeric polymer cross-linked with thermoplastic polymer 10wt% conductive filler material 5-40wt%; Scross-linking agent 1-10wt%; and graphite felt (heat and pressure fused onto at least one surface of the electrode) metal mesh/foil (heat and pressure fused onto a surface of the electrode).

In a particularly preferred embodiment, the flexible, conducting plastic electrode material is comprised of: HDPE 30wt% SEBS block copolymer cross-linked with HDPE 0.lwt% carbon black (fine powder, 13nni) carbon black (coarse powder, 35nm. typically 35nm-10,000nm) I IWO 9/06164 PCT/AU93/00456 graphite fibre (3mm in nlngth) polymer initiator (used in preparation process) 0.00 -5 wt%, typically O.lwt% 2wt% of the SBS copolymer In a second preferred embodiment of the invention the electrode comprises:

HDPE

SEBS block copolymer cross-linked with HDPE graphite fibre polymer initiator (used in preparation process) 0.00wt% 2wt% of the SEBS copolymer 1 I I 1 i j!

I

Generally, the polyblend of thermo-plastic and elastomeric polymer is made by mixing the polymers in a suitable mixer at temperatures above the melting temperatures (Tm) of each constituent. More particularly, the polyblend of thermo-plastic and styrenic block copolymer is made by mixing the polymers in a suitable mixer at temperatures above the melting temperatures (Tm) of each constituent. Typically, the thermo-plastic, styrenic block copolymer and carbon black particles are blended in an internal mixer at 170-2250C for approximately 20 minutes. This mixture is preheated at 220 0 C for 20 minutes then pressuremoulded at 220 0 C and 200-250 Kg/cm 2 for approximately 30 minutes to form a thin flexible, conducting carbon-plastic sheet. The thin carbon-plastic sheet prepared by this method is characterised by more than 10% elongation and less than 0.3 ohm.cm in electrical resistivity.

By heat-pressing a copper mesh on one side and heat-bonding a graphite felt on the other side, an end-electrode for a redox battery is completed. By heat-bonding a graphite felt on both sides, a bipolar electrode for a redox battery is completed.

The advantages of the electrode composite of the invention are its relatively low cost of manufacture, good electrical conductivity, physical strength, flexibility, low solution permeability when utilised in systems such as the vanadium redox flow battery and long 30 chemical stability.

BRIEF DESCRIPTION OF THE DRA WINGS The preferred embodiments of the invention are described in more detail with reference to the following drawings: Fig, 1 is a flowchart illustrating the manufacturing process for the carbon-plastic, bipolar and end-electrode assemblies to be employed in a vanadium redox battery; Fig, 2 is a graph indicating the electrical and mechanical properties of the carbonplastic electrode materials; Fig. 3 is a graph showing the permeation behaviour of the carbon-plastic sheet in the electrolyte of the vanadium battery; Fig. 4 is a graph showing the long-term stability of the electrode operating in the iI i1 1 L -1 L 1 -L ii WO 94/06164 PCT/AU93/00456

II

vanadium battery; Fig. 5 is a microphotograph of a carbon-plastic surface which haa been etched in a solution of 850 grams per litre H 2 S0 4 30 grams Cr03 60 grams H20 at 60 0 C for minutes so as to prepare it for subsequent activation by electrodepositing or chemically depositing an electroactive layer such as polypyrrole, polyaniline or a metal oxide; and Fig. 6 is a flowchart illustrating the manufacturing process for carbon-plastic electrodes to be employed in electrodeposition of polypyrrole, polyaniline or metal oxides.

BEST MODE AND OTHER MODES FOR CARRYING OUT THE INVENTION Referring to Fig. 1, a process for making a conducting plastic electrode, comprises the initial step 11 of dry mixing high density polyethylene (20wt%), styrenebutadiene-styrene (20wt%) and carbon black (60wt%). This mixture is then blended 12 at a blade speed of 50 rpm in an internal mixer at 1950C for approximately twenty minutes.

During the mixing in the internal mixer the mixture is not exposed to air. Graphite fibre is then slowly added to blended mixture 12 and blended 13 for approximately ten minutes.

Polymerization initiator (0.00-0.15wt% of SBS) is added to the blended mixture of 13 and blended 14 for a few minutes. The resulting mixture is pressure-moulded 15 at 250 Kg/cm 2 and 180-220 0 C for at least thirty minutes.. The moulded material is cooled down rapidly 16 to get a thin, smooth, conductive and flexible carbon-plastic electrode sheet.

Referring to Fig. 1 and in particular steps 17, 18 and 19, an end-electrode is prepared by placing a metal mesh preferably a copper or brass mesh, in the bottom of the mould. The carbon-plastic sheet is placed on top of the metal mesh and the mould is heated to approximately 2200C. The temperature is maintained for twenty minutes before applying a pressure of 250 Kg/cm 2 for fifteen minutes in step 17. A window is placed on the top of the hot carbon-plastic sheet and an electrochemically active layer, preferably a graphite felt layer, is placed in this window in step 18 and then a pressure of approximately 60 Kg/cm 2 is applied to the mould for approximately 10-15 minutes. The mould is then rapidly cooled in step 19 at 1-10 0 C/min to obtain a flexible, conducting carbon-plastic and graphite felt endelectrode.

In steps 20 and 21, a bipolar electrode is prepared by 20 placing a window (border about 0.5-8cm, typically 5-8cm, around electrode edges) on either side of the carbon-plastic sheet of 16 and then placing an electrochemically active layer, typically a graphite felt layer S(typically 0.5-2.5cm thick), iito each of the two windows and placing this into a mold. A pressure of approximately 60 Kg/cm 2 is applied to the mould for 10-15 minutes at approximately 2200C. The mould is then rapidly cooled 21 to obtain a conducting carbonplastic and graphite felt bipolar electrode.

Figure 2 illustrates the influence which a styrenic block copolymer, styreneethene/butene-styrene (SEBS), has on the electrical and mechanical properties of the carbonplastic material. The resistivity values of the different compositions of the SEBS block copolymer were determined by ASTM D-991. The mechanical properties of the different compositions of SEBS block copolymer were measured according to ASTM D-638.

SWO 94/06164 PCT/AU93/00456 12 Referring to Fig. 2, the optimum composition of styrene-ethene/butene-styrene (SEBS) block copolymer with good electrical conductivity and good mechanical strength is around Figure 3 illustrates a graph of the permeation test results of a conducting carbonplastic sheet prepared according to the process of Fig. 1. The testing was carried out on a 0.3 mm thin sheet of carbon-plastic. The sheet was used as a separator of a round cell. The solution in one side of the separator was 2 M VOSO 4 in 3 M H 2

SO

4 The other side contained distilled water. On both sides of the separator the respective solutions were continuously pumped through the cell and solution samples were taken periodically from the distilled water side. The samples were then tested with inductively coupled plasma (ICP) method to determine the concentrations of vanadium and sulphur which relate to the permeation rate of the ions through the sheet.

Figure 4 is a graph of the long-term performance of a vanadium redox cell with two electrodes manufactured according to the invention as described above. The voltage efficiencies which relate to the activity and resistivity of the electrode, varied less than over the operating period of 940 cycles of charging/discharging. The average time for one cycle is approximately four hours. Therefore, the total operating period was approximately 3760 hours. A drop of 5% efficiency over 3760 hours indicates that the electrode is substantially reactive and stable for the vanadium redox battery.

Referring to Fig. 5, a photograph of an electrode suitable for electrodeposition after it has been etched in a solution of H 2

SO

4 Cr0 3 and H 2 0 is shown. The electrode is comprised of 20% high density polyethylene, 20wt% SEBS, and 60wt% graphite fibre and is prepared according to process 50 depicted in Fig. 6. Referring to Fig. 6 HDPE and SEBS are dry mixed 51 and blended 52 in a internal mixer at 195 0 C for approximately 20 minutes at a blade speed of 50 rpm. Graphite fibre is slowly added in step 53 to the mixture of step 52 and blended for about 10 minutes. The mixture of step 53 is pressure moulded 54 at 250 Kg/cm 2 for 30 minutes at a temperature of 220 0 C. The mixture of step 54 is cooled down rapidly 55 to form a thin, conducting, smooth and flexible carbon-plastic sheet of carbonplastic. A metal mesh is placed between two sheets of carbon plastic in step 56 and pressure molded at 250 Kg/cm 2 and 2200C for 20 minutes. The mold is cooled in step 57 and immersed in a solution of 850-950 g/l H2S0 4 20-40 g/l Cr0 3 (or K 2 Cr 2 0 7 50-70 g/l at 60-70 0 C for at least 20 minutes to form an electrode for electrodeposition of polypyrrole, polyaniline or metal oxides.

The following example is provided by way of illustration and is not intended to limit the invention in any way.

EXAMPLE 1 Twenty grams of high density polyethylene, sold under the trade name of GM 7665 by the Hostalen Chemical Comp., 10 grams of styrene-ethene/butene-styrene (SEBS) block copolymer, sold under the name of Kraton G1652 by Shell Chemical Australia Pty. Ltd., grams fine carbon black, sold under the name of FW 200 and 5 grams coarse carbon black, sold under the name of XE-2 by Degussa Australia Pty. Ltd., 10 grams of graphite fibre, r II1Tili-I'CI-lil-i.ii- WO 94/06164 PCr/AU93/00456 13 sold under the name of c-203s by Kureha Chemical Industry Co., Ltd. and 0.1 grams of dicumyl peroxide were blended inside an internal mixer at 195oC for 20 minutes. The mixture was placed into a compression mould and moulded into 21x21 cm 2 plate under 250 Kg/cm 2 pressure at 220oC for 30 minutes. The mould was rapidly cooled down to room temperature. The formed sheet had a compressed thickness of 0.7 mm, an electrical resistivity of 0.24 ohm.cm, tensile strength of 21.8 N/mm 2 and elongation of 10.1%. The end-electrodes were fabricated by placing an equal sized brass mesh under the carbon-plastic sheet in the mould, heating up the mould to 2200C and applying a pressure of 250 Kg/cm 2 for 10 minutes. The cover of the mould was then replaced by a rectangular shaped window, and a piece of graphite felt sized 12x11.5cm 2 was put into the window of the same dimensions. A 60 Kg/cm 2 pressure was applied to the mould for 10 minutes at 220 0 C.The mould was rapidly cooled to obtain an end-electrode for a redox electrolysis cell. The formed end-electrode had electrical resistance of 0.7 ohm.cm 2 Two of these end-electrodes have been used in the vanadium battery for more than 3760 hours with recorded voltage efficiencies of approximately 88%.

ADDITIONAL EXAMPLES Conductive graphite fibre have been used successfully to increase the electrical conductivity of carbon-polyethylene composite materials as electrode matrix layer. However, their incorporation results in an increasing melt viscosity and difficult processing. The fabrication of extrudable conductive electrodes requires to reduce graphite fibre content, on the other hand, this can result in a higher resistant material. The purpose of this work was to find materials and compound with the highest conductivity, chemical resistant, flexibility and extrudability.

1. Electrical Conductivity of Hith Density Polyethylene (HDPE) 1.1 Comparison of HDPE types: To increase the processability of the compounds, two higher melt flow index HDPE were used. From Table 1 it can be said that the new HDPE materials have better melt flow index and conductivity.

Materials Weight% HDPE SEBS* Rubber Carbon Black Graphite Fibre Styrene-Ethene-Butene-Styrene Rubber 30 Table 1. Comparison of HDPE types.

Sample 1 Sample 2 Average HDPE MFI MFI volume volume Resistivity Physical Result TYPE (190/2) (190/5) resistivit resistivit (9f.cm) Property j i I 1Yi; Ir 1 -L -L I WO094/06164 p PCr/AU93/00456

I

Very low

MFI

GM 0.2 0.6 0.240 0.240 0,240 Good 7655 GD 3.5 12 0.260 0.219 0.239 Flexible Good 7255 This is the best GC 7.0 23 0.3 16 0.271 0.293 Flexible one (low 7260 resistivity and highest

-MFI)

1.2 The qffects of rubbers: To study the effect of rubber electrical resistivity and also to decrease the resistivity of the composite, four kinds of rubber with different resistivities were used.

Materials Weight% HDPE (GM 7655) Rubber Carbon Black Graphite Fibre Table 2. The effects of various rubbers upon composite conductivity Electrical Sample 1 Sample 2 Average Rubber Resistivity volume volume Resistivity Physical Result of Rubber resistivity resistivity (92.cm) Property Good restivity and good Rigid physical NBR* Low 0.242 0.384 0.313 Tough properties but needs more tests (High Santor Hig 3.71 3.19 3.60 Crcked rssivt enp andh w,4 .7 .6 rceeaktiit eeprop etie _______properties EPDM* High 5.027 2.955 3.991 semi- (High flexible resistivity) (2504)

I

it WO 94/06164 p c- i PCT/AU93/00456 Tough- Good.

flexible material EPDM High 0.219 0.512 0.366 with (it can be (2504) uniform improved) surface Acrylonitrile-Butadiene Rubber i Ethylene-Propylene-Diene Rubber As is shown in Table 2, the best rubber after SEBS are NBR and EPDM (Vistalon 2504). Although the resistivity of NBR is lower than EPDM but after mixing with other components, EPDM (Vistalon 2504) showed better general properties.

1.3 The effects of different grades of Carbon Black: As a result of the comparing of the HDPE grades, HDPE (GC 7260) was chosen and then different types of carbon black were mixed to find the best properties. It was observed that Vulcan XC 72 and 72R were the best materials with good properties. However, to optimise the types and amount of carbon black, this part of experiments needs more materials, information and work.

Materials Weight% HDPE (GC 7260) Rubber Carbon Black Graphite Fibre Table 3. The effects of different grades of Carbon Black Sample 1 Sample 2 Carbon volume volume Average Physical Description Black resistivity resistivity Resistivit Property Type y Degussa XE,2 0.240 0.240 0.240 Good Good FW,200) Cracked ACARB 0.278 0.467 0.372 (Brittle) Less than P optimum Ij WO 94/06164 PC/AU93/00456 Flexible Suitable with material with Vulcan 0.298 0.267 0.282 uniform lowest XC 72 surface resistivity Better Because of flexibility insufficient Vulcan 0.408 0.351 0.378 and material, w/w XC surface was 72R uniformity 2. Electrical Conductivirt of Polvpropylene (PP): 2.1 Homopolymer of PP: For easier processing, high melt flow index (MFI=40) Propathene (homopolymer) was used. Meanwhile, to compare with the other results, instead of Vulcan carbon black, Degussa mixed carbon black (XE2 FW200) and graphite fibre were added.

Materials

PP

Rubber Carbon Black Graphite Fibre Weight% i ,1 Table 4. The effects of different rubbers on the physical rnmnnitp properties of carbon-pp Sample 1 Sample 2 Average Rubber volume volume resistivity Physical Description Type resistivity resistivity (Q.cm) Property Cracked NBR 0.983 0.753 0.859 (brittle) Unsuitable ii! i

C:~

4 WO 9 4\ 1/06164 PCr/AU93/00456 One of the best samples with semi-tough property, but needs more test to SEBS 0.415 0.512 0.464 Flexible reduce resistivity and also replacing of SEBS with EPDM may be resulted to better properties 2.1 Copolymer of PP: To study the roll of a PP-copolymer, Propathene LZM197CR MFI=40 was used in the same conditions.

Materials Weight% CO-PP Rubber Carbon Black Graphite Fibre Table 5. The effects of different rubbers on the physical properties of carboncopolymer composite.

Sample 1 Sample 2 Average Rubber volume volume resistivity Physical Description Type resistivity resistivity (Q.cm) Property Cracked NBR 0.751 0.751 (brittle) Unsuitable brittle, Although the physical with some properties are weak but SEBS 0.218 0.136 0.177 small very low resistance cause cracks on making and testing more one side samples 1. Electrical Conductivity of Poly Vinvlchloride (PVC): Generally, vinyls will withstand continuous exposure to temperature ranging up to 130°F; flexible types, filaments, and some rigid are unaffected even by higher temperature up to 200 0 F. One of the basic advantages is the way it accepts compounding ingredients.

For instance, PVC can be plasticised with a variety of plasticiser to produce soft, yielding i i i -L ;t IYl WO 94/06164 PCT/AU93/00456 materials to almost any desired degree of flexibility. PVC raw materials are available as resin, latexes organosols, plastisols, and compounds.

PVC is extremely resistant to inorganic acids such as hydrochloridric, nitric, phosphoric, and concentrated sulfuric acids. The fatty acids, stearic, oleic, and lionelic, have little effect upon PVC at ambient temperatures. Rigid PVC is extremely resist to oxidising agents such as strong sulfuric, nitric, chromic acids, hydrogen peroxide, and sodium hypochlorite. The common solvents such as ketones, esters, ethers, chlorinated hydrocarbons, and aromatic hydrocarbons soften and in some instances dissolve rigid PVC.

Alcohols and aliphatic hydrocarbons have little effect upon PVC. It is completely resistant to all common animal, mineral, and vegetable oils. (Haper. handbook of plastics and elastomers, McGraw-Hill Book Co. 1975).

Table 6. Comparison of HDPE and PVC properties: Property HDPE PVC (rigid) (low plasticiser content) (high plasticiser content) Excellent electrical (insulation) Properties, Low electrical; losses. Tough and chemically resistant, but weak to varying degree in creep and thermal resistance.

Their thermal stability generally increase with density class.

I,,

Good low-cost, general purpose thermoplastic material, but poor electrical (resistivity) properties. Greatly influenced by plasticisers.

Many varieties available, including flexible and rigid types. Flexible PVC widely used for wire insulation and jacketing.

Extrusion, blow moulding, injection moulding, rotational moulding, film sheet, compression moulding, vacuum forming casting.

Common available form Blow moulding, extrusions, injection moulding, thermoformed parts, stock shapes, film, fibre foams.

Volume resistivity Ohm.cm ASTM D257 6x 1015-1018 1012 -1016 1014-1015 1011- 10 13 ,i-L j 4

I

-WO094/06164 PCT/AU93/00456 Dielectric strength Volt/mil ASTM D149 Dielectric constant c/s ASTM D150 Power Factor c/s ASTM D150 S.g Chemical resistance (sulfuric acid 78%, Chemical resistance (sulfuric acid 93 Tensile strength (psix 104) ASTM D638,651I Young's modulus (psix 105) ASTM D747 Elongation at break ASTM D638 >800 400-500 >400 >300 2.25-2.35 <0.0005 0.94 1 3-3.2 <0.02 <0.1 1.38 1.36 0. 1 1.35 excellent excellent 0.3 1-0. 55 0.8-1.5 50-800 excellent excellent 0.75-0.85 3.0-4.0 2-40 good fai r 0.4-0.6 fair weak 0.2-0.4 5.0-7.0 200-25- 350-450 I WO 94/06164 PTA9/05 PCr/AU93/00456 Flexural strength (psix 104) ASTM D790 Compressive strength (psix 104) ASTM D697 Hardness (Rockwell) ASTM D785 Heat distortion Impact strength ft lb/in notch Izod ASTM D256 Continues heat resistance 0.2-0.3 1.35 1,20 0.2-0.3 0.75-0.85 1.1-1.4 D60-70 (Shore) 144- 190 1,5-12

RHO

165 1-3 R 1051 D76-80 (Shore) 12-17

I

Flammability very slow burning, self-extinguishing very slow burning Water <0.01 0.07-0.40 0.15-0.75 absorption ,u vinyipyraine, 2-methyl-5-vinylpyridine. Examples of polyethylenically unsaturated WO 94/06164 PCT/AU93/00456 Softening point (Vicat) oC ASTM D1525 Resistance to solvents ASTM D543 120-130 80-90 70-80 unaffected below 80°C swell in aromatic hydrocarbons, soluble in ketones and esters.

Due to very difficult processing of pure PVC, Experimental 7102 01 (ICI) was used.

Materials

PVC

Rubber Carbon Black Graphite Fibre Weight% Table 7. The effects of different rubbers on the physical properties of carbon-PVC composite.

i! i Sample 1 Sample 2 Average Rubber volume volume resistivity Physical Description Type resistivity resistivity (Q.cm) Property NBR 0.486 0.626 0.556 It seems tough It needs more test i.

l I 11. WO 94/06164 PCT/AU93/00456 It seems that polymer could not Brittle, but mix with graphite SEBS 0.212 0.800 0.508 without fibre very well. So cracks it may be because of unsuitable mixing and then moulding temperature or polarity of one of the components.

However it needs more testing.

Preferred Materials Thk 1. Carbon Black 1. Degussa FW 200 2. Degussa Printex x E 3. Vulcan 72 x C 4. Vulcan 72 x CR

ACARBP

6. Black Pearl 2000 7. Activated Cole 8. Activated Carbon 2. Graphite Powder 1. Lonza 2. Thai Gypsum 3. Plasticizer and Lubricant 1. Wax op 2. Wax Pe520 3. GMS Loxiol G12 4. Loxiol G15 4. Rubber 1. NBR 2. EPR 3. EPR 4. EPR

EPR

6. EPDM 7. EPDM s (Cabot) (Cabot) (Cabot) (Cabot) (Merck) (Hoechst) (Hoechst)

(IEI)

(IEI)

404 504 805 808 2504 3708 (Vistalon) S(Vistalon) (Vistalon) (Vistalon) (Vistalon) (Vistalon) (Vistalon) 1 lir:~I cii; i i. rLI -i i.iiL 1 4 WO 94/06164 PCT/AU93/00456 8.

9.

11.

12.

13.

14.

Plastic 1.

2.

3.

4.

6.

7.

8.

9.

11.

12.

13.

14.

S

I

S

S

I

I

I

EPDM 7000 BPDM Santoprene ;BS K1162 !EBS K1652 ;BS Aldrich BPR VM42 sobutylene/CO/PE BM x 42 3utyl (Vistalon) (Shell-Keraton) (Shell-Keraton) prc (raw material) (ICI) prc dry blend (ICI) nylon u (ICI) nylon 6 (ICI) Epalex Polyproplyene/carbon black (Poly Pacific) LDPE 21624 (Hoechst) LDPE 1711200 (Hoechst) HDPE 7260 (inechst) HDPE 7655 (Hoechst) HDPE 7260 H (Hoechst) HDPE 7255 (Hoescht) PPW Polypropylene W (Hoechst) PPT Polypropylene T (Hoechst) PPI2m60CR (Hoechst) PP Copolymer (L2m 197CR) (Hoechst)

I

ICI pp (Polypr,:iplene) Unit FURTHER EXAMPLE Preparation Procedure of Conductive Carbon Polymer Composite 350 grams of granulated composite: Typical formulation:- 1. HDPE: TPI TYPE G-2855 2. Carbon Fiber Besfight type HTA C6-S 3. Graphite powder from graphite electrode grinding 4. SEBS Shell G-1652 is spread onto a 0.75 x 420 x 620 mm mould and then the mould is covered on. The mould is placed onto a hydraulic-hot-press and, under no pressure, it is heated up to 170 0 C for minutes, then the pressure is slowly increased up to 45 tons for another 30 minutes, then the moulded composite material is cooled down to room temperature (2 hours) to obtain the thin, smooth and flexible carbon-polymer sheet.

To prepare an end-electrode, a metal mesh (such as copper) is placed in the bottom of 11 1 WO 94/06164 PCT/AU93/00456 24 the mould. The carbon-plastic sheet is placed on top and the mould heated up to 170 0 C. The temperature is maintained for 30 minutes before applying the same pressure of 45 tons for minutes. While keeping the hot carbon-plastic sheet with the metal mesh backing in mould, a 300 x 500 mm window is placed on the top of the hot sheet and a graphite felt is placed in the window. A pressure of a 2 tons is then applied to the mould with the window, and this is maintained for 30 minutes. The mould is then cooled down to room temperature to obtain the carbon-plastic and graphite felt composite end-electrode.

To manufacture a bipolar electrode, two windows, are required. Placing the two windows on both sides of the prepared composite carbon-plastic sheet, two pieces of to electrochemically active layers (graphite felt) are placed into the two windows. By following the same procedure of bonding felt for the end-electrode, a bipolar electrode can be obtained.

INDUSTRIAL APPLICABILITY The electrodes of the invention may be further processed to produce bipolar electrodes and end-electrodes. An electrode of the invention may be can be utilized in vanadium redcx cells and in electrodepositing of polypyrrole, polyaniline or metal oxides.

I

1-

Claims (24)

1. A flexible, conducting plastic electrode comprising: a conductive filler material; 8 thermo-plastic polymer; and an elastomeric polymer at least partially cross-linked with wherein the amount of is such that the electrode is electrically conducting and the degree of cross-linking of with is such that the electrode is flexible and has high tensile strength.

2. The electrode of claim 1 further including: a further electrode component selected from the group consisting of a metal mesh, a metal sheet, a metal foil, and graphite felt, pressure and heat welded in a configuration selected from the group consisting of onto at least one surface of the flexible, conducting plastic electrode, a metal foil between two conducting plastic electrodes, and a metal mesh between two of the conducting plastic electrodes of claim 1.

3. The electrode of claim I wherein the filler material is selected from the group consisting of carbon black, graphite, metal powder, metallized glass fibres, pitch-derived carbon fibres, graphite fibres, polyacrylonitrile-derived carbon fibres and polyacrylonitrile- derived graphite fibres.

4. The electrode of claim 3 wherein the filler material comprises carbon black in an amount of 10-70 wt% of the total composition.

The electrode of claim 3 wheein the filler material comprises a mixture of carbon black and graphite fibres in a weight ratio in the range 5:95 to 95:5 in an amount of 10-70 wt% of the total composition.

6, The electrode of claim 5 wherein the carbon black to graphite fibres is in a ratio of 50:50 wt%.

7. The electrode of any one of claims 3 to 6 wherein at least two different types of carbon black are used, namely, fine carbon black powder (2 35nm) and coarse carbon black powder (35nm 10,000nm) in a weight ratio of fine carbon:coarse carbon of from 1:99 to 99:1.

8. The electrode of claim 3 wherein the electrode has a weight ratio of carbon black plus graphite fibres content to total polymer of 2:3. P

9. The electrode of claim 1 wherein the thermo-plastic polymer is 10-80wt% of the electrode.

10. The electrode of claim 1 wherein the thermo-plastic polymer is selected from the group consisting of low density polyethylene, high density polyethylene, polypropylene, polybutylene or polystyrene.

11. The electrode of claim 1 wherein the elastomeric polymer includes at least one or more polymers selected from the group consisting of styrene-isoprene-styrene, NBR, EPDM, EP, SB, EPR, n-butyl rubber, styrene-butadiene-styrene, santoprene, and styrene-(ethene- lllll~ I -WO 94/06164 PCT/AU93/00456 26 butene)-styrene.

12. The electrode of claim 1 or 11 wherein the elastonieric polymer is from 1-50wt% of the electrode.

13. The electrode of claim 1 wherein the electrode comprises: thermo-plastic polymer 30wt% elastomeric polymer cross-linked with thermoplastic polymer 10wt% conductive filler material 5-40wt%; and graphite felt heat and pressure fused onto at least one.surface of the electrode.

14. A process for making a flexible, conducting plastic electrode, the process comprising: mixing a thermo-plastic polymer, an elastomeric polymer and conductive filler material, the mixing being at a temperature(s) above the melting point temperatures of the thermo-plastic polymer and the elastomeric polymer, pressure moulding the mixture of at a temperature(s) above the melting temperatures of the thermo-plastic polymer and the elastomeric polymer until the polymers are at least partially cross-linked wherein the degree of cross-linking of the thermo-plastic polymer with the elastomeric polymer is such that the electrode is flexible and has high tensile strength, and cooling the cross-linked polymerized mixture of to form the electrode; wherein the amount of the conductive filler material is such that the electrode is electrically conducting.

The process of claim 14 wherein in step the polymerized mixture of is cooled rapidly.

16. The process of claim 14 further comprising adding a polymerization initiator to the mixture of and optionally adding at least one chemical additive to the mixture of

17. The "ess of any one of claims 14 to 16 further including the step of pressure and heat welding at least one electrode material selected from the group consisting of a metal mesh, metal sheet, a metal foil and a graphite felt onto at least one surface of the flexible, conducting plastic electrode.

18. The process of any one of claims 14 to 16 wherein the filler material comprises one or more materials selected from the group consisting of carbon black, graphite, metal powder, metallized glass fibres, pitch-derived carbon fibres, graphite fibres, polyacrylonitrile-derived carbon fibres and polyacrylonitrile-derived graphite fibres.

19. The process of any one of claims 14 or 16 wherein the filler material is comprised of a mixture of carbon black and graphite fibres in a range of 10-70 wt% of the total composition.

The process of any one of claims 14 or 16 wherein the elevated pressure is in the range from 25 2500 Kg/cm 2

21. The process of any one of claims 14 or 16 wherein during the elevated pressure step l i _r i -i WO 94/06164 PCT/AU93/00456 27 the temperature is in the range 150 750°C.

22. A flexible, conducting plastic electrode when prepared by the process of claim 14.

23. An all-vanadium redox battery having a positive compartment containing a catholyte in electrical contact with a positive electrode, the catholyte comprising an electrolyte containing tetravalent vanadium ions or pentavalent vanadium ions, a negative compartment containing an anolyte in electrical contact with a negative electrode, the anolyte comprising an electrolyte containing tetravalent vanadium ions, trivalent vanadium ions or divalent vanadium ions, and an ionic conducting separator disposed between the positive and negative compartments and in contact with the catholyte and anolyte to provide ionic communication therebetween and wherein the catholyte includes a salt of the formula VO(X)y where when y is 2 then X is selected from the group consisting of F, Br and Cl and when y is 1 then X is selected from the group consisting of SO 4 or O, V20 5 V 2 0 3 V 2 0 4 VO, VSO 4 VOSO 4 V 2 (S0 4 3 (V0 2 2 SO 4 and NH 4 VO 3 and the concentration of the salt is 0.1M to and wherein at least one of the positive and negative electrodes is a conducting plastic electrode of claim 1 or 22.

24. A flexible, conducting plastic electrode comprising: a conductive filler material; a thermo-plastic polymer; and an elastomeric polymer; wherein the amount of is such that the electrode is electrically conducting and the amounts of are such that the electrode is flexible and has high tensile strength. :I