Methods for forming magnetically modified electrodes and articles produced thereby

Abstract

The present invention is directed to methods for making magnetically modified electrodes and electrodes made according to the method. Such electrode are useful as electrodes in batteries, such as Ni-MH batteries, Ni—Cd batteries, Ni—Zn batteries and Ni—Fe batteries.

1 . A method for forming a magnetically modified electrode, which comprises: providing a substrate comprising a magnetic material; and forming a coating layer on said substrate, wherein said coating layer comprises particles capable of generating electrochemical energy in the presence of a magnetic field. 
   
   
       2 . The method according to  claim 1 , wherein said substrate comprises a member selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron and combinations thereof. 
   
   
       3 . The method according to  claim 1 , wherein said particles capable of generating electrochemical energy in the presence of a magnetic field are selected from the group consisting of nickel hydroxide, zinc hydroxide, cobalt oxide, manganese oxide, lithium, lithium hydroxide and combinations thereof. 
   
   
       4 . The method according to  claim 1 , wherein said forming a coating layer comprises: preparing a mixture comprising particles capable of generating electrochemical energy in the presence of a magnetic field, a solvent and, optionally, a binder; and applying said mixture to at least a portion of said substrate; and, optionally, drying said mixture for a time effective to remove at least a portion of said solvent therefrom. 
   
   
       5 . The method according to  claim 4 , wherein said mixture is applied by spray coating, spin coating, painting, drop depositing, decal transfer, laminating or rolling. 
   
   
       6 . The method according to  claim 4 , wherein said solvent is selected from the group consisting of water, ethanol, methanol, benzene, toluene and combinations thereof. 
   
   
       7 . The method according to  claim 4 , wherein said solvent is water. 
   
   
       8 . The method according to  claim 4 , wherein said mixture comprises a binder. 
   
   
       9 . The method according to  claim 8 , wherein said binder is selected from the group consisting of polymers, KOH, NaOH, LiOH, fatty acids, liposomes and combinations thereof. 
   
   
       10 . The method according to  claim 8 , wherein said binder comprises a polymer. 
   
   
       11 . The method according to  claim 10 , wherein said polymer is selected from the group consisting of hydroxypropyl methylcellulose, carboxymethyl cellulose, hydroxy methylcellulose, methyl cellulose and combinations thereof. 
   
   
       12 . The method according to  claim 1 , wherein said coating layer further comprises magnetic particles. 
   
   
       13 . The method according to  claim 10 , wherein said magnetic particles comprise a member selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron and combinations thereof. 
   
   
       14 . The method according to  claim 1 , further comprising coating at least a portion of said magnetic particles with an inert material prior to forming said coating layer. 
   
   
       15 . The method according to  claim 14 , wherein said inert material is selected from the group consisting of silanes, polystyrene and combinations thereof. 
   
   
       16 . A method for forming a magnetically modified electrode, which comprises: providing a substrate; and forming a coating layer on said substrate, wherein said coating layer comprises particles capable of generating electrochemical energy in the presence of a magnetic field and magnetic particles. 
   
   
       17 . The method according to  claim 16 , wherein said substrate comprises a member selected from the group consisting of metals, carbon, zinc, semiconductors, semimetals, magnetic materials and combinations thereof. 
   
   
       18 . The method according to  claim 16 , wherein said substrate comprises nickel. 
   
   
       19 . The method according to  claim 16 , wherein said particles capable of generating electrochemical energy in the presence of a magnetic field are selected from the group consisting of nickel hydroxide, zinc hydroxide, cobalt oxide, manganese oxide, lithium, lithium hydroxide and combinations thereof. 
   
   
       20 . The method according to  claim 16 , wherein said magnetic particles are selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron or combinations thereof. 
   
   
       21 . The method according to  claim 19 , wherein said magnetic particles are selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron or combinations thereof. 
   
   
       22 . The method according to  claim 16 , wherein said forming a coating layer comprises: preparing a mixture comprising particles capable of generating electrochemical energy in the presence of a magnetic field, a solvent and, optionally, a binder; and applying said mixture to at least a portion of said substrate; and, optionally, drying said mixture for a time effective to remove at least a portion of said solvent therefrom. 
   
   
       23 . The method according to  claim 22 , wherein said mixture is applied by spray coating, spin coating, painting, drop depositing, decal transfer, laminating or rolling. 
   
   
       24 . The method according to  claim 22 , wherein said solvent is selected from the group consisting of water, ethanol, methanol, benzene, toluene and combinations thereof. 
   
   
       25 . The method according to  claim 22 , wherein said solvent is water. 
   
   
       26 . The method according to  claim 22 , wherein said mixture comprises a binder. 
   
   
       27 . The method according to  claim 26 , wherein said binder is selected from the group consisting of polymers, KOH, NaOH, LiOH, fatty acids, liposomes and combinations thereof. 
   
   
       28 . The method according to  claim 26 , wherein said binder comprises a polymer. 
   
   
       29 . The method according to  claim 28 , wherein said polymer is selected from the group consisting of hydroxypropyl methylcellulose, carboxymethyl cellulose, hydroxy methylcellulose, methyl cellulose and combinations thereof. 
   
   
       30 . The method according to  claim 16 , further comprising coating at least a portion of said magnetic particles with an inert material prior to forming said coating layer. 
   
   
       31 . The method according to  claim 30 , wherein said inert material is selected from the group consisting of silanes, polystyrene and combinations thereof. 
   
   
       32 . A method for forming a magnetically modified electrode, which comprises: providing a substrate; and forming a coating layer comprising particles capable of generating electrochemical energy in the presence of a magnetic field on said substrate, wherein said method further comprises subjecting said particles to an external magnetic field before, during or after forming said coating layer. 
   
   
       33 . The method according to  claim 32 , wherein said external magnetic field has a field strength of from about 0.1 T to about 2.0 T. 
   
   
       34 . The method according to  claim 32 , wherein said external magnetic field has a field strength of about 0.2 T. 
   
   
       35 . The method according to  claim 32 , wherein said particles capable of generating electrochemical energy in the presence of a magnetic field are subjected to an external magnetic field before forming said coating layer. 
   
   
       36 . The method according to  claim 32 , wherein said particles capable of generating electrochemical energy in the presence of a magnetic field are subjected to an external magnetic field after forming said coating layer. 
   
   
       37 . The method according to  claim 32 , wherein said substrate comprises a member selected from the group consisting of metals, carbon, zinc, semiconductors, semimetals, magnetic materials and combinations thereof. 
   
   
       38 . The method according to  claim 32 , wherein said substrate comprises nickel. 
   
   
       39 . The method according to  claim 32 , wherein said particles capable of generating electrochemical energy in the presence of a magnetic field are selected from the group consisting of nickel hydroxide, zinc hydroxide, cobalt oxide, manganese oxide, lithium, lithium hydroxide and combinations thereof. 
   
   
       40 . The method according to  claim 32 , wherein said forming a coating layer comprises: preparing a mixture comprising said capable of generating electrochemical energy in the presence of a magnetic field, a solvent and, optionally, a binder; and applying said mixture to at least a portion of said substrate; and, optionally, drying said mixture for a time effective to remove at least a portion of said solvent therefrom. 
   
   
       41 . The method according to  claim 40 , further comprising subjecting said particles capable of generating electrochemical energy in the presence of a magnetic field to an external magnetic during at least a portion of one of said preparing, applying or drying. 
   
   
       42 . The method according to  claim 40 , wherein said mixture is applied by spray coating, spin coating, painting, drop depositing, decal transfer, laminating or rolling. 
   
   
       43 . The method according to  claim 40 , wherein said solvent is selected from the group consisting of water, ethanol, methanol, benzene, toluene and combinations thereof. 
   
   
       44 . The method according to  claim 40 , wherein said solvent is water. 
   
   
       45 . The method according to  claim 40 , wherein said mixture comprises a binder. 
   
   
       46 . The method according to  claim 45 , wherein said binder is selected from the group consisting of polymers, KOH, NaOH, LiOH, fatty acids, liposomes and combinations thereof. 
   
   
       47 . The method according to  claim 45 , wherein said binder comprises a polymer. 
   
   
       48 . The method according to  claim 47 , wherein said polymer is selected from the group consisting of hydroxypropyl methylcellulose, carboxymethyl cellulose, hydroxy methylcellulose, methyl cellulose and combinations thereof. 
   
   
       49 . The method according to  claim 32 , wherein coating layer further comprises magnetic particles. 
   
   
       50 . The method according to  claim 49 , wherein magnetic particles are selected from the group consisting of Co, Ni, Fe, samarium cobalt, neodymium-iron-boron or combinations thereof. 
   
   
       51 . The method according to  claim 32 , further comprising coating at least a portion of said magnetic particles with an inert material prior to forming said coating layer. 
   
   
       52 . The method according to  claim 51 , wherein said inert material is selected from the group consisting of silanes, polystyrene and combinations thereof. 
   
   
       53 - 94 . (canceled)