High capacity redox electrodes

Abstract

The present disclosure relates to the manufacture and use of redox electrodes. In certain embodiments, the redox electrodes are manufactured using a hybrid material approach, such as using a redox polymer in combination with a support substrate, such as cellulose fibers or paper. In certain implementations, the redox electrodes are suitable for use at voltages greater than 25 V.

1 . An oxidation-reduction (redox) electrode, comprising:
 a support substrate comprising one or more of particles or fibers; and   a redox polymer combined with the support substrate particles or fibers and having a thickness greater than 1 micron with respect to the surface of the support substrate.   
     
     
         2 . The redox electrode of  claim 1 , wherein the redox polymer comprises a conjugated redox polymer. 
     
     
         3 . The redox electrode of  claim 2 , wherein the conjugated redox polymer comprises poly(3,4-ethylenedioxythiophene) (PEDOT). 
     
     
         4 . The redox electrode of  claim 2 , wherein the conjugated redox polymer comprises one or more of a conjugated polythiophene polymer, a conjugated polyaniline polymer, or a conjugated polypyrrole polymer. 
     
     
         5 . The redox electrode of  claim 1 , wherein the support substrate comprises textile fibers, a plastic substrate, or a polymer substrate. 
     
     
         6 . The redox electrode of  claim 1 , wherein the support substrate comprises cellulose fibers. 
     
     
         7 . The redox electrode of  claim 1 , wherein the redox polymer comprises a supporting counterion or anionic copolymer. 
     
     
         8 . The redox electrode of  claim 7 , wherein the supporting counterion or anionic copolymer comprises polystyrene sulfonate (PSS). 
     
     
         9 . The redox electrode of  claim 1 , wherein the redox polymer comprises poly(3,4-ethylenedioxythiophene) (PEDOT): polystyrene sulfonate (PSS). 
     
     
         10 . The redox electrode of  claim 1 , further comprising an ionic cross-linking agent. 
     
     
         11 . The redox electrode of  claim 10 , wherein the ionic cross-linking agent comprises MgSO 4 . 
     
     
         12 . The redox electrode of  claim 1 , further comprising an ionomer coating. 
     
     
         13 . The redox electrode of  claim 1 , further comprising:
 a metallic wire, foil, or mesh about which the support substrate and redox polymer are disposed.   
     
     
         14 . A method for manufacturing a redox electrode, comprising:
 blending an aqueous dispersion of a redox polymer with cellulose fibers to form a slurry;   solution casting the slurry into one or more molds each having a form factor corresponding to the redox electrode to form a respective redox electrode in each mold; and   recovering the respective redox electrode from each mold.   
     
     
         15 . The method of  claim 14 , wherein the aqueous dispersion comprises a PEDOT:PSS aqueous dispersion. 
     
     
         16 . The method of  claim 14 , wherein the slurry is 5-25 wt % PEDOT:PSS. 
     
     
         17 . The method of  claim 14 , wherein the slurry is 14-18 wt % PEDOT:PSS. 
     
     
         18 . The method of  claim 14 , further comprising:
 cross-linking the recovered redox electrodes using an MgSO 4  aqueous solution.   
     
     
         19 . A method for manufacturing a redox electrode, comprising:
 dip coating a cellulose paper substrate in an aqueous dispersion of a redox polymer one or more times; and   forming the redox electrode using the dip coated cellulose paper.   
     
     
         20 . The method of  claim 19 , wherein the aqueous dispersion comprises a PEDOT:PSS aqueous dispersion. 
     
     
         21 . A method for manufacturing a redox electrode, comprising:
 solution casting an aqueous dispersion of a redox polymer onto a cellulose paper substrate; and   forming the redox electrode using the solution cast onto the cellulose paper.   
     
     
         22 . The method of  claim 21 , further comprising:
 mounting the cellulose paper substrate in an aluminum frame at between about 100° C. to about 150° C. prior to solution casting.