Process of increasing energy conversion and electrochemical efficiency of a scaffold material using a deposition material

Abstract

A process for increasing the energy conversion and electrochemical efficiency of a scaffold material using a deposition material comprises flowing by at least one surface of the scaffold material a solution which comprises the deposition material, forming agglomerations of the deposition material with at least one surface of the scaffold material, wherein the deposition material fills pores on the at least one surface of the scaffold material (“scaffold pores”) thereby increasing the surface area of the scaffold material, electrically connecting deposition material to the scaffold material via the formation of agglomerations, wherein said scaffold material is conductive and flow-through and wherein deposition material has a pore size (“deposition material pore size”) which is no larger than the scaffold pore size.

We claim: 
     
         1 . A process for increasing the energy conversion and electrochemical efficiency of a scaffold material using a deposition material, which comprises:
 flowing by at least one surface of the scaffold material a solution which comprises the deposition material;   forming agglomerations of the deposition material with at least one surface of the scaffold material, wherein the deposition material fills pores on the at least one surface of the scaffold material (“scaffold pores”) thereby increasing the surface area of the scaffold material; and   electrically connecting deposition material to the scaffold material via the formation of agglomerations, wherein said scaffold material is conductive and flow-through and wherein deposition material has a pore size (“deposition material pore size”) which is no larger than the scaffold pore size.   
     
     
         2 . The process of  claim 1  wherein scaffold material is porous, electrically conductive and facilitates electrochemical reactions when contacted with reactant in liquid or gas phase. 
     
     
         3 . The process of  claim 1  wherein scaffold material is selected from the group consisting of carbon paper, carbon/graphite felt, carbon cloth, carbon foam, metal foam, carbon aerogel, carbon nanofoam and packed bed electrodes. 
     
     
         4 . The process of  claim 1  wherein scaffold material is an electrode. 
     
     
         5 . The process of  claim 1  wherein the deposition material is electrically conductive and facilitates electrochemical reactions when contacted with reactant in liquid or gas phase. 
     
     
         6 . The process of  claim 1  wherein the deposition material is selected from the group consisting of carbon nanotubes, graphene, carbon nanoparticles, graphite flakes, carbon black, fullerenes, carbon oxides, graphene oxide, functionalized carbon materials, doped carbon materials, catalysts, catalyst nanoparticles, metal nanoparticles, metal nanorods, metal supported catalyst materials, carbon supported catalyst materials, and metal particles. 
     
     
         7 . The process of  claim 1  wherein the solution is water. 
     
     
         8 . The process of  claim 1  wherein the solution comprises an electrolyte which comprises at least one reactant for an electrochemical reaction. 
     
     
         9 . The process of  claim 1  wherein the solution is sulfuric acid. 
     
     
         10 . A process for increasing the energy conversion and electrochemical efficiency of a scaffold material using a deposition material, which comprises
 i) breaking existing bonded agglomerates of the deposition material to form broken agglomerates;   ii) diluting in a solution the broken agglomerates of the deposition material to mitigate interaction and re-agglomeration of the deposition material during flow through the scaffold material; and   iii) flowing the solution through at least one surface of a scaffold material such the broken agglomerates bond and re-agglomerate with the at least one surface of the scaffold material.   
     
     
         11 . The process of  claim 10  wherein sonication is used to break existing bonded agglomerates of the deposition material to form broken agglomerates. 
     
     
         12 . The process of  claim 10  wherein the solution is water. 
     
     
         13 . The process of  claim 10  wherein the solution comprises an electrolyte which comprises at least one reactant for an electrochemical reaction. 
     
     
         14 . The process of  claim 10  wherein the solution is sulfuric acid. 
     
     
         15 . The process of  claim 10  wherein scaffold material is porous, electrically conductive and facilitates electrochemical reactions when contacted with reactant in liquid or gas phase. 
     
     
         16 . The process of  claim 10  wherein scaffold material is selected from the group consisting of carbon paper, carbon/graphite felt, carbon cloth, carbon foam, metal foam, carbon aerogel, carbon nanofoam and packed bed electrodes. 
     
     
         17 . The process of  claim 10  wherein scaffold material is an electrode. 
     
     
         18 . The process of  claim 10  wherein the deposition material is electrically conductive and facilitates electrochemical reactions when contacted with reactant in liquid or gas phase. 
     
     
         19 . The process of  claim 10  wherein the deposition material is selected from the group consisting of carbon nanotubes, graphene, carbon nanoparticles, graphite flakes, carbon black, fullerenes, carbon oxides, graphene oxide, functionalized carbon materials, doped carbon materials, catalysts, catalyst nanoparticles, metal nanoparticles, metal nanorods, metal supported catalyst materials, carbon supported catalyst materials, and metal particles. 
     
     
         20 . A scaffold material with increased energy conversion and electrochemical efficiency properties which comprises a base scaffold material which is electrically conductive and flow-through, coupled with a deposition material deposited in pores on at least one surface of the scaffold material (“scaffold pores”) in the form of agglomerations thereby increasing the surface area of the scaffold material and wherein the deposition material has a pore size (“deposition material pore size”) which is no larger than the scaffold pore size.