Electrochemical Device and Method of Fabricating the Same

Abstract

A method of forming an electrode including an electrochemical catalyst layer is disclosed, which comprises forming a graphitized porous conductive fabric layer, optionally conditioning the graphitized porous conductive fabric layer, and dipping the graphitized porous conductive fabric layer into a solution containing polymer-capped noble metal nanoclusters dispersed therein. The polymer-capped noble metal nanoclusters as an electrochemical catalyst layer are adsorbed onto the graphitized porous conductive fabric layer. An electrochemical device with the electrode made thereby is also contemplated.

1 . An electrochemical device, comprising:
 a first electrode, comprising:
 a first substrate; 
 a porous conductive fabric layer formed on the first substrate, the porous conductive fabric layer being made of carbon fiber; and 
 an electrochemical catalyst layer comprised of a plurality of polymer-capped noble metal nanoclusters, the polymer-capped noble metal nanoclusters being adsorbed over a top surface and/or within pores of the porous conductive fabric layer; 
   a second electrode; and   a separating membrane disposed between the first electrode and the second electrode.   
     
     
         2 . The electrochemical device of  claim 1 , wherein the first electrode further comprises a conditioner layer formed on the porous conductive fabric layer and grabbing the polymer-capped noble metal nanoclusters. 
     
     
         3 . The electrochemical device of  claim 1 , wherein the porous conductive fabric layer is a graphitized film. 
     
     
         4 . The electrochemical device of  claim 1 , wherein the first substrate is a plastic substrate. 
     
     
         5 . The electrochemical device of  claim 1 , wherein the polymer-capped noble metal nanoclusters comprise noble metal selected from a group consisting of palladium, platinum, ruthenium, silver, and gold. 
     
     
         6 . The electrochemical device of  claim 1 , wherein the polymer-capped noble metal nanoclusters comprise a polymer selected from a group consisting of poly(N-vinyl-2-pyrrolidone (PVP), poly(acrylamide) (PAM), poly(vinyl alcohol) (PVAL), poly(acrylic acid) (PM), and poly(ethyleneimine) (PEI). 
     
     
         7 . The electrochemical device of  claim 1 , wherein the second electrode comprises:
 a second substrate; and   a dye-impregnated oxide layer formed on the second substrate.   
     
     
         8 . The electrochemical device of  claim 1 , wherein the first substrate is a conductive substrate or a non-conductive substrate. 
     
     
         9 . The electrochemical device of  claim 1 , wherein the first substrate is a flexible substrate. 
     
     
         10 . An electrochemical device, comprising:
 a first electrode, comprising:
 a conductive fabric layer having a support portion and a porous portion, the porous portion overlying the support portion; and 
 an electrochemical catalyst layer comprised of a plurality of polymer-capped noble metal nanoclusters, the polymer-capped noble metal nanoclusters being adsorbed on a top surface and/or within pores of the porous portion of the conductive fabric layer; 
   a second electrode; and   a separating membrane disposed between the first electrode and the second electrode.   
     
     
         11 . The electrochemical device of  claim 10 , wherein the first electrode further comprises a conditioner layer formed over the conductive fabric layer and grabbing the polymer-capped noble metal nanoclusters. 
     
     
         12 . The electrochemical device of  claim 10 , wherein the conductive fabric layer contains graphite, and the support portion is a copolymer made from the graphite and a polymer. 
     
     
         13 . The electrochemical device of  claim 10 , wherein the conductive fabric layer is a graphitized film. 
     
     
         14 . The electrochemical device of  claim 10 , wherein the conductive fabric layer is made from carbon fibers. 
     
     
         15 . The electrochemical device of  claim 10 , wherein the polymer-capped noble metal nanoclusters comprise noble metal selected from a group consisting of palladium, platinum, ruthenium, silver, and gold. 
     
     
         16 . The electrochemical device of  claim 10 , wherein the polymer-capped noble metal nanoclusters comprise a polymer selected from a group consisting of poly(N-vinyl-2-pyrrolidone (PVP), poly(acrylamide) (PAM), poly(vinyl alcohol) (PVAL), poly(acrylic acid) (PAA), and poly(ethyleneimine) (PEI). 
     
     
         17 . The electrochemical device of  claim 10 , wherein the second electrode comprises:
 a substrate; and   a dye-impregnated oxide layer formed on the substrate.   
     
     
         18 . The electrochemical device of  claim 17 , wherein the second electrode further comprises a porous conductive fabric layer disposed between the substrate and the dye-impregnated oxide layer.