An approach to the mass production of gas diffusion electrodes

The author discusses the production of gas diffusion electrodes, and specifically air cathodes for metal-air batteries. These electrodes have a unique microstructure which is expected to be useful in rechargeable metal-air systems. The Alupower continuous web process for making gas diffusion electrodes is described. One form of the cathode is a four-ply laminate of two reactive layers, a current collector and a microporous hydrophobic film. The reactive layers are carbon-fiber tissues in which a controlled portion of the void volume in the carbon-fiber tissue is filled with aqueous reactive impregnant consisting of high-surface-area carbon, catalysts, and binder. The process is versatile and well-suited for mass production