Global electricity production from renewable sources has grown dramatically in recent years. The intermittent nature of renewable forms of electricity generation has proven difficult to incorporate into regional electrical grids. Grid-scale electricity storage methods are a promising solution to the inefficiencies of unpredictable electricity generation. Redox flow batteries have demonstrated the ability to be used as reasonably low-cost, long-term, grid-scale electrical storage methods. Specifically, vanadium redox flow batteries (VRBs) have been of special interest due to their chemical stability, long life cyclability, and potential for high electrical capacity compared to other redox chemistries. Accompanying these advantages are some research challenges. There have been a number of efforts to improve the electrical conductivity of VRBs by physically or chemically altering the electrodes of the cell. Most VRBs use a carbon or graphite felt as a porous cathode and anode of the battery – the large surface area from the felt is used to increase the number of reaction sites at which the redox reaction can occur. Many modifications to the electrodes have been investigated, including using various highly conductive carbons, metal catalysts, and covering the carbon felt with hydrophilic surface groups. Less attention has been spent improving the membrane surface properties to improve electrical conductivity in the cell. A new approach to improve the rate capability of VRBs involves improving the electrical conductivity of the surface of the membrane itself using air-assisted electrospray deposition of conductive carbons mixed with a binder.

A conductive coating of carbon nanotubes (CNTs) and Nafion dispersion in water was used to coat a Nafion 117 membrane via air-assisted electrospraying to improve the rate capability and cycling performance of VRBs. It was found that electrospraying a highly conductive coating directly onto the surface of the membrane allowed for stable cycling performance at nearly double the current density that was afforded by the pristine Nafion membrane. A templating technique was used during the electrospraying process to allow for alternating domains of coated and uncoated membrane surface, which helped reduce the restriction of proton transport across the membrane, further improving rate capability and capacity retention of the VRB. The interfacial resistance between the membrane and the electrode was greatly diminished with the addition of a very small mass (<0.05 mg/cm²) of CNTs. This method has shown to be a fast, simple, and scalable technique for improving the rate capability of vanadium redox flow batteries, with the potential for extension to other redox flow battery systems.