Roll-to-Roll Flash Joule Heating to Stabilize Electrocatalysts onto Meter-Scale Ni Foam for Advanced Water Splitting

The seamless integration of electrocatalysts onto the electrode is crucial for enhancing water electrolyzers, yet it is especially challenging when scaled up to large manufacturing. Despite thorough investigation, there are few reports that tackle this integration through roll-to-roll (R2R) methodology, a technique crucial for fulfilling industrial-scale demands. Here, we develop an R2R flash Joule heating (R2R-FJH) system to process catalytic electrodes with superior performance. The electrodes exhibited improved stability and activity, showcasing an exceptional performance within an alkaline water electrolysis (AWE) system. They achieved a low operation potential of 1.66 V at 0.5 A cm–2, coupled with outstanding durability over the operation of 800 h. We further demonstrated a prototype of a rolled-up water splitting apparatus, illustrating the efficiency of R2R-FJH electrodes in producing high-purity hydrogen through advanced water oxidation. Our study emphasized the practicality and scalability of the R2R-FJH strategy in the industrial manufacturing of high-performance electrodes for water electrolysis.