Process for the Production of a Hierarchically Structured Porous Precious Metal Catalyst in Powder Form and Its Application

Simple SummaryContent extracted with AI.

This invention describes a method to produce a hierarchically structured, porous powder containing iridium and/or ruthenium compounds. The process uses both 'soft' (amphiphilic polymer) and 'hard' (colloidal particle) templates to create a unique morphology in which large pores (macropores) are structured with smaller pores (mesopores) in their walls. After forming and mixing the precursor components, specialized thermal and chemical treatments remove the templates, resulting in a powder with an exceptionally high surface area and controlled pore architecture. This powder is particularly suitable for use as a catalyst, especially in electrochemical applications like water electrolysis using proton exchange membrane (PEM) technology.

Use CasesContent extracted with AI.

• As a catalyst in acidic water electrolysis (PEM electrolyzers) for green hydrogen production.
• Preparation of inks for fuel cell or electrolyzer electrode coatings.
• Electrocatalysis applications that require highly accessible active sites, such as oxygen evolution reactions (OER).
• General heterogeneous catalysis in chemical industries where high-surface-area catalysts improve efficiency.
• Research and development for advanced catalytic materials in renewable energy devices.

BenefitsContent extracted with AI.

• Significantly increased catalyst surface area, leading to higher catalytic activity.
• Improved control over physical and electrochemical properties through tailored pore structure.
• Enhanced accessibility for reactants to active catalytic sites, resulting in better efficiency.
• Superior mass transport inside catalyst layers, reducing diffusion limitations.
• Greater stability and reproducibility of performance compared to conventional catalyst powders.
• Improved dispersion stability in catalyst inks, leading to better shelf life and easier electrode manufacturing.
• Reduction in toxic by-products during synthesis and potential for template recycling, making the process more environmentally friendly.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to a method for producing a hierarchically structured porous powder of an iridium and/or ruthenium compound, comprising the following steps: (i.) providing a solution which comprises a precious metal precursor, a soft template and a first solvent, the noble metal precursor comprising an iridium and/or ruthenium salt and the soft template being an amphiphilic polymer; (ii.) providing a hard template, the hard template being a colloidal particle; (iii.) mixing the solution (i.) and the hard template (ii.) and drying the mixture; (iv.) thermally treating the solid from (iii.) at a temperature T1, the temperature T1 being higher than the glass transition temperature of the hard template; (v.) adding a second solvent to the solid from (iv.) and subsequently removing the solvent; and (vi.) thermally treating (calcining) the solid from (v.) at a maximum temperature T2 to form the powder of an iridium and/or ruthenium compound, wherein the soft template and the hard template are decomposed by steps (iv.) to (vi.) and the powder of an iridium and/or ruthenium compound is formed, said powder having macropores with pore walls structured by mesopores. The invention further relates to a powder which can be produced by means of the method and to the use of said powder as a catalyst.