Thermodynamically stable binary oxide doped with lower valence element, its synthesis and application in electrochemical devices

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This invention relates to a new type of support material for electrodes in electrochemical devices, such as fuel cells, metal-air batteries, electrolyzers, and sensors. The core technology is a semiconducting binary metal oxide (like SnO2, TiO2, or CeO2) that has been doped with a lower valence element (such as Bi, Gd, or Ca). This specific doping produces a material with high surface area, excellent electrochemical and corrosion stability, and good electrical conductivity, overcoming the degradation problems of traditional carbon supports, especially in harsh oxidative or acidic environments.

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• Electrode support in polymer electrolyte fuel cells (PEFCs), especially for automotive or stationary power applications
• Electrodes in metal-air batteries, providing longer operational lifespans
• Electrolyzer electrodes for green hydrogen production
• Electrochemical sensors operating in aggressive chemical or oxidative environments
• Catalyst support for noble metals (e.g., Pt) in oxygen electrodes for energy devices
• Possible use as co-catalysts in oxygen reduction or evolution reactions

BenefitsContent extracted from patent full text and abstract with AI.

• Greatly improved resistance to corrosion compared to carbon or carbide/nitride supports, enhancing device longevity
• High surface area enables better dispersion of catalyst particles, reducing noble metal loading while maintaining performance
• Stable electrical conductivity even under harsh electrochemical conditions
• Reduced degradation during start/stop cycles in fuel cell operation, minimizing maintenance and replacement costs
• Doped oxides provide tunable electronic properties and may enhance catalytic activity directly
• Manufacturable via cost-effective wet chemistry (e.g., sol-gel synthesis), allowing for controlled nanostructure and scalability

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Patent Abstract

It is the aim of the present invention to provide a support material for applications in fuel cell, metal-air battery, electrolyzer electrodes and sensors showing relative high surface area and good electrical conductivity as well as both high dissolution and electrochemical stability. This aim is achieved according to the present invention by a support material for electrochemical applications, such as fuel cells, metal-air batteries, electrolyzer electrodes and sensors, having a composition of a semiconducting metal or transition metal oxide being doped with a lower valence element according to a general formula that is formulated as: (M Y ) 1-X (D z ) x O 2-´ , where M is a metal or transition metal in Y oxidation state and D represents the lower valence element with an oxidation state with Z