High-surface carrier-free catalyst for electrochemical processes and method for its production

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This patent describes a new type of high-surface area, carrier-free (support-free) metal catalyst with an aerogel structure, suitable for electrochemical applications such as fuel cells, electrolyzers, and metal-air batteries. The invention details both the composition of the catalyst (which can comprise pure or alloyed metals like Pt, Pd, Au, Ni, etc.) and its unique synthesis method, which creates a highly porous, stable, and active material directly from metal precursors without using traditional carbon supports.

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• Electrocatalysts in fuel cells, particularly as cathode catalysts.
• Anode and cathode catalysts in water electrolyzers for hydrogen production.
• Air electrode catalysts in metal-air batteries, such as lithium-air or zinc-air cells.
• Catalysts for other electrochemical devices where high surface area and corrosion resistance are required.

BenefitsContent extracted from patent full text and abstract with AI.

• Increased catalytic surface area, leading to higher electrochemical activity.
• Eliminates the need for traditional carbon supports, preventing problems related to carbon corrosion and instability.
• Significantly improved chemical and electrochemical stability, resulting in longer catalyst life and better performance in harsh operating environments.
• Potential for lower precious metal loading, reducing overall costs without sacrificing activity.
• Applicable to a wide range of metals and alloys, increasing design flexibility for different applications.
• Simplified manufacturing process with fewer steps and no support removal required.

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Patent Abstract

A high-surface area carrier-free catalyst has aerogel structure made of metal, and has BET specific surface area of 30 m 2>/g or more, preferably 50 m 2>/g or more. Independent claims are included for the following: (1) preparation of catalyst, which involves providing an aqueous solution or organic metal salt solution, adding an aqueous or organic sodium borohydride solution, aging the aqueous or organic mixture, washing the obtained metal hydraulic gel using water and acetone, separating the water, introducing obtained acetone-containing metal hydraulic gel into a dryer, drying such that acetone is replaced with liquid carbon dioxide, converting the carbon dioxide to the gas phase by increasing the temperature of the carbon dioxide-containing metal hydraulic gel to more than the critical point of carbon dioxide, and discharging; (2) fuel cell, which consists of fuel cell electrode, membrane electrode assembly and/or catalyst layer containing the catalyst; (3) electrolyzer, which consists of electrode, membrane electrode assembly and/or catalyst layer containing the catalyst; and (4) metal-air battery, which consists of electrode, separator-electrode assembly and/or catalyst layer containing the catalyst.