Method of Manufacturing a Catalyst-Coated Three-Dimensionally Structured Electrode

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This patent describes a method for manufacturing a catalyst-coated, three-dimensionally structured electrode, especially suited for electrochemical applications like electrolyzers and fuel cells. The process involves applying a suspension containing a template material and a metal precursor onto a 3D metal substrate. After drying and thermal treatment, a mesoporous (highly porous at the nano- and microscale) catalyst layer is formed directly on the complex 3D substrate without using binders. This results in electrodes with high surface area, improved catalytic efficiency, and strong mechanical and electrical properties.

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• Electrodes for water electrolysis systems (hydrogen production)
• Anodes or cathodes in fuel cells for energy generation
• Electrodes in chlorine or HCl electrolyzers for industrial chemical production
• Advanced batteries or accumulators requiring high-performance electrodes
• Electrochemical sensors with high surface area and sensitivity
• Medical implants or drug delivery systems using controlled-release from mesoporous structures
• General electrochemical reactors in chemical processing industries

BenefitsContent extracted from patent full text and abstract with AI.

• Binder-free process preserves high electrical conductivity and active sites, leading to superior catalytic performance
• The method enables highly uniform, crack-free, and adherent coatings even on complex 3D-shaped substrates
• Customizable porosity and surface area significantly enhance electrochemical reactions and mass transport
• The process is efficient, reproducible, and economically scalable, capable of coating multiple substrates simultaneously
• Resulting electrodes exhibit excellent mechanical stability and durability under operational conditions
• Versatility in choice of substrate metals and catalyst compositions for targeting specific applications
• Possibility of integrating nanostructured features for advanced functionality in varied fields beyond energy (e.g., sensors, drug delivery)

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Patent Abstract

The invention relates to a method for producing a catalyst-coated three-dimensionally structured electrode. A mesoporous catalyst layer is synthesised on a three-dimensionally structured metal substrate by first generating a suspension from a template, a metal precursor and a solvent and applying it to the three-dimensionally structured metal substrate. The three-dimensionally structured metal substrate is then dried, so that the solvent within the suspension film evaporates and a layer of a catalyst precursor with integrated template structures is obtained. The three-dimensionally structured metal substrate comprising catalyst precursors is then subjected to a thermal treatment so that a mesoporous catalyst layer is created. The invention additionally relates to an electrode that has been produced by the method of the type mentioned at the beginning, and also to an electrochemical cell comprising such an electrode.