Method for Producing Metal-Containing Spherical Porous Carbon Particles

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This invention discloses a novel method for producing metal-containing, spherical, porous carbon particles. The process involves polymerizing a carbon precursor with a structural template in a solvent, adding a metal compound to the resulting polymer solution, and then forming the particles via aerosol spray and thermal treatment. The method enables uniform distribution of metal nanoparticles within the porous carbon spheres, which can be further processed into inks and serve as catalysts, especially for various chemical and electrochemical applications.

Use CasesContent extracted from patent full text and abstract with AI.

• Catalysts for fuel cells (such as proton exchange membrane fuel cells)
• Catalysts for water electrolysis to generate hydrogen
• Catalysts for industrial chemical reactions (heterogeneous catalysis)
• Precursors for making conductive ink for printed electronics or sensor electrodes
• Components in automotive catalytic converters
• Electrocatalysts in batteries, supercapacitors, or electrolyzers
• Active components in sensors or gas storage materials

BenefitsContent extracted from patent full text and abstract with AI.

• Highly uniform and controllable distribution of metal nanoparticles within porous carbon structures
• Spherical and porous morphology increases effective surface area, improving catalytic activity
• Process supports wide variety of metals and templates, allowing tuning for specific applications
• Efficient, reproducible, and economical synthesis procedure scalable to industrial needs
• Porous spheres can be easily processed into inks or dispersions, enhancing manufacturing flexibility
• Enhanced electrical conductivity due to graphitized carbon structure, benefitting electrochemical applications
• Homogeneous metal distribution improves the performance and stability of catalysts
• Potential for flexible application onto various substrates via ink or spray-coating processes

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Patent Abstract

The invention relates to a process for producing metal-containing spherically porous carbon particles. To this end it is preferable when in a first step a carbon precursor is polymerized with a structure-forming template in a solvent to afford a polymer solution, in a second step the metal compound is added to the polymer solution and finally in a third step the metal-containing spherically porous carbon particles are formed by an aerosol spraying process. The invention further relates to a process for producing an ink and to a use of the metal-containing spherically porous carbon particles as catalyst.