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Non-noble metal based electro-catalyst compositions for proton exchange membrane based water electrolysis and methods of making

  • US 10,041,179 B2
  • Filed: 12/21/2016
  • Issued: 08/07/2018
  • Est. Priority Date: 08/08/2012
  • Status: Active Grant
First Claim
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1. A method for preparing an electro-catalyst composition for an anode electrode in a proton exchange membrane-based water electrolysis system, comprising:

  • preparing a surfactant in solution;

    adding an ammonium compound to the surfactant in solution to form a first mixture;

    preparing a non-noble metal precursor in solution;

    combining the first mixture and the non-noble metal precursor in solution to form a first precipitate;

    separating and drying the first precipitate to form a non-noble metal oxide powder comprising two different non-noble metal oxides, each selected from the group consisting of tantalum oxide, tin oxide, niobium oxide, titanium oxide, tungsten oxide, molybdenum oxide, yttrium oxide, scandium oxide, copper oxide, zirconium oxide and nickel oxide;

    doping the non-noble metal oxide powder with a dopant precursor comprising an element selected from the group consisting of fluorine, chlorine, bromine, iodine, sulfur, selenium, tellurium and mixtures thereof;

    preparing an iridium oxide noble metal precursor in solution;

    combining the non-noble metal oxide powder with the iridium oxide noble metal precursor in solution to form a second mixture; and

    separating and drying a precipitate from the second mixture to form the electro-catalyst composition,wherein the resulting electro-catalyst composition is in a form selected from a complete oxide alloy and a complete solid solution, andwherein the electro-catalyst composition is one of the following general formulas;


    Ir1-2xSnxMxO2 and Ir1-2xSnxMxO2;

    Dwherein M represents Nb, Ta, Ti, W, Mo, Y, Sc, Cu, Zr, Ni, and mixtures thereof, D represents F, Cl, Br, I, S, Se, Te, and mixtures thereof, and x is a value from 10% to 45% based on weight of the composition.

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