Composite catalytic material particularly for electrolysis electrodes and method of manufacture
First Claim
1. A porous high surface area composite electroconductive catalytic material, comprising a porous high surface area pre-formed host matrix and a subsequently-applied impregnated catalyst supported by and distributed in the preformed host matrix, the composite catalytic material having an outer face which in use is in contact with a fluid medium, wherein the porous host matrix is a catalytic material comprising at least one platinum-group metal oxide and at least one non-precious metal oxide mixed intimately in a porous high surface area matrix structure and said subsequently-applied impregnated catalyst consists of at least one platinum-group metal, or at least one platinum-group metal oxide, or mixture thereof.
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Abstract
A porous high surface area composite electroconductive catalytic material, particularly as electrocatalyst for electrolysis electrodes, comprises a porous pre-formed matrix which is a catalytic mixed crystal material of at least one platinum group metal oxide and at least one valve metal oxide throughout which a subsequently-added additional catalyst preferably consisting of at least one platinum group metal and/or oxide is dispersed by chemideposition in an oxidizing or reducing atmosphere preferably followed by an annealing post heat treatment. The porous matrix may be ruthenium-titanium oxide and the additional catalyst advantageously comprises at least two oxides of ruthenium, rhodium, palladium and iridium, other combinations being possible.
57 Citations
20 Claims
- 1. A porous high surface area composite electroconductive catalytic material, comprising a porous high surface area pre-formed host matrix and a subsequently-applied impregnated catalyst supported by and distributed in the preformed host matrix, the composite catalytic material having an outer face which in use is in contact with a fluid medium, wherein the porous host matrix is a catalytic material comprising at least one platinum-group metal oxide and at least one non-precious metal oxide mixed intimately in a porous high surface area matrix structure and said subsequently-applied impregnated catalyst consists of at least one platinum-group metal, or at least one platinum-group metal oxide, or mixture thereof.
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8. A porous high surface area composite electroconductive catalytic material comprising a porous pre-formed matrix on the surface of a valve metal base and a subsequently-applied catalyst dispersed throughout the porous matrix, the composite catalytic material having an outer face which in use is in contact with a fluid medium, characterized in that the porous matrix is a catalytic mixed crystal material comprising at least one platinum-group metal oxide and at least one co-formed non-precious metal oxide forming a porous high surface area coating on the valve metal base, the subsequently-applied catalyst being dispersed in this structure by chemideposition from at least one thermodecomposable platinum-group metal compound followed by annealing whereby both (a) the platinum-group metal oxide of the preformed matrix and (b) the subsequently-applied catalyst disposed inside the matrix structure are exposed through the pores of the composite electrocatalytic material to the medium contacting the outer face of the composite caatalytic material and wherein the subsequently-applied catalyst consists of at least one platinum-group, or at least one platinum-group metal oxide, or mixture thereof.
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9. A porous high surface area composite electroconductive catalytic material comprising a porous preformed catalytic matrix and a subsequently-applied additional catalyst dispersed throughout and supported by the preformed matrix, characterized in that:
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(a) the preformed matrix is a mixed catalytic material comprising at least one platinum-group metal oxide mixed intimately with at least one non-precious metal oxide in a porous high surface area support structure; (b) the subsequently-applied additional catalyst is a modifier catalyst which is of different composition to the mixed catalytic material of the preformed matrix; and (c) the subsequently-applied additional catalyst is carried by the preformed matrix as a thin discontinuous layer non-uniformly distributed in the porous high surface area support structure. - View Dependent Claims (10, 11, 13)
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18. The method of any one of claims to 12 or 13, wherein the porous matrix consists of a used electrocatalytic coating of a dimensionally stable electrolysis electrode.
Specification