Catalyst electrodes, and methods of making and using the same

Patent metadata

Field	Value
Publication number	US-10927448-B2
Application number	US-201715704741-A
Country	US
Kind code	B2
Filing date	Sep 14, 2017
Priority date	Oct 10, 2011
Publication date	Feb 23, 2021
Grant date	Feb 23, 2021

Abstract

Methods of making catalyst electrodes comprising sputtering at least Pt and Ir onto nanostructured whiskers to provide multiple alternating layers comprising, respectively in any order, at least Pt and Ir. In some exemplary embodiments, catalyst electrodes described, or made as described, herein are anode catalyst, and in other exemplary embodiments cathode catalyst. Catalysts electrodes are useful, for example, in generating H 2 and O 2 from water.

First claim

What is claimed is:

1. A method of making an anode catalyst electrode comprising:
sputtering at least Pt and Ir onto nanostructured whiskers to provide multiple alternating layers comprising respectively in any order Pt and Ir; and
radiation annealing at least some of the multiple alternating layers comprising respectively Pt and Ir at least in part in an atmosphere comprising an absolute oxygen partial pressure of at least 2 kPa oxygen to provide the anode catalyst electrode.

2. The method of claim 1 , wherein the radiation annealing is at least in part conducted at an incident energy fluence of at least 20 mJ/mm 2 .

3. The method of claim 1 , wherein the Pt and Ir are present in an atomic ratio in a range from 10:1 to 1:10.

4. The method of claim 1 , wherein the whiskers are attached to a backing.

5. The method of claim 4 , wherein the backing is a membrane, and wherein the method further comprises acid washing to remove cation impurities prior to attaching the nanostructured whiskers to the membrane.

6. A method of making an anode catalyst electrode comprising:
sputtering at least Pt and Ir onto nanostructured whiskers to provide multiple alternating layers comprising respectively in any order Pt and Ir, wherein at least a portion of the multiple alternating layers are up to 20 Angstroms thick, to provide the anode catalyst electrode to provide the anode catalyst electrode.

7. The method of claim 6 , wherein the Pt and Ir are present in an atomic ratio in a range from 1:5 to 5:1.

8. The method of claim 6 , wherein the whiskers are attached to a backing.

9. The method of claim 8 , wherein backing is a membrane, and wherein the method further comprises acid washing to remove cation impurities prior to attaching the nanostructured whiskers to the membrane.

10. A method of making an anode catalyst electrode comprising:
sputtering at least Pt, Ir, and Ru onto nanostructured whiskers to provide multiple alternating layers comprising respectively in any order Pt, Ir, and Ru to provide the anode catalyst electrode.

11. The method of claim 10 further comprising radiation annealing at least some of the multiple alternating layers comprising respectively in any order Pt, Ir, and Ru catalyst at least in part in air with an irradiation at an incident energy fluence of at least 20 mJ/mm 2 .

12. The method of claim 10 , wherein the Pt, Ir, and Ru are present in atomic ratios in a range from 0.1:5:5 to 10:0.05:0.05.

13. The method of claim 10 , wherein the whiskers are attached to a backing.

14. The method of claim 13 , wherein backing is a membrane, and wherein the method further comprises acid washing to remove cation impurities prior to attaching the nanostructured whiskers to the membrane.

15. A method of generating hydrogen and oxygen from water, the method comprising:
providing a membrane electrode assembly comprising an anode catalyst comprising nanostructured whiskers having thereon multiple alternating layers comprising respectively in any order Pt and Ir, and a cathode;
providing water in contact with the catalyst; and
providing an electrical potential with sufficient current across the membrane electrode assembly to convert at least a portion of the water to hydrogen and oxygen on the cathode and anode respectively.

Assignees

• 3M Innovative Properties Co

Inventors

• Debe Mark K
• Atanasoski Radoslav
• Hendricks Susan M
• Vernstrom George D

Classifications

• C25B11/04 Primary

  characterised by the material · CPC title

• C25B11/097

  comprising two or more noble metals or noble metal alloys · CPC title

• C23C14/205

  by cathodic sputtering · CPC title

• C25B9/23

  comprising ion-exchange membranes in or on which electrode material is embedded · CPC title

• C23C14/3414 Primary

  Metallurgical or chemical aspects of target preparation, e.g. casting, powder metallurgy · CPC title