Method for producing a catalyst system for gas reactions

Patent metadata

Field	Value
Publication number	US-2022387977-A1
Application number	US-202017754971-A
Country	US
Kind code	A1
Filing date	Aug 31, 2020
Priority date	Oct 21, 2019
Publication date	Dec 8, 2022
Grant date	—

Abstract

A method for producing a catalyst system for gas reactions comprising at least one planar structure of noble metal having gas-permeable openings, comprising the steps of:(1) providing at least one noble metal powder consisting of at least substantially spherical noble metal particles, and(2) repeatedly applying the noble metal powder or powders provided in step (1) in layers to a substrate in a build chamber, respectively followed by an at least partial melting of the respective noble metal powder applied as a layer with high-energy radiation, and allowing the melted noble metal powder to solidify within the scope of additive manufacturing.

First claim

1 .- 13 . (canceled)

14 . A method for producing a catalyst system for gas reactions comprising at least one planar structure of noble metal having gas-permeable openings, comprising the steps of:
(1) providing at least one noble metal powder consisting of at least substantially spherical noble metal particles, and (2) repeatedly applying the noble metal powder or powders provided in step (1) in layers to a substrate in a build chamber, respectively followed by an at least partial melting of the respective noble metal powder applied as a layer with high-energy radiation, and allowing the melted noble metal powder to solidify within the scope of additive manufacturing, wherein the or every planar structure of noble metal comprising gas-permeable openings has an individual weight per unit area in the range of 25 to 2500 g/m 2 , wherein the noble metal particles of the noble metal powder or powders have a particle size distribution with a d 10 value of ≥5 μm and a d 90 value of ≤80 μm, and wherein the noble metal of the noble metal particles of the noble metal powder or powders is selected from the group consisting of noble metal alloys of platinum with 1-15 wt. % rhodium, platinum with 2-15 wt. % rhodium and 0.1-20 wt. % palladium, platinum with 2-15 wt. % rhodium, 0.1-20 wt. % palladium, and 0.1-2 wt. % ruthenium, platinum with 2-15 wt. % rhodium, 0.1-20 wt. % palladium, and 0.1-5 wt. % iridium, palladium with 3-15 wt. % platinum, palladium with 1-20 wt. % platinum and 1-10 wt. % rhodium, palladium with 1-25 wt. % tungsten, and palladium with 1-15 wt. % nickel.

15 . The method according to claim 14 , wherein at least 80% of the noble metal particles, relative to their number, satisfy the condition 0.8 ≤d min /d max ≤1.0, wherein d min is the minimum diameter and d max is the maximum diameter of an individual noble metal particle.

16 . The method according to claim 14 , wherein the noble metal particles are produced by an atomization process.

17 . The method according to claim 14 , wherein the d 50 value of the particle size distribution is in the range from 20 to 30 μm.

18 . The method according to claim 14 , wherein the d 10 value is ≥10 μm and the d 90 value is ≤45 μm.

19 . The method according to claim 18 , wherein the d 10 value is in the range of ≥10 μm to ≤20 μm, and the d 90 value is in the range of ≥30 μm to ≤45 μm.

20 . The method according to claim 14 , wherein the catalyst system comprises or consists of one planar structure of noble metal, a plurality of identical planar structures of noble metal, or a plurality of different planar structures of noble metal, and wherein the one planar structure of noble metal, the plurality of identical planar structures of noble metal, or the plurality of different planar structures of noble metal constitute a complete catalyst system for gas reactions or a catalyst subsystem in the sense of a part of a complete catalyst system for gas reactions.

21 . The method according to claim 14 , wherein the planar structures of noble metal are planar objects selected from the group consisting of grids, perforated plates, screens, and nets.

22 . The method according to claim 14 , wherein the planar structure of noble metal or planar structures have a surface area in the range of 0.25 to 35 square meters.

23 . The method according to claim 21 , wherein the net or nets have a structure akin to a woven fabric, a weft knitted fabric, or a warp knitted fabric.

24 . The method according to claim 23 , wherein the structure of the net is as if it were based on round wire and/or on wire with a cross-sectional shape other than round.

25 . The method according to claim 24 , wherein, independently of the cross-sectional shape, the wire cross-sectional area ranges from 400 to 22500 μm 2 .

26 . The method according to claim 14 , wherein the selection of digital 3D design data within the context of additive manufacturing influences surface roughness, porosity, and/or solidity of the noble metal material of the noble metal planar formation or planar formations.

Assignees

• Heraeus Deutschland Gmbh & Co Kg

Inventors

• Boll Willi
• Humm Stephan
• Hubert Peter
• Hirschel Pascal

Classifications

• B22F1/052

  characterised by a mixture of particles of different sizes or by the particle size distribution · CPC title

• B01J23/8993 Primary

  with chromium, molybdenum or tungsten · CPC title

• B22F10/60

  Treatment of workpieces or articles after build-up · CPC title

• B22F10/20 Primary

  Direct sintering or melting · CPC title

• B22F1/065

  Spherical particles · CPC title