Electrode catalyst layer for carbon dioxide electrolysis cell, electrolysis cell and carbon dioxide electrolysis apparatus comprising the same

Patent metadata

Field	Value
Publication number	US-2025341009-A1
Application number	US-202519270809-A
Country	US
Kind code	A1
Filing date	Jul 16, 2025
Priority date	Mar 19, 2020
Publication date	Nov 6, 2025
Grant date	—

Abstract

The embodiments provide a method to produce an electrode catalyst layer for reduction of carbon dioxide. The catalyst layer is made to exhibit high partial current density and to endure a long-term operation by controlling the wettability. The catalyst layer comprises a metallic catalyst supported on carbon material, an ion-conductive material, and a hydrophilic polymer; and is characterized in that a BET specific surface area (AN2) of said catalyst layer determined by nitrogen gas-adsorption and a BET specific surface area (AH2O) of said catalyst layer determined by water vapor-adsorption are in a ratio (AH2O/AN2) of 0.08 or less.

First claim

1 . A process for producing an electrode catalyst layer for a carbon dioxide electrolysis cell, comprising:
applying a composition comprising a metallic catalyst supported on carbon material, an ion-conductive material, and a hydrophilic polymer on a substrate to form a layer of the composition; and drying the applied composition to obtain the electrode catalyst layer, wherein a content of the hydrophilic polymer is reduced in the layer of the applied composition.

2 . The process according to claim 1 , reducing the content of the hydrophilic polymer comprises extraction of the applied layer with an organic solvent.

3 . The process according to claim 2 , wherein the organic solvent is at least one selected from the group consisting of acetone, ethanol, methanol, dimethyl sulfoxide, dimethyl-acetamide, N, N-dimethylformamide, and a mixture thereof.

4 . The process according to claim 1 , wherein reducing the content of the hydrophilic polymer comprises firing the formed composition layer at a high temperature.

5 . The process according to claim 4 , wherein the conditions of the firing at a high temperature include heating the composition layer at 400° C. or less.

6 . The process according to claim 1 , wherein a BET specific surface area (A N2 ) of the catalyst layer determined by nitrogen gas-adsorption and a BET specific surface area (A H2O ) of the catalyst layer determined by water vapor-adsorption are in a ratio (A H2O /A N2 ) of 0.05 or less.

7 . The process according to claim 1 , wherein the hydrophilic polymer is selected from the group consisting of polyvinyl alcohol, polyvinylpyrrolidone, methoxypolyethylene oxide methacrylate, polyacrylic acid, polyethyleneimine, polyvinylamine, cyclodextrin and methylcellulose.

8 . The process according to claim 1 , wherein a thickness of the electrode catalyst layer is from 5 to 200 μm.

9 . The process according to claim 1 , wherein a pore-diameter distribution of the electrode catalyst layer measured by a mercury injection method shows the highest peak of frequency distribution in the diameter range of 5 to 200 μm provided that the diameter and the logarithmic differential pore volume are plotted on the horizontal and vertical axes, respectively.

10 . The process according to claim 1 , wherein the carbon material is at least one selected from the group consisting of carbon particles, carbon nanotubes and graphenes.

11 . The process according to claim 1 , wherein the metallic catalyst is at least one metal or oxide thereof selected from the group consisting of Au, Ag, Cu, Pt, Pd, Ni, Co, Fe, Mn, Ti, Cd, Zn, In, Ga, Pb and Sn, and the metallic catalyst also comprises at least one structure selected from the group consisting of nanoparticles, nanostructures and nanowires.

12 . The process according to claim 11 , wherein the metallic catalyst comprises nanoparticles and a mean diameter of the nanoparticles is from 1 to 15 nm.

13 . The process according to claim 1 , wherein said metallic catalyst has a weight per unit area of the catalyst layer in a range of 0.01 to 5 mg/cm 2 .

14 . The process according to claim 1 , wherein the ion-conductive material is a cation-exchange resin or an anion-exchange resin.

15 . The process according to claim 1 , wherein the ion-conductive material is contained in the catalyst layer in a weight per area of 0.01 to 1 mg/cm 2 .

Assignees

• Toshiba Kk

Inventors

• Kofuji Yusuke
• Ono Akihiko
• Kudo Yuki
• Kitagawa Ryota
• MOTOSHIGE Asahi
• Yamagiwa Masakazu
• Tamura Jun
• Yoshida Takashi
• Mikoshiba Satoshi

Classifications

• C25B13/04

  characterised by the material · CPC title

• C25B1/00

  Electrolytic production of inorganic compounds or non-metals · CPC title

• C25B11/055

  characterised by the substrate or carrier material · CPC title

• C25B9/23

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

• C25B11/077

  the compound being a non-noble metal oxide · CPC title