Method for producing a metal substrate catalyst unit

The method of plating and leaching on a nickel substrate addresses the challenge of continuous production and impurity tolerance, resulting in efficient and cost-effective catalyst units for electrolysis applications.

DE102020204747B4Active Publication Date: 2025-11-27FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV +1
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Patent Information

Application Number
DE102020204747
Authority / Receiving Office
DE · DE
Patent Type
Patents
Current Assignee / Owner
Filing Date
2020-04-15
Publication Date
2025-11-27
Estimated Expiration
2040-04-15

AI Technical Summary

Technical Problem

Existing manufacturing methods for metal substrate catalyst units, particularly those with a Raney surface structure, face challenges in achieving continuous production and have low tolerance for iron impurities.

Method used

A method involving plating a foil of aluminum, manganese, iron, or zinc on a nickel, copper, or cobalt substrate, followed by heat treatment and leaching to create a Raney structure, allowing for continuous production and improved efficiency.

Benefits of technology

Enables the production of metal substrate catalyst units with increased productivity and lower costs, suitable for applications in electrolysis processes such as hydrogen, oxygen, chlorine production, and CO2 reduction.

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Abstract

Method for producing a metal substrate catalyst unit in which, in a first process step (i) a foil of aluminium, manganese, iron, cobalt or zinc or aluminium, manganese, iron, cobalt or zinc powder is applied to at least one surface of a planar substrate consisting of nickel, copper or cobalt, or the substrate is formed from an iron alloy coated on at least one outer surface with nickel, copper or cobalt, by means of roll cladding to form an aluminium, manganese, iron, cobalt or zinc cover layer, in a second procedural step ii) perforations are formed through the substrate coated in this way, in a third procedural step iii) a heat treatment is carried out at a minimum temperature that is at least 70% of the melting temperature of the foil material on the Kelvin scale and a maximum temperature that is below the lowest melting temperature of the coated substrate, and thereafter in a fourth procedural step iv) a leaching of aluminium, manganese, iron, cobalt or zinc with a basic or acidic aqueous liquid to form a Raney structure on the at least one surface formed with aluminium, manganese, iron, cobalt or zinc is carried out.
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