Porous Electrolessly Deposited Coatings

Abstract

A new electroless plating approach to generate a porous metallic coating is described in which a metal is electrolessly deposited on a surface. Microparticles in the metal are removed to leave pores in the metal coating. Another method of forming electroless coatings is described in which a blocking ligand is attached to the surface, followed by a second coating step. The invention includes coatings and coated apparatus formed by methods of the invention. The invention also includes catalyst structures comprising a dense substrate and a porous metal adhered to the dense substrate, which is further characterized by one or more of the specified features.

Description

RELATED APPLICATIONS[0001]In accordance with 35 U.S.C. sect. 119(e), this application claims priority to U.S. Provisional Application No. 60 / 972,210, filed Sep. 13, 2007.INTRODUCTION[0002]There has been a long history of work devoted to forming porous metal coatings. For example, in U.S. Pat. No. 1,628,190, issued in 1927, Raney described a method of making porous nickel by alloying the nickel with aluminum and subsequently dissolving the aluminum to leave porous nickel.[0003]More recently, there has been a great deal of interest in forming metallic coatings in microchannels. Tonkovich et al. in WO 2006 / 127889A2 (PCT / US2006 / 020220, which is incorporated herein as if reproduced in full) describe a variety of microchannel apparatus and numerous ways of forming catalysts on microchannel walls including designs for structured walls that may be subsequently coated with a catalyst. The patent also mentions the use of a polymeric templating agent followed by treatment with a metallic templ...

AI Technical Summary

Benefits of technology

[0004]Electroless plating of metals such as platinum on substrates has attracted much interest because it can improve resistance to corrosion and abrasion, or increase desirable electrical properties, or act as catalysts for various chemical reactions. Pt and Pt-alloy catalysts have been widely used as catalysts for various chemical reactions, such as steam methane reforming, partial oxidation, CO2 reforming, auto-thermal reforming of gasoline, combustion, ammonia oxidation, dehydrogenation and hydrocracking of alkanes, oxidative dehydrogenation of alkanes and NOx abatement in automotive emission control. They are also used as anode and cathode catalysts in low-temperature fuel cells such as alkaline fuel cell, phosphoric acid fuel cell, proton exchange membrane fuel cell and direct methanol fuel cell. It is expected that higher Pt surface area will result in higher catalytic activity. However, electroless plating and electroplating usually generate a dense Pt layer with low surface area.

[0007]JP2000282248 (2000) reported Rh plating baths with ammonium-di(pyridine-2,6-dicarboxylate)-rhodium (III), RhClx(NH3)6-x (x denotes 0 to 3), rhodium acetate, a triethylenetetramine complex of rhodium chloride or a diethylenetriamine complex of rhodium. The deposition is executed preferably at a pH 8 to 9 at 70-95° C. While electroless plating has many advantages over other plating methods, including the ability to plate almost any substrate and the ability to achieve uniform coating loadings over objects of almost any shape, coatings prepared by electroless plating are dense with low surface area. Conventional electroless plated coatings require high metal loadings and produce low surface area coatings which limits their utility, particularly for catalytic applications of precious metals wherein effective use of the expensive metals is important for economic as well as technical reasons. Thus a need exists for an electroless plating process that produces a porous, high surface area coating and can be used with precious metals as well as other metals.SUMMARY OF THE INVENTION

Problems solved by technology

At least initially the size of the microparticles and the pores is about the same since the particles are oxidized or dissolved away; however, the pore sizes may change if the porous meal coating is subsequently heated or subjected to corrosive conditions.

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