Preparing in situ electrocatalytic films in solid polymer electrolyte membranes, composite microelectrode structures produced thereby and chloralkali process utilizing the same

Claim 2

A process for producing an in situ metallic electrocatalytic film proximate the surface of a solid polymer electrolyte membrane to form a composite structure useful in promoting electrochemical reactions in fuel cells, sensors, chloralkali processes, dialysis, or electrochemical synthesis cells, said method comprising the steps of: loading metal ions into the ionomer matrix of a solid polymer electrolyte membrane to achieve a loading level of metal ions sufficient for forming an electronically coherent film of metal within the ionomer matrix, said metal ions being selected as those which will constitute the chemical composition of the electrocatalytic film; and exposing at least one face of the metal-ion-loaded membrane to a chemical reductant under controlled conditions of time and temperature sufficient to cause the metal ions in the membrane to diffuse towards the exposed face and to be reduced to the metal (0) state while within the membrane, and to produce in situ within the ionomer matrix of the membrane an electronically coherent porous film of metal located predominately within the membrane and near its surface, the electronically coherent film being comprised of metal particles in electrical contact with one another.

Claim 3

A process as claimed in claim 1 wherein the membrane is a cation-exchange membrane and the selected electrode metal is introduced as a cationic salt of the metal.

Claim 4

A process as claimed in claim 1 wherein the membrane is an anion-exchange membrane and the selected electrode metal is introduced as an anionic salt of the metal.

Claim 5

A process as claimed in claim 1 wherein the placing of metal ions into the ionomer matrix is performed by ion exchange utilizing a co-solvent in conjunction with an ionic salt of the selected metal to swell the solid polymer electrolyte and thereby increase the loading level and lower diffusional resistance therein.

Claim 6

A process as claimed in claim 1 wherein both faces of the solid polymer electrolyte membrane are exposed to the reductant, thereby producing a bi-polar metal-ionomer-metal composite structure with metallic electrocatalytic films at both faces connected only by an ionic-current path through the ionomer matrix.

Claim 7

A process as claimed in claim 1 wherein the solid polymer electrolyte membrane is selected from the group consisting of a perfluorosulfonic acid ionomer and a perfluorocarboxylic acid ionomer.

Claim 8

A process as claimed in claim 6 wherein said ionomer is a perfluorinated ionomer.

Claim 9

A process as claimed in claim 1 wherein the selected electrode metal is a noble metal.

Claim 10

A process as claimed in claim 8 wherein the electrode metal is platinum which is impregnated into the membrane by utilizing a cationic salt selected from the group consisting of Pt(NH 3 ) 4 Cl 2 and Pt(NO 2 ) 2 (NH 3 ) 2 .

Claim 11

A process as claimed in claim 9 wherein said salt is utilized in conjunction with a co-solvent.

Claim 12

A process as claimed in claim 10 wherein the co-solvent system is CH 3 OH/H 2 O.

Claim 13

A process as claimed in claim 1 wherein the reductant is dissolved in a solvent.

Claim 14

A process as claimed in claim 1 wherein the reductant is a neat reactant.

Claim 15

A process as claimed in claim 1 wherein the reductant is a gas.

Claim 16

A process as claimed in claim 1 wherein the reductant is selected from the group consisting of N 2 H 4 ; NaBH 4 ; SNSO 4 ; CH 3 OH and H 2 .

Claim 17

A composite structure produced by the process of claim 1.

Claim 18

A process for producing a thin, in situ metallic electrocatalytic film proximate the surface of a solid polymer electrolyte membrane to form a composite structure useful in promoting chemical reactions in fuel cells, sensors, chloralkali processes, dialysis, or electrochemical synthesis cells, said method comprising the steps of: impregnating a solid polymer electrolyte membrane by ion-exchange with a cationic salt of a selected electrode metal to produce a metal-cation-loaded membrane with a loading level of metal cations sufficient for forming an electronically coherent film of metal particles in electrical contact with one another within the membrane; exposing at least one face of the metal-cation-loaded membrane to a chemical reductant to cause the cations in the membrane to diffuse toward the exposed face and to reduce the cations to the metal (0) state while within the membrane, and to produce within the ionomer matrix of the membrane an electronically coherent porous electrocatalytic film of metal predominately within the membrane and near its surface; and controlling the thickness and morphology of the electrocatalytic film and the electrochemical activity of the resultant composite structure by controlling the loading-level in the impregnating step, and by controlling the temperature, chemical nature and concentration of the reductant.

Claim 19

A process for producing a thin, in situ metallic electrocatalytic film proximate the surface of a solid polymer electrolyte membrane to form a composite structure useful in promoting chemical reactions in fuel cells, sensors, chloralkali processes, dialysis, or electrochemical synthesis cells, said method comprising the steps of: impregnating a solid polymer electrolyte membrane by ion-exchange with a cationic salt of a selected electrode metal to produce a metal-cation-loaded membrane with a loading level of metal cations sufficient for forming an electronically coherent film of metal particles in electrical contact with one another within the membrane; exposing at least one face of the metal-cation-loaded membrane to a chemical reductant to cause the cations in the membrane to diffuse toward the exposed face and to reduce the cations to the metal (0) state while within the membrane, and to produce within the ionomer matrix of the membrane an electronically coherent porous electrocatalytic film of metal predominately within the membrane and near its surface; and controlling the thickness and morphology of the electrocatalytic film and the electrochemical activity of the resultant composite structure by controlling the loading-level in the impregnating step, and by controlling the temperature, chemical nature and concentration of the reductant.

Claim 20

A composite metal-ionomer catalytic electrode structure characterized by large surface-area-per-unit volume of the electrode material and protection of the electrode from chemical and mechanical degradation by forming the same within the membrane, said structure comprising: an ionomer matrix forming a solid polymer electrolyte membrane, said membrane having at least one face; and a thin, porous electronically coherent film of metal located predominately within the membrane and near one face of the membrane, said film being formed in situ within the ionomer matrix and having a morphology characterized by metal particles that provide a large surface-area-per-unit volume for ion exchange, and are in electrical contact with each other.

Claim 21

A composite metal-ionomer catalytic electrode structure characterized by large surface-area-per-unit volume of the electrode material and protection of the electrode from chemical and mechanical degradation by forming the same within the membrane, said structure comprising: an ionomer matrix forming a solid polymer electrolyte membrane, said membrane having at least one face; and a thin, porous electronically coherent film of metal located predominately within the membrane and near one face of the membrane, said film being formed in situ within the ionomer matrix and having a morphology characterized by metal particles that provide a large surface-area-per-unit volume for ion exchange, and are in electrical contact with each other.

Claim 22

A composite metal-ionomer catalytic electrode as claimed in claim 18 wherein said metal particles form a dendritic morphology.

Claim 23

A composite metal-ionomer catalytic electrode as claimed in claim 18 wherein the metal composition of the film is selected from the group consisting of a single metal, an alloy and a mixed metal.

Claim 24

A composite metal-ionomer catalytic electrode as claimed in claim 18 wherein said film has a thickness on the order of 2-10 microns.

Claim 25

A composite metal-ionomer catalytic electrode as claimed in claim 18 wherein said membrane has two faces and a film as recited is formed proximate each face, thereby producing a bi-polar structure.

Claim 26

A chloralkali process of the type wherein respective anode and cathode reaction zones are separated by a solid polymer electrolyte membrane, said process comprising the steps of: providing a cathode reaction zone suitable for conducting a gas phase reaction therein; providing an anode reaction zone suitable for conducting a liquid phase reaction therein; providing, in the space between the anode and cathode reaction zones, a bi-polar structure comprising a solid polymer electrolyte membrane with a thin, porous, electronically conductive, high-surface-area metallic electrocatalytic film of metal particles formed in situ within the ionomer matrix at each surface thereof, where the particles are in electrical contact with one another; connecting the films of the bi-polar structure to a power supply so that one film serves as the anode and one film serves as the cathode; introducing acidified brine into the anode reaction zone; introducing an oxygen containing gas into the cathode reaction zone; conducting the following half cell reaction at the anode: 4Cl - →2CL 2 +4e - ; conducting the following half cell reaction at the cathode: 0 2 +4H + +4e - →2H 2 O; utilizing the high surface area of contact between the ionomer matrix of the solid polymer electrolyte and the electrodes to facilitate the reactions; removing chlorine gas and spent brine from the anode reaction zone; and removing H 2 O plus any excess gas from the cathode reaction zone.

Claim 27

A chloralkali process of the type wherein respective anode and cathode reaction zones are separated by a solid polymer electrolyte membrane, said process comprising the steps of: providing a cathode reaction zone suitable for conducting a gas phase reaction therein; providing an anode reaction zone suitable for conducting a liquid phase reaction therein; providing, in the space between the anode and cathode reaction zones, a bi-polar structure comprising a solid polymer electrolyte membrane with a thin, porous, electronically conductive, high-surface-area metallic electrocatalytic film of metal particles formed in situ within the ionomer matrix at each surface thereof, where the particles are in electrical contact with one another; connecting the films of the bi-polar structure to a power supply so that one film serves as the anode and one film serves as the cathode; introducing acidified brine into the anode reaction zone; introducing an oxygen containing gas into the cathode reaction zone; conducting the following half cell reaction at the anode: 4Cl - →2CL 2 +4e - ; conducting the following half cell reaction at the cathode: 0 2 +4H + +4e - →2H 2 O; utilizing the high surface area of contact between the ionomer matrix of the solid polymer electrolyte and the electrodes to facilitate the reactions; removing chlorine gas and spent brine from the anode reaction zone; and removing H 2 O plus any excess gas from the cathode reaction zone.

Claim 28

A process for producing an in situ metallic electrocatalytic film proximate the surface of a solid polymer electrolyte membrane to form a composite structure useful in promoting electrochemical reactions in fuel cells, sensors, chloralkali processes, dialysis, electrochemical synthesis cells, said method comprising the steps of: impregnating a solid polymer electrolyte membrane with metal ions to produce a metal-ion-loaded membrane, said metal ions being selected as those which will constitute the chemical composition of the electrocatalytic film; controlling the loading of the metal ions in the impregnating step to provide a loading of metal ions sufficient for forming an electronically coherent film of metal within the ionomer matrix; and exposing at least one face of the metal-ion-loaded membrane to a chemical reductant to cause the metal ions in the membrane to diffuse towards the exposed face and to reduce the ions to the metal (0) state while within the membrane and to form in situ within the ionomer matrix of the membrane of the solid polymer electrolyte membrane an electrocatalytic porous film located predominately within the membrane and near its surface having a morphology characterized by metal particles that provide a large surface-area-per-unit volume and which are in electrical contact with each other.

Claim 29

A process for producing an in situ metallic electrocatalytic film proximate the surface of a solid polymer electrolyte membrane to form a composite structure useful in promoting electrochemical reactions in fuel cells, sensors, chloralkali processes, dialysis, electrochemical synthesis cells, said method comprising the steps of: impregnating a solid polymer electrolyte membrane with metal ions to produce a metal-ion-loaded membrane, said metal ions being selected as those which will constitute the chemical composition of the electrocatalytic film; controlling the loading of the metal ions in the impregnating step to provide a loading of metal ions sufficient for forming an electronically coherent film of metal within the ionomer matrix; and exposing at least one face of the metal-ion-loaded membrane to a chemical reductant to cause the metal ions in the membrane to diffuse towards the exposed face and to reduce the ions to the metal (0) state while within the membrane and to form in situ within the ionomer matrix of the membrane of the solid polymer electrolyte membrane an electrocatalytic porous film located predominately within the membrane and near its surface having a morphology characterized by metal particles that provide a large surface-area-per-unit volume and which are in electrical contact with each other.