The Dow Chemical Company

James W. Mcmichael

Richard N. Beaver

Carl E. Byrd

Harry S., Jr. Burney

Carl E Byrd

Richard N Beaver

Lloyd E Alexander

Stephen L Kelly

R Neal Beaver

James W Mcmichael

Jr Burney Harry S

Cathodes useful in electrolytic cells, such as a chlor-alkali cell, are disclosed which have a metallic-surfaced substrate coated with an electrocatalytic coating. The electrocatalytic coating includes palladium and at least one primary electrocatalytic metal, such as a platinum group metal. The coating optionally includes at least one secondary electrocatalytic metal, such as nickel, cobalt, iron, copper, manganese, molybdenum, cadmium, chromium, tin and silicon. Also disclosed is non-electrolytic reduction method for preparing the cathodes. The method provides a tightly adherent coating, improves electrocatalyst loading and reduces cathode production costs.

Electrocatalytic cathodes and method of preparation

Cathodes useful in electrolytic cells, such as a chlor-alkali cell, are disclosed which have a metallic-surfaced substrate coated with an electrocatalytic coating. The electrocatalytic coating includes palladium and at least one primary electrocatlaytic metal, such as a platinum group metal. The coating optionally includes at least one secondary electrocatalytic metal, such as nickel, cobalt, iron, copper, manganese, molybdenum, cadmium, chromium, tin and silicon. Also disclosed is a non-electrolytic reduction method for preparing the cathodes. The method provides a tightly adherent coating, improves electrocatalyst loading and reduces cathode production costs.

Cathodes useful in an electrolytic cell, such as a chlor-alkali cell, are disclosed which have a metallic-surfaced substrate coated with a catalytic coating composition. In one aspect, the catalytic coating includes a base layer of at least one primary electrocatalytic metal with particles of at least one electrocatalytic metal oxide entrapped therein. In another aspect, at least one upper oxide layer is formed on the base layer. Each upper oxide layer includes a substantially heterogeneous mixture of at least one primary electrocatalytic metal oxide and at least one secondary electrocatalytic metal oxide. The catalytic coatings are tightly adherent to the underlying substrate, resist loss during cell operation and exhibit low hydrogen overvoltage potentials. Also disclosed are methods for preparing the cathodes.

Electrocatalytic cathodes and methods of preparation

The invention is a method of making an electrode which comprises applying to an electroconductive nickel-containing substrate a coating solution of metal oxide precursor compound(s) and an etchant capable of etching the surface of the substrate and/or any previously applied coating, heating to remove volatiles from the so-coated substrate to cause the metal values of the precursor compounds and those etched from the substrate or previous coating to be concentrated and recoated on the substrate or previously applied coating, and further heating, in the presence of oxygen, air or an oxidizing agent, to a temperature sufficient to oxidize the metal values.

Preparation and use of electrodes

The invention is a method for preparing electrocatalytic oxides and applying them to substrates that cannot be heated to temperatures sufficiently high to convert electrocatalytic salts into electrocatalytic oxide comprising:

Process for preparation of an electrocatalyst

A substrate is coated with a solution of metal oxide precursor compounds and an etchant for etching the substrate, the metal oxide precursor compounds are thermally concentrated by removing volatiles therefrom, and the so-concentrated metal oxides precursors are thermally oxidized in-situ on the substrate. The so-formed compositions are useful, e.g., as electrode material in electrochemical apparatuses and processes.

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Richwood, TX, United States of America

Carl E Byrd