Catalyst electrodes, and methods of making and using the same

Abstract

Methods of making catalyst electrodes comprising sputtering at least Pt and Ir onto nanostructured whiskers to provide multiple alternating layers comprising, respectively in any order, at least Pt and Ir. In some exemplary embodiments, catalyst electrodes described, or made as described, herein are anode catalyst, and in other exemplary embodiments cathode catalyst. Catalysts electrodes are useful, for example, in generating H 2 and O 2 from water.

1 . A method of making catalyst electrode comprising:
 sputtering at least Pt and Ir onto nanostructured whiskers to provide multiple alternating layers comprising respectively in any order Pt and Ir; and   radiation annealing at least some of the multiple alternating layers comprising respectively Pt and Ir at least in part in an atmosphere comprising an absolute oxygen partial pressure of at least 2 kPa oxygen.   
     
     
         2 . The method of  claim 1 , wherein the radiation annealing is at least in part conducted at an incident energy fluence of at least 20 mJ/mm 2 . 
     
     
         3 . The method of  claim 1 , wherein the Pt and Ir are present in an atomic ratio in a range from 10:1 to 1:10. 
     
     
         4 . The method of  claim 1 , wherein the whiskers are attached to a backing. 
     
     
         5 . The method of any  claim 4 , wherein the backing is a membrane, and wherein the method further comprises acid washing to remove cation impurities prior to attaching the nanostructured whiskers to membrane. 
     
     
         6 . A method of making catalyst electrode comprising:
 sputtering at least Pt and Ir onto nanostructured whiskers to provide multiple alternating layers comprising respectively in any order Pt and Ir, wherein at least a portion of the multiple alternating layers are up to 20 Angstroms thick.   
     
     
         7 . The method of  claim 6 , wherein the Pt and Ir are present in an atomic ratio in a range from 1:5 to 5:1. 
     
     
         8 . The method of  claim 6 , wherein the whiskers are attached to a backing. 
     
     
         9 . The method of  claim 8 , wherein backing is a membrane, and wherein the method further comprises acid washing to remove cation impurities prior to attaching the nanostructured whiskers to membrane. 
     
     
         10 . A method of making catalyst electrode comprising:
 sputtering at least Pt, Ir, and Ru onto nanostructured whiskers to provide multiple alternating layers comprising respectively in any order Pt, Ir, and Ru.   
     
     
         11 . The method of  claim 10  further comprising radiation annealing the nanostructured thin film catalyst at least in part in air with an irradiation at an incident energy fluence of at least 20 mJ/mm 2 . 
     
     
         12 . The method of  claim 10 , wherein the Pt, Ir, and Ru are present in atomic ratios in a range from 0.1:5:5 to 10:0.05:0.05. 
     
     
         13 . The method of  claim 10 , wherein the whiskers are attached to a backing. 
     
     
         14 . The method of  claim 13 , wherein backing is a membrane, and wherein the method further comprises acid washing to remove cation impurities prior to attaching the nanostructured whiskers to membrane. 
     
     
         15 . (canceled)