Method for producing a catalyst system for gas reactions

A method for producing a catalyst system for gas reactions comprising at least one planar structure of noble metal having gas-permeable openings, comprising the steps of:

• (1) providing at least one noble metal powder consisting of metal particles, wherein at least 80% of the noble metal particles, relative to their number, satisfy the condition 0.823 dmin/dmax≤1.0, wherein dmin is the minimum diameter and dmax is the maximum diameter of an individual noble metal particle, and
• (2) repeatedly applying the noble metal powder or powders provided in step (1) in layers to a substrate in a build chamber, respectively followed by an at least partial melting of the respective noble metal powder applied as a layer with radiation in the form of a laser or electron beam, and allowing the melted noble metal powder to solidify as part of an additive manufacturing process,
• wherein the at least one planar structure of noble metal comprising gas-permeable openings has an individual weight per unit area in the range of 25 to 2500 g/m2,
• wherein the noble metal particles of the noble metal powder or powders have a particle size distribution with a d10 value of ≥5 μm, a d50 value in the range of 20 to 30 μm, and a d90 value of ≤80 μm,
• and wherein the noble metal of the noble metal particles of the noble metal powder or powders is selected from the group consisting of noble metal alloys of
• platinum with 1-15 wt. % rhodium,
• platinum with 2-15 wt. % rhodium and 0.1-20 wt. % palladium,
• platinum with 2-15 wt. % rhodium, 0.1-20 wt. % palladium, and 0.1-2 wt. % ruthenium,
• platinum with 2-15 wt. % rhodium, 0.1-20 wt. % palladium, and 0.1-5 wt. % iridium, palladium with 3-15 wt. % platinum,
• palladium with 1-20 wt. % platinum and 1-10 wt. % rhodium,
• palladium with 1-25 wt. % tungsten, and
• palladium with 1-15 wt. % nickel.

A method for producing a catalyst system for gas reactions comprising at least one planar structure of noble metal having gas-permeable openings, comprising the steps of:

• (1) providing at least one noble metal powder consisting of metal particles, wherein at least 80% of the noble metal particles, relative to their number, satisfy the condition 0.8≤dmin/dmax≤1.0, wherein dmin is the minimum diameter and dmax is the maximum diameter of an individual noble metal particle, and
• (2) repeatedly applying the noble metal powder or powders provided in step (1) in layers to a substrate in a build chamber, respectively followed by an at least partial melting of the respective noble metal powder applied as a layer with radiation in the form of a laser or electron beam, and allowing the melted noble metal powder to solidify as part of an additive manufacturing process,
• wherein the at least one planar structure of noble metal comprising gas-permeable openings has an individual weight per unit area in the range of 25 to 2500 g/m2 and a surface area in the range of 0.25 to 35 square meters,
• wherein the noble metal particles of the noble metal powder or powders have a particle size distribution with a d10 value of ≥5 μm and a d90 value of ≤80 μm,
• and wherein the noble metal of the noble metal particles of the noble metal powder or powders is selected from the group consisting of noble metal alloys of
• platinum with 1-15 wt. % rhodium,
• platinum with 2-15 wt. % rhodium and 0.1-20 wt. % palladium,
• platinum with 2-15 wt. % rhodium, 0.1-20 wt. % palladium, and 0.1-2 wt. % ruthenium,
• platinum with 2-15 wt. % rhodium, 0.1-20 wt. % palladium, and 0.1-5 wt. % iridium,
• palladium with 3-15 wt. % platinum,
• palladium with 1-20 wt. % platinum and 1-10 wt. % rhodium,
• palladium with 1-25 wt. % tungsten, and
• palladium with 1-15 wt. % nickel.