Patent ID: 7968488
Filing Date: 2011-06-28
Classification: C23C,H01M,Y02E,Y10T

Abstract:
1. A method of making a catalyst particle, the method comprising: a) providing a web material having a release layer formed on an upper surface thereof; b) forming a composite film on the web material; c) removing the composite film from the web material as a plurality of composite particles, wherein each composite particle comprises: a support having a diameter up to about 150 microns and a thickness in the range of about 50 nm to about 1 micron; a first metal layer disposed on the support and a second metal layer disposed on the support opposite the first metal layer, the metal layers each having a thickness in the range of from about atomic thickness to about 10 nm, wherein the metal layers are catalytically active and disposed on said support layer in discontinuous islands having a diameter between about 0.1 nm to about 5.0 nm, wherein said islands include edge sites that are uncoordinated and a portion of said islands are isolated and a portion have a connectivity above a percolation threshold of said islands and wherein said islands are positioned on an exposed support surface segments.