Base Metal Catalyst Stabilization via ALD Armored Coating

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Solution Overview

Problem

Precious metal catalysts used in the petrochemical industry are expensive and prone to deactivation due to leaching and sintering in condensed-phase reaction conditions, while base metal catalysts lack stability under similar conditions.

Innovation Solution

A method involving atomic layer deposition (ALD) or chemical vapor deposition (CVD) to create a protective thin film over metal or metal-containing particles, forming an 'armored' surface with channels that expose the particles to the environment, preventing leaching and sintering while maintaining catalytic activity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If base metal catalysts are used to replace precious metal catalysts, then cost is reduced, but stability against leaching and sintering deteriorates

Engineering Contradiction:

ImprovecostVSAvoidstability

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent applies the nesting principle by placing base metal catalyst particles inside a protective shell formed by atomic layer deposition (ALD). The ALD coating encapsulates the catalyst particles, creating a nested structure where the active base metal catalyst is protected within a stable oxide shell, thereby preventing leaching and sintering while maintaining catalytic activity

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent creates a composite material system combining base metal catalyst particles with ALD-deposited oxide coatings. This composite structure integrates the high catalytic activity of base metals with the stability and resistance to leaching/sintering of the oxide shell, achieving both cost-effectiveness and reliability

Inventive Principle:

Principle #40Composite materials

2Reliability

If a protective coating is applied to prevent leaching and sintering, then stability is improved, but catalytic activity may deteriorate due to blocked active sites

Engineering Contradiction:

ImprovestabilityVSAvoidcatalytic activity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent utilizes porous ALD coatings that contain controlled porosity and defects. These porous structures allow reactant molecules to diffuse through the coating and access the active catalyst sites while the coating still provides protection against leaching and sintering. The porosity ensures that catalytic activity is maintained despite the presence of the protective layer

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The ALD coating is applied with controlled thickness and non-uniformity to create local variations in protection. Thinner regions or defective areas of the coating allow enhanced mass transport to active sites, while thicker regions provide stronger protection. This local quality variation optimizes both stability and catalytic activity

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method effectively stabilizes base metal catalysts against sintering and leaching in both organic and aqueous condensed-phase reactions, maintaining their catalytic activity and extending their lifespan.

Implementation Method 1

The method comprises depositing upon the surface by atomic layer deposition, (ALD), chemical vapor deposition (CVD), or any other suitable thin film-forming methodology

Methodology Applied

Scientific EffectAtomic layer deposition:

Implementation Method 2

The method comprises depositing upon the surface by atomic layer deposition, (ALD), chemical vapor deposition (CVD), or any other suitable thin film-forming methodology

Methodology Applied

Scientific EffectChemical vapor deposition: Chemical Vapour Deposition

Implementation Method 3

The armored surface is then calcined for a time and at a temperature sufficient to form channels in the protective thin film

Methodology Applied

Scientific EffectCalcination: Heat Treatment

Data Source

PatentUS10137434B2Method to stabilize base metal catalysts by overcoating via atomic layer deposition and resulting product

Publication Date: 2018.11.27 WISCONSIN ALUMNI RES FOUND

AI summary

A method for stabilizing a metal or metal-containing particle supported on a surface is described, along with the resulting composition of matter. The method includes the steps of depositing upon the surface a protective thin film of a material of sufficient thickness to overcoat the metal or metal-containing particle and the surface, thereby yielding an armored surface; and then calcining the armored surface for a time and at a temperature sufficient to form channels in the protective thin film, wherein the channels so formed expose a portion of the metal- or metal-containing particle to the surrounding environment. Also described is a method of performing a heterogeneous catalytic reaction using the stabilized, supported catalyst.