Composite Body with Metal-Containing Particles on Carbon Material
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Solution Overview
Problem
Conventional methods for supporting metal-containing catalyst particles on metal oxides face limitations in achieving high concentration, uniform dispersion, and stability, especially at high temperatures, due to limited pore volume and aggregation issues.
Innovation Solution
A composite body is created by mixing metal hydrate salts with porous carbon material, followed by melt-infiltration and high-temperature calcination, allowing for size-controlled metal oxide particles to be supported or connected by carbon, maintaining particles at intervals and preventing aggregation during high-temperature reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If metal salt is supported on metal oxide support using conventional wet impregnation method, then the metal salt can be supported on the support, but the amount of salt that can be supported is limited due to limited pore volume and it takes a long time
Solution Approach 1:
The patent changes the physical state of the metal salt from solid to liquid by heating above its melting point, transforming the impregnation process from conventional wet impregnation to melt impregnation. This parameter change enables rapid and complete infiltration of metal salt into the support pores, overcoming the time limitation while maximizing the amount of metal salt that can be supported.
Solution Approach 2:
The patent utilizes the phase transition of metal salt from solid to liquid state through heating. By controlling the temperature above the melting point of the metal salt during impregnation, the liquid metal salt can fully penetrate the support structure, and subsequent cooling solidifies it in place, achieving high loading capacity and uniform distribution.
2Quantity of substance
If high concentration of metal particles is supported on support, then the catalytic activity increases, but the particles aggregate and stability decreases
Solution Approach 1:
The patent utilizes the porous structure of the metal oxide support to physically separate metal particles. The pores act as natural spacers that maintain intervals between metal particles even at high concentrations, preventing aggregation while preserving high catalytic activity. The porous architecture allows high metal loading without compromising particle stability.
3Stability of the object's composition
If complicated processes are used to ensure high dispersibility and stability of particles, then the particles can be well-dispersed, but the preparation procedures become complex and the support occupies much weight and space
Solution Approach 1:
The patent employs a self-service approach where the metal oxide support's inherent porous structure automatically performs the dispersion function. The porous architecture naturally spaces out metal particles during impregnation, eliminating the need for additional dispersion-promoting agents or complex multi-step procedures. The support structure itself provides the stabilizing effect through its physical geometry.
4Quantity of substance
If pre-formed metal oxide support is used, then the metal salt can be supported, but the amount of salt that can be ultimately supported is limited by the pore volume
Solution Approach 1:
By utilizing the liquid phase of melted metal salt during impregnation, the patent achieves complete pore filling that is not limited by the constraints of conventional liquid impregnation methods. The molten state allows the metal salt to flow into and fill the entire pore volume, maximizing the amount of metal that can be supported per unit volume of support.
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
This method enables uniform high-concentration support of metal-containing catalyst particles, enhancing their activity and stability, and allows for rapid diffusion of reactants, suitable for various applications including catalysis, adsorption, and separation membranes.
Implementation Method 1
a second step of melt-infiltrating the first metal hydrate salt and the second metal hydrate salt in the pores of the porous carbon material particles
Implementation Method 2
a fourth step of subjecting the resultant carbon material particles to high temperature calcination at a temperature and condition that thermally decompose the first metal hydrate salt, the second metal hydrate salt and the porous carbon material
Implementation Method 3
thereby forming the first metal oxide particles and the second metal oxide particles in which the particle sizes are controlled by the pores of the porous carbon material
Data Source
AI summary
The present invention relates to a composite body in which first metal-containing particles and second metal-containing particles are supported on a carbon material or connected by a carbon material, and a method for producing the same. The above composite body can, if the first metal-containing particles exhibit a catalytic activity, be applied as a reaction catalyst and can also be used in various fields such as the manufacture of the adsorbent or the separation membrane.