Core-shell catalyst with Pt-Pd solid solution shell
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Solution Overview
Problem
Existing core-shell catalysts have low oxidation activity due to a single-type atom shell structure, and require specific synthesis methods involving impregnation or organic polymer layers, limiting their effectiveness in gas detection and oxidation processes.
Innovation Solution
A core-shell type catalyst with a core of a single metal element and a shell of a solid-phase structure composed of two metal elements and oxygen, supported on a high-specific-surface metal oxide carrier, utilizing a 1:1 atomic ratio of selected metal elements like Pt and Pd, and heat treatments to enhance oxidation activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a core-shell catalyst uses a shell portion formed of a single type of atom, then the manufacturing process is simple, but the oxidation activity is low
Solution Approach 1:
The shell portion is formed of a solid-phase structure composed of two types of metal atoms (Pt and Pd) and oxygen, creating a composite material that enhances oxidation activity while maintaining manufacturing feasibility through a systematic synthesis process
2Productivity
If a core-shell catalyst uses a shell portion formed of a solid-phase structure composed of two types of metal and oxygen, then the oxidation activity is high, but the manufacturing process becomes complex
Solution Approach 1:
The catalyst is manufactured by impregnation with a solution containing both metal chlorides before heat treatment, pre-positioning the metal atoms in the shell portion so that during subsequent heat treatment they form the desired solid-phase structure without requiring complex multi-step processing
Solution Approach 2:
Heat treatment is applied to transform the impregnated metal chloride solution into a solid-phase structure composed of metal atoms and oxygen, utilizing parameter changes in temperature and chemical state to achieve the high-activity shell structure
3Ease of manufacture
If conventional catalysts are used, then the manufacturing process is straightforward, but stability and humidity resistance are insufficient
Solution Approach 1:
The core-shell structure combines a single-metal core with a solid-phase shell composed of two metals and oxygen, creating a composite material that enhances both stability and humidity resistance while maintaining manufacturing feasibility
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 catalyst exhibits high oxidation activity, particularly for hydrogen, and is effective in gas sensors for detecting CO, LP gas, and methane, offering improved stability and humidity resistance compared to conventional catalysts.
Implementation Method 1
a core-shell type catalyst in which a core portion is composed of a single metal material and a shell portion is formed so as to have a solid-phase structure that is composed of two types of metal and oxygen, the core-shell type catalyst having a high oxidation activity
Implementation Method 2
a carrier (catalyst support) to immobilize the catalyst particulate
Data Source
AI summary
A core-shell structure (a diameter is about 5 nm) is located on an Al2O3 catalyst support. Platinum (Pt metal) is a core, and a shell that surrounds the core has a solid solution structure (A1-xBxOY) (where X is a composition that composes A and B, and Y is a composition of oxygen (O)) that is composed of platinum, palladium, and oxygen.