Partially Embedded Catalytic Nanoparticles for Stability
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Solution Overview
Problem
Current catalytic materials face challenges such as high loading of expensive catalysts, non-optimal selectivity, efficiency, stability, and lifetime, requiring elevated temperatures, and struggling with sintering and agglomeration, which limits their performance and longevity in various applications.
Innovation Solution
The development of porous catalytic materials with partially embedded catalytic nanoparticles, where proximal portions are chemically or physically bound to a matrix, and distal portions are exposed, offering enhanced mechanical and thermal stability, and modified to create catalytically active species at the interface between the matrix and channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional catalytic materials are used, then catalyst loading is high, but cost increases and selectivity is non-optimal
Solution Approach 1:
The patent applies local quality by creating distinct regions on the nanoparticle surface with different properties. The proximal portions embedded in the matrix have different catalytic characteristics than the distal portions exposed to channels, allowing optimized selectivity and activity in specific locations while reducing overall catalyst loading.
Solution Approach 2:
The patent uses composite materials by combining catalytic nanoparticles with a matrix material to form a hybrid structure. This composite approach enables the system to achieve high selectivity and activity with lower catalyst loading by leveraging the synergistic effects between the nanoparticle and matrix components.
2Duration of action of stationary object
If conventional catalytic materials are used, then initial activity is sufficient, but stability and lifetime are reduced due to sintering and agglomeration
Solution Approach 1:
The patent applies the nesting principle by embedding nanoparticles within the matrix structure. The proximal portions of the nanoparticles are nested within the matrix material, which physically constrains them and prevents sintering and agglomeration, thereby extending catalyst lifetime and maintaining stability.
Solution Approach 2:
The patent implements beforehand cushioning by providing the matrix material as a protective environment before sintering can occur. The matrix acts as a cushioning medium that prevents direct contact between nanoparticles, thereby preventing agglomeration and maintaining catalyst stability throughout operation.
3Use of energy by moving object
If conventional catalytic materials are used, then standard operating temperatures are required, but energy consumption increases
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical properties of the catalyst system through the nanoparticle-matrix interface. The unique interfacial structure creates new catalytic pathways that lower the activation energy required for reactions, enabling operation at reduced temperatures while maintaining or improving catalytic efficiency.
4Quantity of substance
If catalyst loading is reduced, then cost decreases, but performance and activity may be compromised
Solution Approach 1:
The patent applies local quality by concentrating catalytic activity in specific regions at the nanoparticle-matrix interface. The distal portions exposed to channels provide high catalytic activity per unit area, compensating for reduced overall loading while maintaining or enhancing productivity through optimized local catalytic sites.
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 approach results in improved selectivity, reduced catalyst loading, increased longevity, lower operating temperatures, and enhanced thermal stability, minimizing sintering and agglomeration, leading to more efficient and durable catalytic performance.
Implementation Method 1
at least part of the proximal portions of the nanoparticles are physically bound to the matrix material
Implementation Method 2
at least part of the proximal portions is chemically bound to the matrix material at the interface between the matrix material and the catalytic nanoparticles by covalent interaction
Implementation Method 3
the compound includes one of local oxidation or reduction of at least one of the interconnected matrix material and the catalytic nanoparticles near the proximal portions between the matrix material and the catalytic nanoparticles
Implementation Method 4
the compound includes one of local oxidation or reduction of at least one of the interconnected matrix material and the catalytic nanoparticles near the proximal portions between the matrix material and the catalytic nanoparticles
Implementation Method 5
a plurality of catalytic nanoparticles having proximal portions and distal portions... the distal portions of the nanoparticles are exposed to the interconnected channels
Data Source
AI summary
Aspects of the present application provides for enhanced catalytic materials, which can feature multiple functional and/or catalytic species, and methods of their formation. The materials can include catalytic nanoparticles (NPs) partially embedded within a supporting matrix. Treatment of the material, e.g., thermal, optical, microwave, plasma, and/or chemical treatment, can lead to the formation of functionally, e.g., catalytic or co-catalytic, relevant chemical and structural/morphological species or features at the NP-matrix, NP-pore, and matrix-pore interfaces. The treated material is characterized by enhanced properties, e.g., greater mechanical stability.