Flexible Structured Base Material for High-Utilization Catalysts
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Solution Overview
Problem
Existing granular catalysts for wastewater treatment have internal structures that reduce active site density, leading to material waste and increased costs, while 2D catalysts with hard templates are fragile and limit mass transfer efficiency.
Innovation Solution
A base material with a structured surface composed of transition metal and oxide, concentratedly distributed on the surface, providing flexibility and high porosity for improved mass transfer and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If granular catalysts with internal structures are used, then catalyst volume is reduced, but active site density decreases and material utilization is wasted
Solution Approach 1:
The invention extracts and eliminates the internal structure of granular catalysts, transforming them into two-dimensional flat structures. This removal of internal void spaces allows every part of the catalyst material to be exposed and accessible, ensuring that 100% of the catalyst material contributes to active sites rather than being wasted in inaccessible internal regions.
Solution Approach 2:
The invention transitions from three-dimensional granular catalysts to two-dimensional flat catalyst structures. This dimensional reduction eliminates internal structures and creates a planar geometry where all catalyst material is accessible from the surface, maximizing active site density while maintaining reduced overall volume through thin-film configuration.
2Area of moving object
If catalyst size is reduced to micro/nano powder form, then specific surface area increases, but additional membrane separation and recovery processes are required
Solution Approach 1:
The invention employs thin-film catalyst structures that provide high specific surface area similar to powdered catalysts but maintain structural integrity as continuous films. These thin films can be easily separated from reaction mixtures and recovered without requiring complex membrane separation processes, combining the advantages of high surface area with simplified recovery operations.
Solution Approach 2:
The invention segments the catalyst into thin-film layers that can be easily separated from the reaction system. These segmented thin films maintain high surface area for catalytic activity while their discrete, planar structure enables simple separation and recovery processes compared to fine powders.
3Shape
If hard template is used for 2D catalyst preparation, then catalyst structure is defined, but flexibility is lost and catalytic layer becomes dense and fragile
Solution Approach 1:
The invention changes the physical and chemical parameters of the catalyst support and active layer during preparation and treatment processes. By controlling parameters such as porosity, thickness, and material composition, the catalyst achieves both well-defined structure and enhanced mechanical flexibility, eliminating the brittleness associated with hard template methods.
Solution Approach 2:
The invention creates composite catalyst structures combining multiple materials with complementary properties. The composite structure integrates materials that provide structural definition with materials that confer flexibility and mechanical strength, resulting in a catalyst layer that is both structurally well-defined and mechanically robust.
Data Source
AI summary
A base material includes a base layer. The base layer includes a structured surface. The base layer includes a transition metal and a transition metal oxide, and a sum of the transition metal and a transition metal oxide accounts for at least 90 wt. % of the base layer. The transition metal oxide is concentratedly distributed on the structured surface. The base material is flexible in at least one direction, and has a bending angle of not less than 90° when being bent.