Composite Fuel Cell Catalyst Support for Carbon Corrosion Resistance

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Solution Overview

Problem

Fuel cell catalysts face challenges with carbon corrosion due to the low electrical conductivity of TiO2 supports, which limits the electrochemical durability and catalytic activity of platinum particles.

Innovation Solution

A method involving the formation of a carbon support dispersion solution, mixing a metal precursor, and irradiating an electron beam to support metals, resulting in a second metal-supported carbon support with improved electrical conductivity and oxidation resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If TiO2 is used as catalyst support to increase oxidation resistance, then carbon corrosion is suppressed, but electrical conductivity decreases

Engineering Contradiction:

Improveoxidation resistanceVSAvoidelectrical conductivity

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent uses a composite support structure consisting of TiO2 nanoparticles dispersed on carbon carriers. This composite combines the oxidation resistance of TiO2 with the electrical conductivity of carbon, resolving the contradiction between these two properties. The TiO2 particles provide oxidation protection while the carbon matrix maintains electron transport pathways.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The TiO2 is distributed as nanoparticles on the carbon support surface rather than using bulk TiO2. This local distribution allows the carbon support to maintain its bulk conductivity while providing oxidation-resistant surfaces where catalyst particles are supported. Each local region has optimized properties: carbon for conductivity, TiO2 for oxidation resistance.

Inventive Principle:

Principle #3Local quality

2Productivity

If carbon carriers are used to support platinum nanoparticles for high reaction efficiency, then catalytic activity increases, but carbon corrosion occurs at high potentials

Engineering Contradiction:

Improvecatalytic activityVSAvoidcarbon corrosion

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

TiO2 nanoparticles act as an intermediary layer between the carbon support and platinum catalyst particles. This intermediary protects the carbon from direct exposure to harsh oxidative conditions at high potentials, preventing carbon corrosion while maintaining the structural integrity and catalytic activity of the platinum particles.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The TiO2 layer is applied beforehand to the carbon support to create a protective barrier before the catalyst is deployed. This pre-established protective layer cushions the carbon support against oxidative attacks during fuel cell operation, preventing the harmful carbon corrosion that would otherwise occur at high potentials.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If high-temperature graphitization is applied to increase crystallinity of carbon carrier, then oxidation initiation temperature increases, but manufacturing complexity increases

Engineering Contradiction:

Improveoxidation initiation temperatureVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of changing the fundamental structure of carbon through high-temperature graphitization, the patent changes the chemical environment by coating TiO2 nanoparticles on the carbon surface. This parameter change (adding oxidation-resistant coating) achieves the same goal of increasing oxidation resistance without requiring extreme manufacturing conditions.

Inventive Principle:

Principle #35Parameter changes

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 approach enhances the catalytic activity of platinum particles and prevents carbon corrosion, improving the electrochemical durability and performance of fuel cells by maintaining the oxidation resistance of metal oxides while ensuring efficient electron transfer.

Implementation Method 1

supporting a first metal by irradiating an electron beam on the first metal precursor-mixed solution

Methodology Applied

Scientific EffectElectron beam irradiation: Electron Beam

Implementation Method 2

supporting a second metal by irradiating an electron beam on a second metal precursor-injected mixed solution

Methodology Applied

Scientific EffectElectron beam deposition: Deposition (physical)

Implementation Method 3

forming a carbon support dispersion solution

Methodology Applied

Scientific EffectDispersion: Dispersion (of waves)

Implementation Method 4

forming a first metal precursor-mixed solution by mixing a solution of a first metal precursor with the carbon support dispersion solution

Methodology Applied

Scientific EffectPrecipitation: Precipitation

Data Source

PatentEP4379870A1Oxidation-resistant catalyst for fuel cell, method of manufacturing the same, and fuel cell including the same

Publication Date: 2024.06.05 KORENS RTX CO LTD

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AI summary

Provided are an oxidation-resistant catalyst for fuel cells, a manufacturing method thereof, and a fuel cell including the same. In the case of the catalyst for a fuel cell according to the present disclosure, the fuel cell catalyst according to the present disclosure has oxidation-resistant features of a metal oxide while maintaining the electrical conductivity of a carbon support. Accordingly, catalytic activity of platinum particles, which are the active points in fuel cells, can be improved, and metal oxides can prevent platinum particles from directly interacting with carbon supports, thereby resolving the problem of carbon corrosion at the platinum/carbon interface.