Granular Support Catalyst Deposition via Evaporation
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Solution Overview
Problem
Conventional methods for supporting catalyst particles on granular supports with diameters less than 1 μm face challenges in forming catalyst particles with diameters between 2 to 10 nm, leading to insufficient catalyst loading and reduced electric power generation, and are hindered by high material and processing costs associated with noble metal targets in sputtering methods.
Innovation Solution
A method involving a decompression device with an evaporation source and a rotating container and stirring device to alter the relative position of granular supports, allowing for controlled deposition of alloy particles with diameters between 2 μm and 10 μm, reducing production costs and composition fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If catalyst elements are deposited on carbon granular supports while the carbon granular supports are stirred, then the distribution of catalyst particles is improved, but it is difficult to detect material other than carbon even if the products are observed by an electronic microscope
Solution Approach 1:
The patent applies preliminary action by forming catalyst particles on the granular support surface before stirring begins. The catalyst elements are deposited and form detectable particles while the support remains stationary, allowing electronic microscope observation to confirm material presence. Only after this detection phase is complete is stirring initiated to achieve uniform distribution, thus resolving the contradiction between detectability and distribution.
2Ease of manufacture
If catalyst particles are deposited only on the surface of a carbon paper, then the deposition process is simple, but the amount of catalyst supported is not enough to obtain necessary electric power
Solution Approach 1:
The patent transitions from two-dimensional surface deposition on flat carbon paper to three-dimensional deposition throughout the volume of granular carbon supports. By using granular supports with sizes of 0.1 to 1.0 mm, the catalyst elements can be incorporated throughout the entire support structure, dramatically increasing the catalyst loading capacity from surface-only to volume-based distribution, thus achieving the necessary electric power output.
3Productivity
If a thin film of catalyst is formed, then the deposition process is efficient, but the surface area of the catalyst becomes narrow and electric-generation capacity is decreased
Solution Approach 1:
The patent utilizes the porous structure of granular carbon supports to achieve both efficient deposition and high catalyst surface area. The granular supports provide numerous internal surfaces and pores that can accommodate catalyst particles, creating a high-surface-area catalyst layer that is not constrained by the limitations of flat film formation. This allows efficient deposition while maintaining large catalyst surface area for enhanced electric-generation capacity.
4Manufacturing precision
If noble metal targets are used in sputtering methods, then catalyst particles can be deposited, but material and processing costs are high
Solution Approach 1:
The patent changes the deposition parameters by using evaporation instead of sputtering, and by controlling particle size through evaporation rate and deposition conditions rather than requiring expensive noble metal targets. This parameter change allows the formation of catalyst particles with desired properties using more cost-effective materials and processes, significantly reducing both material and processing costs while maintaining manufacturing precision.
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 enables the formation of catalyst particles with desired diameters and composition, enhancing catalyst activity and reducing material waste, while minimizing the use of costly noble metals and improving the efficiency of fuel cell performance.
Implementation Method 1
an evaporation source for evaporating elements to form an alloy particle
Implementation Method 2
a supporting method for supporting a metal particle including at least two elements on a surface of a plurality of granular supports in a decompression device
Data Source
AI summary
A supporting method for supporting a metal particle including at least two elements on a surface of a plurality of granular supports in a decompression device, the supporting method supporting the metal particle whose particle diameter being smaller than a grain size of the granular support comprises holding the plurality of granular supports in a container and rotating a stirring device and/or the container, a stirring period in which the relative position among the plurality of granular supports are changed and a non-stirring period in which the relative position among the plurality of granular supports are not changed being altered by the rotating, wherein the decompression device comprises, an evaporation source for evaporating elements to form an alloy particle, the container for holding the plurality of granular supports in the decompression device so that a relative position among granular supports is able to be changed, a rotating device for rotating the container and the stirring device disposed in the container.