Ion Soft-Landing for Catalyst Surface Preparation
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Solution Overview
Problem
Current catalyst preparation methods offer limited control over catalyst particle size and composition, resulting in wide distributions unless precise conditions are met, which is not sufficient for achieving consistent catalytic activity.
Innovation Solution
The method involves ionizing a composition containing compounds capable of catalytic activity, separating ions by mass/charge ratio, and soft-landing them onto a surface using an ionization apparatus with a heated capillary, ion funnel, and mass analyzer to achieve precise deposition of ions at specific locations, allowing for precise control over catalyst particle size and composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional catalyst preparation methods (precipitation, impregnation, co-precipitation, sol-gel, chemical vapor deposition) are used, then catalyst surfaces can be prepared with certain compositions, but control over catalyst particle size is limited or nonexistent, resulting in wide size distributions
Solution Approach 1:
The patent replaces conventional mechanical/chemical preparation methods (precipitation, impregnation, sol-gel) with a physical ion beam deposition method. Ions of the desired catalyst composition are generated, mass-selected, and deposited directly onto the surface, eliminating the need for complex chemical synthesis and size control procedures while achieving precise particle size control through ion energy and flux parameters
Solution Approach 2:
The patent changes the fundamental parameters of the deposition process by using ion beams with specific mass-to-charge ratios selected by a mass analyzer. By controlling ion energy, flux, and mass selection, the method achieves precise control over catalyst particle size and composition that is not attainable with conventional chemical methods
2Manufacturing precision
If precise conditions are met in conventional methods to control particle size, then catalyst composition can be controlled, but the process requires great care and precise conditions which increases operational difficulty
Solution Approach 1:
The patent replaces delicate chemical processes requiring precise control of pH, temperature, and reagent ratios with a physical ion beam method. The mass analyzer automatically selects ions of the desired composition, and the deposition process is controlled by simple parameters (ion energy, flux, deposition time) that are much easier to control precisely than chemical reaction conditions
3Ease of operation
If conventional methods are used without great care, then preparation is simpler, but wide distribution of particle sizes results, reducing catalytic activity consistency
Solution Approach 1:
The patent replaces chemical synthesis methods with physical ion beam deposition, where the mass analyzer inherently selects only ions of the desired mass-to-charge ratio. This physical selection mechanism guarantees narrow particle size distribution and consistent catalytic activity without requiring the operator to exercise great care in chemical process control
Solution Approach 2:
The mass analyzer and ion beam system automatically ensure precise particle size control through their inherent physical principles. The system self-regulates to deposit ions of the selected mass-to-charge ratio, providing reliable and consistent catalyst preparation without requiring complex operational procedures or expert intervention
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 preparation of catalytic surfaces with defined chemical composition and controlled particle size, enabling systematic studies to determine optimal cluster size and composition for catalytic activity, and allows for the analysis of reactivity in-situ.
Implementation Method 1
ionizing a composition containing at least one compound capable of having catalytic activity as an ion and other compositions, to generate ions
Implementation Method 2
separating the ions of the at least one compound by mass/charge ratio from the other ionized components of the composition
Implementation Method 3
a second set of Einzel lenses distal to the RIT mass analyzer for controlling velocity and focusing for soft-landing the ions of the compound onto the surface
Implementation Method 4
a heated capillary distal to the ionization apparatus, in which the heated capillary transfers the ions into a first vacuum region
Data Source
AI summary
The invention provides methods and apparatuses that utilize mass spectrometry for preparation of a surface to have catalytic activity through molecular soft-landing of mass selected ions. Mass spectrometry is used to generate combinations of atoms in a particular geometrical arrangement, and ion soft-landing selects this molecular entity or combination of entities and gently deposits the entity or combination intact onto a surface.