Additive Manufacturing for Noble Metal Catalysts With Gas-Permeable Openings
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Solution Overview
Problem
Existing methods for producing catalyst systems for gas reactions, such as the Andrussow and Ostwald processes, lack flexibility and efficiency in manufacturing noble metal catalysts with complex geometries and optimal noble metal usage.
Innovation Solution
A method involving additive manufacturing, where noble metal powders with specific spherical particle size distributions and alloy compositions are layered and partially melted with high-energy radiation to create planar structures with gas-permeable openings, allowing for flexible production of catalyst systems with optimized noble metal use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional production methods are used for catalyst systems, then manufacturing simplicity is maintained, but flexibility and efficiency in producing complex geometries are poor
Solution Approach 1:
The patent replaces conventional mechanical manufacturing methods with additive manufacturing technology. This allows complex three-dimensional catalyst geometries to be produced directly from digital models without complex tooling or assembly processes, achieving high flexibility while maintaining manufacturing simplicity through digital control.
Solution Approach 2:
The patent utilizes controllable parameters of additive manufacturing (laser power, scanning speed, layer thickness, powder composition) to optimize catalyst geometry and noble metal distribution. By adjusting these parameters, complex geometries can be produced efficiently with precise control over catalyst structure and metal utilization.
2Adaptability or versatility
If additive manufacturing is used with conventional powder, then production flexibility is improved, but manufacturing precision and surface quality deteriorate
Solution Approach 1:
The patent applies local quality control by using spherical powder particles with specific size ranges (d10≥5μm, d90≤80μm) that ensure uniform packing and melting behavior in different regions of the catalyst structure. This localized optimization of powder properties maintains high manufacturing precision while preserving the flexibility of additive manufacturing.
Solution Approach 2:
The patent performs preliminary preparation of spherical noble metal powder with controlled size distribution before the additive manufacturing process. This pre-processing ensures that the powder meets specific quality criteria for precise layer deposition and melting, thereby achieving high manufacturing precision while maintaining production flexibility.
3Reliability
If noble metal usage is increased to improve catalytic activity, then catalytic performance is enhanced, but cost and material efficiency worsen
Solution Approach 1:
The patent creates planar structures with gas-permeable openings and porous features through additive manufacturing. This increases the surface area and catalytically active sites per unit mass of noble metal, enhancing catalytic activity while reducing the total amount of expensive noble metal required.
Solution Approach 2:
The patent transitions from traditional bulk or simple geometric catalyst forms to complex three-dimensional planar structures with gas-permeable openings. This dimensional complexity maximizes the utilization of noble metal by creating extensive surface area within a compact form, improving both catalytic activity and material efficiency.
4Manufacturing precision
If particle size distribution is not controlled, then material cost is reduced, but manufacturing precision and catalyst performance deteriorate
Solution Approach 1:
The patent optimizes the particle size distribution parameters of the noble metal powder (d10≥5μm, d90≤80μm) to achieve the best balance between manufacturing precision and material cost. This controlled size range ensures proper flow, packing, and melting characteristics for high-precision additive manufacturing while avoiding the need for excessively fine (expensive) powders.
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 method enables the production of catalyst systems with highly catalytically active surfaces while minimizing noble metal usage, offering improved flexibility and efficiency compared to conventional production methods.
Implementation Method 1
repeatedly applying the noble metal powder or powders provided in step (1) in layers to a substrate in a build chamber, respectively followed by an at least partial melting of the respective noble metal powder applied as a layer with high-energy radiation
Implementation Method 2
at least partial melting of the respective noble metal powder applied as a layer with high-energy radiation, and allowing the melted noble metal powder to solidify
Data Source
AI summary
A method for producing a catalyst system for gas reactions comprising at least one planar structure of noble metal having gas-permeable openings, comprising the steps of:(1) providing at least one noble metal powder consisting of at least substantially spherical noble metal particles, and(2) repeatedly applying the noble metal powder or powders provided in step (1) in layers to a substrate in a build chamber, respectively followed by an at least partial melting of the respective noble metal powder applied as a layer with high-energy radiation, and allowing the melted noble metal powder to solidify within the scope of additive manufacturing.