Non-Noble Metal Catalyst Precursors for Fuel Cells

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Solution Overview

Problem

The high cost and limited availability of platinum-based catalysts for oxygen reduction reactions in polymer electrolyte membrane fuel cells (PEMFCs) pose a significant challenge, as well as the need for alternative electrocatalysts that can replace noble metals and improve catalytic activity.

Innovation Solution

A catalyst precursor comprising a microporous support, a non-noble metal precursor, and a pore-filler, where the micropores are filled with the pore-filler and non-noble metal precursor to create a catalyst with a higher density of active sites, specifically designed for oxygen reduction reactions, using iron or cobalt as the non-noble metal and perylene-tetracarboxylic-dianhydride or phenanthroline as the pore-filler, which are then pyrolyzed in a nitrogen-containing gas to enhance catalytic activity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If platinum-based catalysts are used for oxygen reduction reactions, then high catalytic activity is achieved, but cost and availability become prohibitive

Engineering Contradiction:

Improvecatalytic activityVSAvoidcost and availability

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent replaces expensive platinum-based catalysts with non-noble metal catalysts (Fe, Co, Ni) supported on carbon materials. This substitution uses abundant, inexpensive materials to achieve comparable catalytic activity for oxygen reduction reactions, directly addressing the cost and availability issues while maintaining reliability

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention creates composite catalyst systems combining non-noble metals (Fe, Co, Ni) with carbon support materials and nitrogen-containing compounds. These composite structures enhance the catalytic activity of the non-noble metals, allowing them to compete with platinum while remaining cost-effective and abundant

Inventive Principle:

Principle #40Composite materials

2Reliability

If micropores are filled with pore-filler and non-noble metal precursor, then density of active sites increases, but micropore surface area decreases

Engineering Contradiction:

Improvedensity of active sitesVSAvoidmicropore surface area

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent applies local quality by concentrating non-noble metal precursors and pore-fillers specifically within the micropores of the carbon support. This localized placement ensures that the limited micropore surface area is utilized efficiently to create high densities of active sites, while the overall catalyst structure maintains sufficient surface area for reactant access

Inventive Principle:

Principle #3Local quality

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 resulting catalysts exhibit significantly higher volumetric activity, up to 100 times greater than prior art catalysts, making them viable alternatives to platinum-based catalysts for PEMFCs, with improved performance and reduced costs.

Implementation Method 1

the micropores of the microporous support are filled with the pore-filler and the non-noble metal precursor

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

which are then pyrolyzed in a nitrogen-containing gas to enhance catalytic activity

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Implementation Method 3

catalysts play an essential role in boosting the reaction kinetics to produce the desired high power densities

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS9573117B2Catalyst precursors, catalysts and methods of producing same

Publication Date: 2017.02.21 INSTITUT NATIONAL DE LA RECHERCHE SCIENTIFIQUE

AI summary

A catalyst precursor comprising (A) a microporous support; (B) a non-noble metal precursor; and (C) a pore-filler, wherein the micropores of the microporous support are filled with the pore-filler and the non-noble metal precursor so that the micropore surface area of the catalyst precursor is substantially smaller than the micropore surface area of the support when the pore-filler and the non-noble metal precursor are absent is provided. Also, a catalyst comprising the above catalyst precursor, wherein the catalyst precursor has been pyrolysed so that the micropore surface area of the catalyst is substantially larger than the micropore surface area of catalyst precursor, with the proviso that the pyrolysis is performed in the presence of a gas that is a nitrogen precursor when the microporous support, the non-noble metal precursor and the pore-filler are not nitrogen precursors is also provided. Methods of producing the catalyst precursor and the catalyst are provided.