Pt-Cu-Ru Core-Shell Nanoparticles for Fuel Cell Catalysts

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Solution Overview

Problem

Current fuel cell electrocatalysts, particularly those using platinum, suffer from high activation polarization losses and inefficiencies, necessitating the development of more active and durable catalysts for oxygen reduction and other reactions to enhance fuel cell performance for commercial electric drive applications.

Innovation Solution

A composite material comprising nanoparticles with a specific alloy composition of platinum, copper, and ruthenium, supported on activated carbon, with a structured surface structure, is synthesized using a multi-stage process involving gel formation, pyrolysis, metallization, and hardening, to achieve improved catalytic activity and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional platinum-based electrocatalysts are used, then the fuel cell can operate, but the activation polarization losses are high and catalytic activity is insufficient

Engineering Contradiction:

Improvecatalytic activityVSAvoidactivation polarization losses

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent employs a composite material consisting of a core-shell structured nanoparticle with a platinum-rich shell and a copper-rich core. This composite structure combines the high catalytic activity of platinum with the cost-effectiveness and structural stability of copper, achieving enhanced catalytic performance while reducing activation polarization losses compared to traditional pure platinum catalysts.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The catalyst exhibits local quality differentiation through its core-shell structure, where the platinum-rich shell provides high catalytic activity at the surface for oxygen reduction reactions, while the copper-rich core provides structural support and cost reduction. This spatial differentiation of material properties optimizes both catalytic performance and energy efficiency.

Inventive Principle:

Principle #3Local quality

2Reliability

If platinum content is increased to improve catalytic activity, then specific catalyst activity improves, but the cost and weight of the fuel cell system increase

Engineering Contradiction:

Improvespecific catalyst activityVSAvoidcatalyst mass

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The core-shell composite structure allows the system to achieve high specific catalyst activity through the platinum-rich shell while minimizing the overall platinum content by using a copper-rich core. This composite approach reduces the total mass of precious metals required while maintaining or enhancing catalytic performance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent substitutes expensive platinum with cheaper copper in the core region, using the more abundant and cost-effective copper material where full platinum coverage is not necessary for maintaining catalytic activity, thereby reducing overall catalyst mass and cost.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If alloy composition is optimized for higher activity, then mass activity improves, but the structural stability and durability may be compromised

Engineering Contradiction:

Improvemass activityVSAvoidstructural stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The core-shell composite structure provides an optimal balance between activity and stability, where the platinum-rich shell ensures high mass activity for oxygen reduction, while the copper-rich core provides structural stability and resistance to degradation. The distinct separation of functions in the core and shell regions maintains both performance and durability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The catalyst employs local quality differentiation where the platinum-rich shell provides high catalytic activity and resistance to degradation at the reactive surface, while the copper-rich core provides structural stability and support. This spatial distribution of material properties simultaneously optimizes mass activity and structural stability.

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 composite material exhibits enhanced specific catalyst activity and mass activity for oxygen reduction and methanol oxidation reactions, surpassing the performance of traditional platinum-based catalysts, with potential shifts in electrode potential and improved durability, making it suitable for fuel cell applications.

Implementation Method 1

a composite material having electrocatalytic activity

Methodology Applied

Scientific EffectElectrocatalysis: Catalysis

Implementation Method 2

pyrolyzing the gel of step (α) in a reducing atmosphere and/or inert atmosphere to form a composite including an electrically conductive matrix and nanoparticles

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Implementation Method 3

pyrolyzing the gel of step (α) in a reducing atmosphere and/or inert atmosphere to form a composite including an electrically conductive matrix and nanoparticles

Methodology Applied

Scientific EffectReduction: Reduction

Data Source

PatentEP2735044B1Electrocatalytic composite(s), associated composition(s), and associated process(ES)

Publication Date: 2021.01.06 MEBIUS D O O

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AI summary

Compositions having electrocatalytic activity and composites having electrocatalytic activity, as well as processes for making compositions and composites are described. Also process for using such compositions and/or composites, such as, for example, a machine or equipment are described Some aspects of embodiments and/or embodiments of the present invention are directed to a nanosize transition metal alloy (such as for example an alloy comprising copper, cobalt, nickel, palladium, platinum, ruthenium, the like, and combinations thereof) that is electrocatalytically active. Some other aspects of embodiments and/or embodiments of the present invention are directed to a composite material comprising a nanosize transition metal alloy and a carbonaceous matrix.