Pt-TMC Catalyst Platform for Fuel Cell Activity

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Solution Overview

Problem

Current transition metal carbides (TMCs) for fuel cell applications, such as group 4 and 6 TMCs, do not match the electrocatalytic activity of conventional platinum (Pt) catalysts like Pt/C, necessitating improved catalysts and supports for enhanced performance.

Innovation Solution

A method involving the formation of transition metal carbide supports using multi-walled carbon nanotubes and halide salts, followed by atomic layer deposition of platinum nanoparticles, creating a Pt-TMC catalyst platform with controlled particle size and dispersion for improved catalytic activity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If transition metal carbides (TMCs) are used as catalysts, then cost is reduced and abundance is increased, but electrocatalytic activity is insufficient compared to Pt/C

Engineering Contradiction:

Improveplatinum loadingVSAvoidelectrocatalytic activity

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent creates a composite catalyst system combining transition metal carbides (TMCs) with platinum nanoparticles deposited on TMC supports. This composite structure leverages the low cost and abundance of TMCs while incorporating sufficient platinum activity through controlled deposition, achieving a balance between cost reduction and maintained electrocatalytic performance

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by creating discrete platinum nanoparticles on specific TMC support structures. The platinum is not uniformly distributed but rather localized in controlled nanoparticle form on the TMC surface, concentrating catalytic activity at specific sites while minimizing overall platinum usage

Inventive Principle:

Principle #3Local quality

2Reliability

If platinum is deposited to enhance catalytic activity, then electrocatalytic activity improves, but platinum loading and cost increase

Engineering Contradiction:

Improveelectrocatalytic activityVSAvoidplatinum loading

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent utilizes atomic layer deposition (ALD) to precisely control platinum nanoparticle size, distribution, and concentration on the TMC support. By adjusting ALD parameters such as deposition cycles and precursor dosage, the patent optimizes platinum loading to achieve maximum catalytic activity with minimum platinum quantity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces conventional platinum deposition methods with atomic layer deposition (ALD), which provides atomic-level precision in controlling platinum nanoparticle formation. This substitution enables much more efficient platinum utilization compared to traditional deposition techniques

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If conventional Pt/C catalysts are used, then electrocatalytic activity is high, but cost and platinum dependency increase

Engineering Contradiction:

Improveelectrocatalytic activityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive, scarce platinum-on-carbon-black catalysts with a system based on abundant, low-cost transition metal carbides. While some platinum is still used, the overall platinum loading is significantly reduced, making the catalyst more cost-effective and less dependent on scarce precious metals

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Stability of the object's composition

If transition metal carbide supports are synthesized at high temperature, then carbide formation is achieved, but energy consumption increases

Engineering Contradiction:

Improvecarbide phase purityVSAvoidsynthesis energy

Core Design Contradiction:

Stability of the object's compositionVSUse of energy by moving object

Solution Approach 1:

The patent utilizes phase transition principles in the synthesis of transition metal carbides from metal halide precursors and carbon nanotubes. By controlling the thermal processing to achieve specific phase transitions, the patent forms pure carbide phases while optimizing energy consumption through controlled heating profiles

Inventive Principle:

Principle #36Phase transitions

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 approach results in a Pt-TMC catalyst platform with enhanced electrocatalytic activity and durability, comparable to or exceeding that of traditional Pt/C catalysts, while reducing platinum loading and costs, and maintaining high surface area and stability.

Implementation Method 1

The mixture is heated to a temperature greater than about 900° C. to form a transition metal carbide support

Methodology Applied

Scientific EffectThermal reaction: Exothermic Reaction

Implementation Method 2

the depositing comprises atomic layer deposition (ALD) of platinum nanoparticles utilizing a platinum precursor and an oxygen precursor in a rotating ALD reactor

Methodology Applied

Scientific EffectAtomic layer deposition: Physical Vapour Deposition

Data Source

PatentUS11552303B2Methods, catalysts, and supports for electrochemical devices

Publication Date: 2023.01.10 UNIVERSITY OF WYOMING

AI summary

Embodiments described herein relate to methods for preparing catalysts and catalyst supports. In one embodiment, transition metal carbide materials, having a nanotube like morphology, are utilized as a support for a precious metal catalyst, such as platinum. Embodiments described herein also relate to proton exchange membrane fuel cells that incorporate the catalysts described herein.