High-Temperature Pulse Synthesis for Stable Single-Atom Dispersions
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Solution Overview
Problem
The stability of single atom catalysts is challenged by thermodynamically driven atom aggregation, and existing technologies are limited to single element catalysts, which do not realize synergistic interactions among different atoms.
Innovation Solution
A method of synthesizing atomic dispersions by applying high temperature heating pulses to substrates loaded with precursors or clusters of elements, causing partial single atom dispersion and forming stable atom-substrate bonds, which can be iteratively applied to achieve multi-atom dispersions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wet chemical synthesis is used to achieve atomic dispersions, then single atom catalysts can be synthesized, but thermal stability deteriorates due to atom aggregation at higher temperatures
Solution Approach 1:
The patent changes the temperature parameter from conventional low-temperature wet chemical synthesis to high-temperature synthesis (above 500°C), which fundamentally alters the synthesis pathway to achieve thermodynamically stable single atom dispersions that resist aggregation
Solution Approach 2:
The patent employs periodic heating and cooling cycles during synthesis, where repeated thermal treatment promotes stable atom-substrate bonding while preventing uncontrolled aggregation, achieving both dispersion and thermal stability
2Ease of manufacture
If single element catalysts are used, then synthesis is simplified, but synergistic interactions among different atoms cannot be realized
Solution Approach 1:
The patent develops a universal high-temperature synthesis methodology that can accommodate multiple different metal precursors and substrate combinations, enabling the creation of diverse single atom and multi-atom catalysts with various catalytic functions beyond what single element catalysts can provide
Solution Approach 2:
The patent creates composite catalyst structures by combining different metal atoms on substrate materials, where the interaction between dissimilar atoms generates synergistic effects that enhance catalytic performance for specific reactions
3Reliability
If high temperature synthesis is applied, then thermal stability of single atoms is improved, but compatibility with temperature-sensitive materials deteriorates
Solution Approach 1:
The patent applies high temperature locally and transiently only to the catalyst synthesis zone, allowing temperature-sensitive substrates and precursors to remain stable elsewhere in the system, thus achieving thermal stability improvement without sacrificing material compatibility
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 method achieves dispersed and stable single atoms and multi-atom groupings on substrates with stable atom-substrate bonding, enhancing thermal stability and enabling synergistic interactions among different atoms for improved catalytic performance.
Implementation Method 1
one or more heating elements to apply one or more temperature pulses to the loaded substrate
Implementation Method 2
causing at least partial single atom dispersion of the element on the substrate
Implementation Method 3
applying one or more temperature pulses to the loaded substrate, where a pulse of the one or more temperature pulses applies a target temperature
Data Source
AI summary
One or more first precursors can be provided on a substrate. The substrate with the one or more first precursors thereon can be subjected to multiple first heating cycles. Each first heating cycle can include a first temperature pulse applied to the substrate for a first duration and a first cooling period following the first temperature pulse. Each first temperature pulse can apply a temperature between 500 K and 4000 K, inclusive. Each first duration can be between 1 millisecond and 1 minute, inclusive.