Physical Vapor Deposition of Metal Single-Atom Catalysts

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional methods for synthesizing single-atom catalysts face challenges such as limited metal and support choices, complex procedures, environmental hazards, and high costs, leading to low yield and instability of single atoms, which impede their industrial application.

Innovation Solution

A method involving the deposition of metal single atoms on a water-soluble support using physical vapor deposition, followed by dispersion and separation, which is environmentally friendly, economical, and applicable to various metals and supports, without the need for expensive equipment or additional treatments like acid or heat treatment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional chemical methods are used to synthesize single-atom catalysts, then metal single atoms can be dispersed on supports, but the process causes environmental harm and requires expensive equipment

Engineering Contradiction:

Improvestability of single atomsVSAvoidenvironmental harm

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces chemical synthesis methods with a physical vapor deposition method. Metal atoms are deposited onto support particles in a vacuum chamber without using chemical reagents or catalysts. This mechanical/physical approach eliminates environmental contamination from chemical waste while achieving stable single-atom dispersion on the support surface

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and eliminates the harmful chemical components from the synthesis process. By using physical vapor deposition instead of chemical methods, the process removes toxic chemicals, solvents, and byproducts entirely, leaving only the metal atoms and support material needed for the catalyst

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If conventional synthesis methods are used, then single-atom catalysts can be prepared, but the procedures are complex and require additional treatments

Engineering Contradiction:

Improvequality of single-atom catalystVSAvoidcomplexity of synthesis procedure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple synthesis steps into a single physical vapor deposition process. The metal atoms are deposited directly onto the support particles in one continuous operation, eliminating the need for separate impregnation, drying, calcination, and reduction steps required by conventional chemical methods

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The support particles themselves serve as the substrate for metal deposition without requiring pre-treatment or modification. The physical vapor deposition process automatically achieves uniform metal distribution on the support surface, eliminating the need for additional acid treatments or heat treatments to stabilize the single atoms

Inventive Principle:

Principle #25Self-service

3Quantity of substance

If conventional methods are used to prepare single-atom catalysts, then metal dispersion can be achieved, but the metal loading is low and yield is poor

Engineering Contradiction:

Improvemetal loadingVSAvoidyield of single-atom catalyst

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The support particles are prepared in advance with controlled size and surface properties before the vapor deposition step. This preliminary preparation ensures that when metal atoms are deposited, they can achieve high loading densities uniformly distributed across the support surface, maximizing both metal loading and catalytic yield

Inventive Principle:

Principle #10Preliminary action

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 preparation of high-density single-atom catalysts with well-defined structures, maximizing reactivity per unit mass and ensuring maximum atom utilization, thus being economically viable and universally applicable.

Implementation Method 1

depositing metal single atoms on a water-soluble support

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentUS11173481B2Metal single-atom catalyst and method for preparing the same

Publication Date: 2021.11.16 GLOBAL FRONTIER CENT FOR MULTISCALE ENERGY SYST

AI summary

Disclosed are a metal single-atom catalyst and a method for preparing the same. The method uses a minimal amount of chemicals and is thus environmentally friendly compared to conventional chemical and/or physical methods. In addition, the method enables the preparation of a single-atom catalyst in a simple and economical manner without the need for further treatment such as acid treatment or heat treatment. Furthermore, the method is universally applicable to the preparation of single-atom catalysts irrespective of the kinds of metals and supports, unlike conventional methods that suffer from very limited choices of metal materials and supports. Therefore, the method can be widely utilized to prepare various types of metal single-atom catalysts. All metal atoms in the metal single-atom catalyst can participate in catalytic reactions. This optimal atom utilization achieves maximum reactivity per unit mass and can minimize the amount of the metal used, which is very economical.