Single-Atom Dispersion Synthesis Using Pulsed High-Temperature Heating
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Solution Overview
Problem
The stability of single atom catalysts is challenged by thermodynamically driven atom aggregation, leading to performance degradation, and existing technologies are limited to single element catalysts that do not realize synergistic interactions among different atoms.
Innovation Solution
A method involving high temperature synthesis using heating pulses to disperse and stabilize single atoms or multi-atom groupings on substrates, achieving stable atom-substrate bonding through controlled temperature pulses and cooling periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high temperature synthesis is used to improve thermal stability of single atoms, then thermal stability is improved, but synthesis difficulty increases and compatibility with temperature-sensitive materials decreases
Solution Approach 1:
The patent applies periodic heating pulses with controlled duration and temperature to achieve single atom dispersion. The pulsed heating method allows the system to reach high temperatures briefly for atomization while avoiding continuous high temperature exposure that would degrade temperature-sensitive substrates. This periodic thermal action resolves the contradiction by enabling thermal stability improvement without requiring sustained high temperature synthesis conditions.
Solution Approach 2:
The patent changes the temperature parameter dynamically through pulsed heating, varying both temperature magnitude and exposure time. By controlling the pulse duration and repetition frequency, the method achieves effective atom dispersion at lower average temperatures, making the synthesis compatible with temperature-sensitive materials while still obtaining thermally stable single atom catalysts.
2Quantity of substance
If conventional synthesis methods are used to achieve single atom dispersion, then atom-use efficiency is improved, but thermal stability deteriorates due to atom aggregation at high temperatures
Solution Approach 1:
The pulsed heating method creates periodic thermal stress that prevents continuous atom aggregation. The brief high temperature pulses atomize metal precursors while the cooling periods between pulses allow atoms to be trapped in stable configurations on the substrate. This periodic action maintains single atom dispersion even after high temperature exposure, resolving the contradiction between atom-use efficiency and thermal stability.
Solution Approach 2:
The method applies preliminary high temperature pulses to atomize precursors before they can aggregate, then immediately follows with cooling to stabilize the dispersed atoms. This preliminary atomization action prevents subsequent aggregation that would occur in conventional synthesis, thereby maintaining both high atom-use efficiency and thermal stability.
3Device complexity
If single element catalysts are used to simplify catalyst design, then manufacturing complexity is reduced, but catalytic functionality is limited due to lack of synergistic interactions
Solution Approach 1:
The patent extends the single atom dispersion method to accommodate multiple metal elements simultaneously. The pulsed heating process can disperse different metal precursors on the same substrate, creating multi-element single atom catalysts or multi-atom cluster catalysts. This universal approach maintains the simplicity of the synthesis method while enabling diverse catalytic functionalities through synergistic interactions between different elements.
Solution Approach 2:
The method merges multiple metal precursors in a single synthesis process, allowing different elements to be co-dispersed on the substrate. The pulsed heating simultaneously atomizes and distributes multiple metal species, creating combined catalyst systems that leverage synergistic effects while maintaining the ease of the original synthesis protocol.
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 with enhanced thermal stability, enabling optimal atom-use efficiency and unique coordination environments 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
during the pulse, causing at least partial single atom dispersion of the element on the substrate
Implementation Method 3
after the pulse, maintaining a cooling period
Data Source
AI summary
Disclosed are single atom dispersions and multi-atom dispersions, and systems and methods for synthesizing the atomic dispersions. An exemplary method of synthesizing atomic dispersions includes: positioning a loaded substrate which includes a substrate which is loaded with at least one of: a precursor of an element or a cluster of an element, applying one or more temperature pulses to the loaded substrate where a pulse of the temperature pulse(s) applies a target temperature for a duration, maintaining a cooling period after the pulse, and providing single atoms of the element dispersed on the substrate after the one or more temperature pulses. The target temperature applied by the pulse is between 500 K and 4000 K, inclusive, and the duration is between 1 millisecond and 1 minute, inclusive.