Supported Metal Catalyst With Uniform Pores for Lower Diffusion Resistance
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Solution Overview
Problem
The effectiveness factor of active metal particles in existing supported metal catalysts, such as those using MCND, is not sufficiently high due to wide variations in pore diameter, leading to diffusion resistance and reduced catalytic performance.
Innovation Solution
A supported metal catalyst is designed with conductive particles having uniform pore diameters and a high proportion of active metal particles supported in a surface layer region, within 15 nm from the surface, to enhance catalytic efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If active metal particles are supported in pores with widely varying diameters (as in MCND), then the support structure is simple and easy to manufacture, but the effectiveness factor of active metal particles decreases due to diffusion resistance at deep pore positions
Solution Approach 1:
The invention changes the pore diameter parameter from widely varying (as in MCND) to uniformly controlled within 1-20 nm. This is achieved by using a template method where spherical particles with controlled diameters are used as templates to form pores with uniform dimensions, thereby resolving the contradiction between ease of manufacture and manufacturing precision of pore structures
Solution Approach 2:
The invention employs porous conductive particles with specifically controlled pore structures (1-20 nm diameter, uniform distribution) as the support material. This porous structure allows active metal particles to be positioned at shallow depths, reducing diffusion resistance while maintaining ease of manufacture through template-based fabrication
2Quantity of substance
If active metal particles are supported at deep positions in pores, then more active metal can be loaded, but the catalytic reaction rate decreases due to diffusion resistance
Solution Approach 1:
The invention applies local quality by concentrating active metal particles in specific regions (shallow positions within 15 nm from pore surface) rather than uniformly distributing them throughout deep pores. This localized positioning ensures high catalytic activity at the surface while still utilizing the porous structure for support, resolving the contradiction between loading amount and reaction rate
Solution Approach 2:
The template method performs preliminary action by pre-forming uniform pore structures before introducing active metal particles. This ensures that particles are deposited at controlled shallow positions from the outset, preventing deep pore accumulation and maintaining high catalytic efficiency while achieving adequate loading
3Device complexity
If the standard deviation of pore diameter is large (as in MCND), then the pore structure formation is simple, but it is difficult to control the supporting position of active metal particles
Solution Approach 1:
The invention changes the pore diameter distribution parameter from large standard deviation (MCND) to small standard deviation (≤50% of average diameter). This is achieved through template-based formation using spherical particles of uniform size, which directly transfers their size uniformity to the resulting pore structure, enabling precise control of active metal particle supporting positions
Solution Approach 2:
The invention uses a copying approach where the uniform spherical template particles serve as models that are replicated in the final pore structure. The templates' uniform dimensions are copied into the pore geometry, ensuring consistent pore diameters and enabling precise control over where active metal particles will be supported
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 configuration increases the effectiveness factor of the active metal particles by reducing diffusion resistance and enhancing catalytic reaction rates, thereby improving the performance of the catalyst.
Implementation Method 1
the catalytic reaction rate is lower due to diffusion resistance of reactants used in a catalytic reaction and products generated by the catalytic reaction
Data Source
AI summary
The present invention provides a supported metal catalyst with excellent effectiveness factor of active metal particles which are also free from deactivation by contacting with ionomer.According to the present invention, provided is a supported metal catalyst, comprising a support that is a collective body of conductive particles; and dispersed active metal particles supported on the conductive particles, wherein the conductive particles include a plurality of pores, an average entrance pore diameter of the pores is 1 to 20 nm, a standard deviation of the average entrance pore diameter is equal to or less than 50% of the average entrance pore diameter, a number fraction of the active metal particles supported in a surface layer region of the conductive particles divided by the total number of the active metal particles is equal to or more than 50%, and the surface layer region is a region on a surface of the conductive particles or a region in the pores within a depth of 15 nm from the surface.