Vapor-Deposited Encapsulating Layers for Molecular Catalysts

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Solution Overview

Problem

Molecular transition metal catalysts in homogeneous solutions exhibit high catalytic activity but poor stability and short lifetimes due to intermolecular interactions, and immobilization on solid supports while increasing stability can lead to decreased selectivity and leaching issues, especially in the presence of water.

Innovation Solution

The use of atomic layer deposition (ALD) to encapsulate molecular catalysts on solid metal oxide supports, creating a hybrid heterogeneous catalyst with a vapor-deposited coating layer that adheres the catalyst to the substrate, allowing for stable operation in green solvents like water.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If molecular catalysts are immobilized on solid supports, then catalyst stability and lifetime are improved, but catalyst selectivity decreases and leaching occurs

Engineering Contradiction:

Improvecatalyst stabilityVSAvoidcatalyst selectivity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent divides the catalyst system into distinct functional components: the molecular catalyst retains its discrete molecular structure and selectivity, while the support provides stability. The catalyst is segmented from the support through a carefully designed interface that prevents leaching without compromising the catalyst's molecular integrity and selectivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces an intermediary layer or interface between the molecular catalyst and the solid support that mediates the interaction. This intermediary prevents direct harmful interactions that cause leaching and deactivation, while allowing the catalyst to maintain its selectivity through preserved molecular structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If molecular catalysts are used in homogeneous solutions, then catalytic activity is high, but catalyst lifetime is short due to intermolecular interactions

Engineering Contradiction:

Improvecatalytic activityVSAvoidcatalyst lifetime

Core Design Contradiction:

ProductivityVSDuration of action of moving object

Solution Approach 1:

The patent extracts the molecular catalyst from the homogeneous solution environment where intermolecular deactivation occurs, and anchors it to a solid support. This extraction removes the catalyst from the harmful intermolecular interaction pathway while preserving its catalytic function through proper interface design.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs thin film or surface layer structures on the solid support that create a protective environment for the immobilized catalyst. These thin films allow the catalyst to maintain high activity by preserving access to substrates while preventing deactivation pathways.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If water is used as solvent to improve environmental safety, then catalyst deactivation via multimer formation is promoted

Engineering Contradiction:

Improvesolvent compatibilityVSAvoidcatalyst stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies preliminary protective measures by immobilizing the catalyst on the solid support before water-induced deactivation can occur. The solid support interface pre-prevents the formation of water-promoted multimers by maintaining the catalyst in an isolated, stable state even in aqueous environments.

Inventive Principle:

Principle #9Preliminary anti-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 approach significantly extends the lifetime of molecular catalysts, maintains catalytic activity, and enables the use of environmentally friendly solvents, while preventing leaching and deactivation, thus enhancing catalyst stability and reactivity.

Implementation Method 1

The use of atomic layer deposition (ALD) to encapsulate molecular catalysts on solid metal oxide supports, creating a hybrid heterogeneous catalyst with a vapor-deposited coating layer

Methodology Applied

Scientific EffectVapor deposition: Physical Vapour Deposition

Implementation Method 2

The use of atomic layer deposition (ALD) to encapsulate molecular catalysts on solid metal oxide supports

Methodology Applied

Scientific EffectAtomic layer deposition: Chemical Vapour Deposition

Data Source

PatentUS20240149262A1Immobilization of Molecular Catalysts on Solid Powders via Vapor Deposition of Encapsulating Nano-Layers for Use as Heterogeneous Chemical Catalysts

Publication Date: 2024.05.09 GEORGIA TECH RES CORP

AI summary

An exemplary embodiment of the present disclosure provides a heterogeneous chemical catalyst comprising a substrate, a molecule attached to the substrate via a binding site, wherein the molecule comprises a catalytic active site, and a coating layer coating at least a portion of the binding site. Another embodiment of the present disclosure provides a method of preparing a heterogeneous chemical catalyst. This method comprises providing a substrate, attaching a molecule to the substrate via a binding site, wherein the molecule comprises a catalytic active site, and coating, with a coating layer, at least a portion of the binding site to form the heterogeneous chemical catalyst.