Wet chemical and plasma methods of forming stable PtPd catalysts
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B01J-021/00
B01J-021/04
B01J-023/00
B01J-023/02
B01J-023/08
B01J-023/14
B01J-023/40
B01J-023/42
B01J-023/44
B01J-023/56
B82Y-030/00
B01J-037/34
B01J-035/00
B82Y-040/00
출원번호
US-0175894
(2014-02-07)
등록번호
US-9216406
(2015-12-22)
발명자
/ 주소
Van Den Hoek, Willibrordus G.M.
Biberger, Maximilian A.
출원인 / 주소
SDCmaterials, Inc.
대리인 / 주소
Morrison & Foerster LLP
인용정보
피인용 횟수 :
18인용 특허 :
294
초록▼
A nano-particle comprising: an interior region comprising a mixed-metal oxide; and an exterior surface comprising a pure metal. In some embodiments, the mixed-metal oxide comprises aluminum oxide and a metallic pinning agent, such as palladium, copper, molybdenum, or cobalt. In some embodiments, the
A nano-particle comprising: an interior region comprising a mixed-metal oxide; and an exterior surface comprising a pure metal. In some embodiments, the mixed-metal oxide comprises aluminum oxide and a metallic pinning agent, such as palladium, copper, molybdenum, or cobalt. In some embodiments, the pure metal at the exterior surface is the same as the metallic pinning agent in the mixed-metal oxide in the interior region. In some embodiments, a catalytic nano-particle is bonded to the pure metal at the exterior surface. In some embodiments, the interior region and the exterior surface are formed using a plasma gun. In some embodiments, the interior region and the exterior surface are formed using a wet chemistry process. In some embodiments, the catalytic nano-particle is bonded to the pure metal using a plasma gun. In some embodiments, the catalytic nano-particle is bonded to the pure metal using a wet chemistry process.
대표청구항▼
1. A method of forming nano-particles comprising: forming a plurality of aluminum oxide-palladium carrier nano-particles using a plasma gun; andaffixing a plurality of catalytic platinum nano-particles to the aluminum oxide-palladium carrier nano-particles using a wet chemistry process. 2. The metho
1. A method of forming nano-particles comprising: forming a plurality of aluminum oxide-palladium carrier nano-particles using a plasma gun; andaffixing a plurality of catalytic platinum nano-particles to the aluminum oxide-palladium carrier nano-particles using a wet chemistry process. 2. The method of claim 1, wherein forming the plurality of aluminum oxide-palladium carrier nano-particles using the plasma gun comprises: loading a quantity of aluminum oxide material and a quantity of palladium material into the plasma gun;vaporizing the quantity of aluminum oxide material and the quantity of palladium material using the plasma gun, thus forming a vapor cloud comprising vaporized aluminum oxide and vaporized palladium; andquenching the vapor cloud, thus condensing the vaporized aluminum oxide and the vaporized palladium into carrier nano-particles. 3. The method of claim 2, wherein vaporizing the quantity of aluminum oxide material and the quantity of palladium material comprises: flowing a working gas into a reactor of the plasma gun;delivering energy to the working gas, thus forming a plasma stream; andflowing the quantity of aluminum oxide material and the quantity of palladium material into the plasma stream. 4. The method of claim 3, wherein the working gas comprises argon and H2. 5. The method of claim 1, wherein the wet chemistry process comprises: mixing a platinum solution with the aluminum oxide-palladium carrier nano-particles; andbonding a plurality of catalytic platinum nano-particles formed from the platinum solution to the aluminum oxide-palladium carrier nano-particles. 6. The method of claim 5, wherein the platinum solution is a platinum nitrate solution or a platinum chloride solution. 7. The method of claim 1, wherein the aluminum oxide-palladium carrier nano-particles have an average grain size of approximately 10 nanometers or less. 8. The method of claim 1, wherein the catalytic platinum nano-particles have a diameter of approximately 1 nanometer or less. 9. The method of claim 1, wherein the catalytic platinum nano-particles have a diameter of approximately 0.5 nanometer. 10. A nano-particle comprising: a carrier nano-particle comprising aluminum oxide and palladium; anda plurality of catalytic platinum nano-particles affixed to the carrier nano-particle;wherein the nano-particle is formed by the method of claim 1. 11. A nano-particle comprising: a carrier nano-particle comprising aluminum oxide and palladium; anda plurality of catalytic platinum nano-particles bonded to the carrier nano-particle. 12. The nano-particle of claim 11, wherein the aluminum oxide-palladium carrier nano-particles have an average grain size of approximately 10 nanometers or less. 13. The nano-particle of claim 11, wherein the catalytic platinum nano-particles have a diameter of approximately 1 nanometer or less. 14. The nano-particle of claim 13, wherein the catalytic platinum nano-particles have a diameter of approximately 0.5 nanometer. 15. A method of forming a catalyst, the method comprising: providing a support structure;providing a plurality of nano-particles, wherein the nano-particles comprise a catalytic platinum nano-particle bonded to an aluminum oxide-palladium carrier nano-particles; andbonding the plurality of nano-particles to the support structure. 16. The method of claim 15, wherein providing the plurality of nano-particles comprises: forming a plurality of aluminum oxide-palladium carrier nano-particles using a plasma gun; andaffixing a plurality of catalytic platinum nano-particles to the aluminum oxide-palladium carrier nano-particles using a wet chemistry process. 17. The method of claim 16, wherein forming the plurality of aluminum oxide-palladium carrier nano-particles using the plasma gun comprises: loading a quantity of aluminum oxide material and a quantity of palladium material into the plasma gun;vaporizing the quantity of aluminum oxide material and the quantity of palladium material using the plasma gun, thus forming a vapor cloud comprising vaporized aluminum oxide and vaporized palladium; andquenching the vapor cloud, thus condensing the vaporized aluminum oxide and the vaporized palladium into carrier nano-particles. 18. The method of claim 17, wherein vaporizing the quantity of aluminum oxide material and the quantity of palladium material comprises: flowing a working gas into a reactor of the plasma gun;delivering energy to the working gas, thus forming a plasma stream; andflowing the quantity of aluminum oxide material and the quantity of palladium material into the plasma stream. 19. The method of claim 18, wherein the working gas comprises argon and H2. 20. The method of claim 16, wherein the wet chemistry process comprises: mixing a platinum solution with the aluminum oxide-palladium carrier nano-particles; andbonding a plurality of catalytic platinum nano-particles formed from the platinum solution to the aluminum oxide-palladium carrier nano-particles. 21. The method of claim 20, wherein the platinum solution is a platinum nitrate solution or a platinum chloride solution. 22. The method of claim 15, wherein bonding the plurality of carrier nano-particles to the support structure comprises performing a calcining process. 23. The method of claim 15, wherein: the support structure is a porous ceramic material; andthe plurality of nano-particles are disposed within the pores of the ceramic material. 24. The method of claim 15, wherein the aluminum oxide-palladium carrier nano-particles have an average grain size of approximately 10 nanometers or less. 25. The method of claim 15, wherein the catalytic platinum nano-particles have a diameter of approximately 1 nanometer or less. 26. The method of claim 15, wherein the catalytic platinum nano-particles have a diameter of approximately 0.5 nanometer. 27. A catalyst comprising: a support structure; anda plurality of nano-particles, wherein the nano-particles comprise a catalytic platinum nano-particle bonded to an aluminum oxide-palladium carrier nano-particle;wherein the plurality of nano-particles are bonded to the support structure; andwherein the catalyst is formed by the method of claim 15. 28. A catalyst comprising: a support structure;a plurality of nano-particles, wherein the nano-particles comprise a catalytic platinum nano-particle bonded to an aluminum oxide-palladium carrier nano-particle; andwherein the plurality of nano-particles are bonded to the support structure. 29. The catalyst of claim 28, wherein: the support structure is a porous ceramic material; andthe plurality of nano-particles are disposed within the pores of the ceramic material. 30. The catalyst of claim 28, wherein the aluminum oxide-palladium carrier nano-particles have an average grain size of approximately 10 nanometers or less. 31. The catalyst of claim 28, wherein the catalytic platinum nano-particles have a diameter of approximately 1 nanometer or less. 32. The catalyst of claim 31, wherein the catalytic platinum nano-particles have a diameter of approximately 0.5 nanometer.
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