Non-noble Metal Oxygen Reduction Catalyst Prepared Using Non-Porous Porosity Precursors

Simple SummaryContent extracted from patent full text and abstract with AI.

This invention introduces a method for creating non-noble metal catalysts for the oxygen reduction reaction (ORR), crucial in fuel cells and metal-air batteries. The method uses inexpensive, non-porous, thermally decomposable chemicals as porosity precursors, combined with nitrogen/carbon-containing organic compounds and non-noble metal sources. The synthesized catalysts offer effective ORR activity comparable to platinum-based materials but at significantly lower cost. The process involves mixing, heat treatment, acid washing, and a second heat treatment to achieve the desired porosity and performance.

Use CasesContent extracted from patent full text and abstract with AI.

• Polymer electrolyte fuel cells (PEFCs) for electric vehicles
• Metal-air batteries for portable electronics or grid storage
• Proton-exchange membrane fuel cells (PEMFCs) for stationary or automotive applications
• Replacement of platinum catalysts in fuel cell cathodes
• Hydrogen energy systems requiring cost-efficient oxygen reduction catalysts

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly reduces the cost of oxygen reduction catalysts by eliminating the need for expensive noble metals like platinum
• Uses readily available, low-cost non-porous chemicals instead of costly specialty porous materials or metal-organic frameworks
• Provides strong catalytic performance suitable for commercial fuel cell applications
• Decreases reliance on precious, price-volatile metals and supports sustainability
• Simple, scalable synthesis with control over catalyst porosity and performance
• Enables further adoption and commercialization of clean energy technologies by improving economic competitiveness

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The present invention disclose a method for preparing non-noble metal catalysts (NNMCs) using non-porous, thermally decomposable chemicals as the catalysts' porosity precursors. The composition of these and other precursors are detailed below, along with the variety of conditions involved in the catalysts' manufacture. In one aspect, the individual precursors comprise: a) a non-porous salt that thermally decomposes upon heat-treatment, releasing gas and acting as the porosity precursor; b) a nitrogen- and carbon-containing organic compound that undergoes structural changes upon heat-treatment, therefore acting as the N- and C-precursor; and c) a non-noble metal precursor. In another aspect, the synthesis method comprises: a) the mixing of the precursors; b) a first heat-treatment step; c) an acid-washing step to remove possible side phases; and d) a second heat treatment step that increases the material's ORR-activity and yields the final catalyst.