Fuel cell cathode catalyst

Patent metadata

Field	Value
Publication number	US-12113224-B2
Application number	US-202318334187-A
Country	US
Kind code	B2
Filing date	Jun 13, 2023
Priority date	Dec 27, 2019
Publication date	Oct 8, 2024
Grant date	Oct 8, 2024

Abstract

A fuel cell catalyst for oxygen reduction reactions including Pt—Ni—Cu nanoparticles supported on nitrogen-doped mesoporous carbon (MPC) having enhanced activity and durability, and method of making said catalyst. The catalyst is synthesized by employing a solid state chemistry method, which involves thermally pretreating a N-doped MPC to remove moisture from the surface; impregnation of metal precursors on the N-doped MPC under vacuum condition; and reducing the metal precurors in a stream of CO and H 2 gas mixture.

First claim

What is claimed is:

1. A catalyst comprising Pt—Cu—Ni alloy nanoparticles supported on nitrogen-doped mesoporous carbon.

2. The catalyst according to claim 1 , wherein said nanoparticles have an octahedral or rhombic shape and a particle size from about 8-10 nm.

3. The catalyst according to claim 1 , wherein the Pt—Cu—Ni alloy nanoparticles supported on nitrogen-doped mesoporous carbon have enhanced ORR activity and durability.

4. The catalyst according to claim 1 , obtained by a method comprising:
thermally pretreating a nitrogen-doped MPC support material to remove moisture;
evacuating the pretreated nitrogen-doped MPC support to further remove air from pores in the support;
impregnating metal precursors comprising platinum, nickel, and copper onto the pretreated nitrogen-doped MPC under vacuum condition to obtain a precursor-impregnated nitrogen-doped MPC support material;
heating the precursor-impregnated nitrogen-doped MPC support material to a functional temperature in a range of from 150° C. to 300° C.; and
delivering a functional gas comprising a gas mixture which comprises H 2 and CO to the precursor-impregnated nitrogen-doped MPC support material, the metal precursors reacting with the functional gas to form shaped platinum alloy nanoparticles supported on nitrogen-doped MPC.

5. The catalyst according to claim 4 , wherein thermally pretreating comprises heating the nitrogen-doped MPC to a first temperature in an atmosphere comprising air, Ar, N 2 , O 2 or combinations thereof.

6. The catalyst according to claim 4 , wherein thermally pretreating comprises heating the nitrogen-doped MPC in air.

7. The catalyst according to claim 4 , wherein the method comprises delivering the functional gas at a partial pressure ratio of from 0:100 to 1:1 of H 2 to CO, and a volumetric flow rate of from 10 sccm to 1000 sccm.

8. The catalyst according to claim 4 , wherein the method further comprises maintaining the functional temperature for a period of from 0 hours to 5 hours in the presence of a functional gas.

9. A method for oxygen reduction catalysis, said method comprises employing a catalyst which comprises Pt—Cu—Ni alloy nanoparticles supported on nitrogen-doped mesoporous carbon according to claim 1 .

10. A method for oxygen evolution catalysis, said method comprises employing a catalyst which comprises Pt—Cu—Ni alloy nanoparticles supported on nitrogen-doped mesoporous carbon according to claim 1 .

11. A method for formic acid oxidation catalysis, said method comprises employing a catalyst which comprises Pt—Cu—Ni alloy nanoparticles supported on nitrogen-doped mesoporous carbon according to claim 1 .

12. A method for methanol oxidation catalysis, said method comprises employing a catalyst, which comprises Pt—Cu—Ni alloy nanoparticles supported on nitrogen-doped mesoporous carbon according to claim 1 .

13. A method for ethanol oxidation catalysis, said method comprises employing a catalyst, which comprises Pt—Cu—Ni alloy nanoparticles supported on nitrogen-doped mesoporous carbon according to claim 1 .

14. A fuel cell comprising a catalyst, which comprises Pt—Cu—Ni alloy nanoparticles supported on nitrogen-doped mesoporous carbon according to claim 1 .

15. The fuel cell according to claim 14 , which is a hydrogen proton exchange membrane fuel cell, a direct formic acid fuel cell, a direct methanol fuel cell, a direct ethanol fuel cell, or a metal air battery.

16. Platinum alloy nanoparticles supported on nitrogen-doped mesoporous carbon (MPC), obtained by a method comprising:
in a chamber removing moisture from a nitrogen-doped mesoporous carbon material, the nitrogen-doped mesoporous carbon material having one or more pores;
evacuating the nitrogen-doped mesoporous carbon material to further remove air from the pores;
applying a vacuum to the chamber;
delivering precursors comprising platinum, nickel, and copper to obtain a precursor-impregnated nitrogen-doped mesoporous carbon material;
purging the chamber using a purge gas;
heating the precursor-impregnated nitrogen-doped mesoporous carbon material to a functional temperature in a range of from 150° C. to 300° C.; and
delivering a functional gas comprising a gas mixture which comprises H 2 and CO to the precursor-impregnated nitrogen-doped mesoporous carbon material, the precursors reacting with the functional gas to form shaped platinum alloy nanoparticles within the one or more pores of the nitrogen-doped mesoporous carbon material.

17. The platinum alloy nanoparticles according to claim 16 , wherein heating of the precursor-impregnated nitrogen-doped mesoporous carbon material is at a ramping rate of 15° C./min to 200° C.

18. The platinum alloy nanoparticles according to claim 17 , wherein the method further comprises maintaining at 200° C. for 1 hour in H 2 /CO (5/120 cm 3 /min).

Assignees

• Toyota Eng & Mfg North America
• Univ Akron

Inventors

• Zhou Li Qin
• Huang Kan
• Jia Hongfei
• Shen Xiaochen
• Peng Zhenmeng
• Kato Hisao

Classifications

• H01M2004/8689

  Positive electrodes · CPC title

• Y02E60/50

  Fuel cells · CPC title

• Y02P70/50

  Manufacturing or production processes characterised by the final manufactured product · CPC title

• H01M8/08

  Fuel cells with aqueous electrolytes · CPC title

• H01M2300/0005

  Acid electrolytes · CPC title