Nanostructured catalyst supports

• US 8,278,011 B2
• Filed: 02/23/2009
• Issued: 10/02/2012
• Est. Priority Date: 12/09/2004
• Status: Expired

• Current Assignee: ONED Material Incorporated
• Original Assignee: Nanosys Incorporated (Shoei Electronic Materials, Inc.)
• Inventors: Zhu, Yimin, Goldman, Jay L., Qian, Baixin, Stefan, Ionel C.
• Primary Examiner(s): Hailey, Patricia L
• Application Number:
  US12/391,057
• Publication Number:
  US 20120021331A1
• Time in Patent Office: 1,317 Days
• Field of Search: 502/177, 502/178, 429523-528, 429/231.5, 429/245, 501/88, 977/762, 977/775, 977/813, 977/948
• US Class Current: 429/523
• CPC Class Codes: B01J 23/42 Platinum
• CPC Class Codes: B01J 27/22 Carbides
• CPC Class Codes: B01J 27/224 Silicon carbide
• CPC Class Codes: B01J 35/0013 Colloids
• CPC Class Codes: B01J 35/23 in a colloidal state
• CPC Class Codes: C01B 32/956 Silicon carbide
• CPC Class Codes: C01P 2004/64 Nanometer sized, i.e. from 1-100 nanometer
• CPC Class Codes: C04B 35/52 based on carbon, e.g. graphite
• CPC Class Codes: H01B 1/04 mainly consisting of carbon-silicon compounds, carbon or silicon
• CPC Class Codes: H01M 2008/1095 Fuel cells with polymeric electrolytes
• CPC Class Codes: H01M 4/02 Electrodes composed of, or comprising, active material
• CPC Class Codes: H01M 4/133 Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/8605 Porous electrodes
• CPC Class Codes: H01M 4/8657 layered
• CPC Class Codes: H01M 4/8663 Selection of inactive substances as ingredients for catalytic active masses, e.g. binders, fillers
• CPC Class Codes: H01M 4/8807 Gas diffusion layers
• CPC Class Codes: H01M 4/9016 Oxides, hydroxides or oxygenated metallic salts
• CPC Class Codes: H01M 4/9075 Catalytic material supported on carriers, e.g. powder carriers H01M4/8807, H01M4/881, H01M4/8814, H01M4/925 take precedence
• CPC Class Codes: H01M 4/92 Metals of platinum group H01M4/94 , H01M4/9058 take precedence
• CPC Class Codes: H01M 4/925 supported on carriers, e.g. powder carriers
• CPC Class Codes: H01M 4/926 : on carbon or graphite
• CPC Class Codes: H01M 8/0234 : Carbonaceous material
• CPC Class Codes: H01M 8/0241 : Composites
• CPC Class Codes: H01M 8/04194 : Concentration measuring cells
• CPC Class Codes: H01M 8/1007 : with both reactants being gaseous or vaporised H01M8/12 takes precedence
• CPC Class Codes: H01M 8/1011 : Direct alcohol fuel cells [DAFC], e.g. direct methanol fuel cells [DMFC]
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/50 : Fuel cells

Abstract

The present invention relates to SiC nanostructures, including SiC nanopowder, SiC nanowires, and composites of SiC nanopowder and nanowires, which can be used as catalyst supports in membrane electrode assemblies and in fuel cells. The present invention also relates to composite catalyst supports comprising nanopowder and one or more inorganic nanowires for a membrane electrode assembly.

Claims

1. A catalyst support for a membrane electrode assembly of a fuel cell, comprising one or more SiC nanostructures, wherein the SiC nanostructures have at least one metal catalyst disposed thereon, wherein the SiC nanostructures comprise SiC nanopowder, wherein the SiC nanopowder is cross-linked by graphene sheets.

2. The catalyst support of claim 1, further comprising one or more nanowires comprising RuO₂, SiC, GaN, TiO₂, SnO₂, WC_x, MoC_x, ZrC, WN_x, or MoN_x.

3. The catalyst support of claim 1, wherein the catalyst metal comprises one or more of Pt, Au, Pd, Ru, Re, Rh, Os, Ir, Fe, Co, Ni, Cu, Ag, V, Cr, Mo, W, and alloys or mixtures thereof.

4. The catalyst support of claim 1, wherein the catalyst metal comprises nanoparticles having a diameter less than about 10 nm.

5. The catalyst support of claim 1, further comprising a proton conducting polymer in contact with the SiC nanopowder.

6. The catalyst support of claim 1, wherein the membrane electrode assembly is a component in a hydrogen fuel cell or a direct methanol fuel cell (DMFC).

7. The catalyst support of claim 1, wherein the catalyst metal comprises PtRu nanoparticles.

8. A catalyst support for a membrane electrode assembly of a fuel cell, comprising one or more SiC nanostructures, wherein the SiC nanostructures have at least one metal catalyst disposed thereon, wherein the SiC nanostructures comprise a composite of SiC nanopowder and SiC nanowires, and wherein the nanopowder and the nanowires are cross-linked by graphene sheets.

9. A catalyst support for a membrane electrode assembly of a fuel cell comprising a composite of SiC nanopowder and inorganic nanowires, wherein at least one of the SiC nanopowder and the inorganic nanowires have at least one metal catalyst disposed thereon, and wherein the SiC nanopowder and the inorganic nanowires are cross-linked by graphene sheets.

10. The catalyst support of claim 9, wherein the nanowires comprise RuO₂, SiC, GaN, TiO₂, SnO₂, WC_x, MoC_x, ZrC, WN_x, or MoN_x nanowires.

11. The catalyst support of claim 9, wherein the catalyst metal comprises one or more of Pt, Au, Pd, Ru, Re, Rh, as, Ir, Fe, Co, Ni, Cu, Ag, V, Cr, Mo, W, and alloys or mixtures thereof.

12. The catalyst support of claim 9, wherein the catalyst metal comprises nanoparticles having a diameter less than about 10 nm.

13. The catalyst support of claim 9, further comprising a proton conducting polymer in contact with the SiC nanopowder and nanowires.

14. The catalyst support of claim 9, wherein the membrane electrode assembly is a component in a hydrogen fuel cell or a direct methanol fuel cell (DMFC).

15. The catalyst support of claim 9, wherein the catalyst metal comprises Pt nanoparticles.