Wet chemical and plasma methods of forming stable PTPD catalysts
First Claim
1. A method of forming nano-particles, the method comprising:
- forming a plurality of aluminum-palladium carrier nano-particles using a plasma gun, wherein the aluminum-palladium carrier nano-particles comprise an interior region and an exterior surface, the interior region comprising a mixed-metal oxide that includes aluminum oxide and palladium, and the exterior surface comprising pure metallic palladium; and
affixing platinum nano-particles to the pure metallic palladium on the aluminum-palladium carrier nano-particles using a wet chemistry process;
wherein forming the plurality of aluminum-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 in a desired ratio, wherein the aluminum oxide material and the palladium material are in powder form;
vaporizing the quantity of aluminum oxide material and the quantity of palladium material using the plasma gun, thereby forming a vapor cloud comprising vaporized aluminum oxide and vaporized palladium; and
quenching the vapor cloud, thereby condensing the vaporized aluminum oxide and the vaporized palladium into carrier nano-particles.
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Accused Products
Abstract
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.
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Citations
17 Claims
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1. A method of forming nano-particles, the method comprising:
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forming a plurality of aluminum-palladium carrier nano-particles using a plasma gun, wherein the aluminum-palladium carrier nano-particles comprise an interior region and an exterior surface, the interior region comprising a mixed-metal oxide that includes aluminum oxide and palladium, and the exterior surface comprising pure metallic palladium; and affixing platinum nano-particles to the pure metallic palladium on the aluminum-palladium carrier nano-particles using a wet chemistry process; wherein forming the plurality of aluminum-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 in a desired ratio, wherein the aluminum oxide material and the palladium material are in powder form; vaporizing the quantity of aluminum oxide material and the quantity of palladium material using the plasma gun, thereby forming a vapor cloud comprising vaporized aluminum oxide and vaporized palladium; and quenching the vapor cloud, thereby condensing the vaporized aluminum oxide and the vaporized palladium into carrier nano-particles. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method of forming a catalyst, the method comprising:
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providing a support structure; forming a plurality of aluminum-palladium nano-particles using a plasma gun; and bonding the plurality of nano-particles to the support structure; wherein forming the plurality of aluminum-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 in a desired ratio, wherein the aluminum oxide material and the palladium material are in powder form; vaporizing the quantity of aluminum oxide material and the quantity of palladium material using the plasma gun, thereby forming a vapor cloud comprising vaporized aluminum oxide and vaporized palladium; and quenching the vapor cloud, thereby condensing the vaporized aluminum oxide and the vaporized palladium into carrier nano-particles. - View Dependent Claims (14, 15, 16, 17)
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Specification