# US 2014/0155252 A1 · Method of making

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- Number: US 2014/0155252 A1
- Document ID: US20140155252A1
- Status: Published application
- Kind: A1
- Application number: 14/172,499
- Filed: 2014-02-04
- Published: 2014-06-05
- Earliest claimed: 2011-11-14
- Assignees: United Technologies Corporation
- Inventors: Minhua Shao; Belabbes Merzougui
- Web page: https://patentgrep.com/patent/US20140155252A1

## CPC

- H01M 4/8663: {Selection of inactive substances as ingredients for catalytic active masses, e.g. binders, fillers}
- H01M 4/926: {on carbon or graphite}
- H01M 4/8657: {layered}
- H01M 2008/1095: {Fuel cells with polymeric electrolytes}
- Y02E 60/50: Fuel cells
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A method of forming a catalyst structure includes providing a catalyst support structure having a core and an inner carbide film on the core, depositing catalyst nanoparticles on the catalyst support structure, and forming an outer carbide film on the catalyst support structure after the step of depositing catalyst nanoparticles. The outer carbide film is preferentially formed on the catalyst support structure compared to the catalyst particles.

## Claims

### Claim 1

A method of forming a catalyst structure, the method comprising:
providing a catalyst support structure having a core and an inner carbide film on the core;
depositing catalyst nanoparticles on the catalyst support structure; and
forming an outer carbide film on the catalyst support structure after the step of depositing catalyst nanoparticles, wherein the outer carbide film is preferentially formed on the catalyst support structure compared to the catalyst particles.

### Claim 2 (depends on 1)

The method of claim 1, wherein the outer carbide film surrounds the catalyst particles to anchor the catalyst particles to the catalyst support structure.

### Claim 3 (depends on 1)

The method of claim 1, wherein the catalyst support structure comprises carbon or modified carbon.

### Claim 4 (depends on 1)

The method of claim 1, wherein the catalyst particles are selected from the group consisting of platinum, gold, iridium, osmium, palladium, rhodium and ruthenium and alloys and combinations thereof.

### Claim 5 (depends on 1)

The method of claim 1, wherein the catalyst particles have a diameter between about 0.2 nanometers and about 100 nanometers.

### Claim 6 (depends on 1)

The method of claim 1, wherein the outer carbide film comprises at least one of tungsten carbide, boron carbide, niobium carbide, molybdenum carbide, tantalum carbide, titanium carbide and combinations thereof.

### Claim 7 (depends on 1)

The method of claim 1, wherein the outer carbide film has a uniform thickness of 1 atomic layer to 2 atomic layers.

### Claim 8 (depends on 1)

The method of claim 1, wherein the outer carbide film has a non-uniform thickness.

### Claim 9 (depends on 1)

The method of claim 1, wherein the outer carbide film is small clusters.

### Claim 10 (depends on 1)

The method of claim 1, wherein the inner carbide film has a uniform thickness of 1 atomic layer to 2 atomic layers.

### Claim 11 (depends on 1)

The method of claim 1, wherein the inner carbide film has a non-uniform thickness.

### Claim 12 (depends on 1)

The method of claim 1, wherein the inner carbide film is thicker than the outer carbide film.

### Claim 13 (depends on 1)

The method of claim 1, wherein the inner carbide film comprises at least one of tungsten carbide, boron carbide, niobium carbide, molybdenum carbide, tantalum carbide, titanium carbide and combinations thereof.

### Claim 14 (depends on 1)

The method of claim 1, wherein a carbide loading is about 50% or less.

### Claim 15 (depends on 1)

The method of claim 1, wherein the step of forming the outer carbide film comprises:
mixing the catalyst support structure with a carbide precursor; and
microwave irradiating the catalyst support structure mixed with the carbide precursor.

### Claim 16 (depends on 15)

The method of claim 15, wherein the carbide precursor comprises a tungsten salt, a boron salt, a niobium salt, a molybdenum salt, a tantalum salt or a titanium salt.

### Claim 17 (depends on 1)

The method of claim 1, wherein the step of forming the outer carbide film comprises depositing an amount of carbide on the catalyst support structure so that the catalyst structure has a carbide loading of about 50% or less.

### Claim 18 (depends on 1)

The method of claim 1, wherein the step of forming the outer carbide film comprises depositing an amount of carbide on the catalyst support structure so that the catalyst structure has a carbide loading of about 30% or less.