Conductive thin film for carbon corrosion protection
09755244 ยท 2017-09-05
Assignee
Inventors
Cpc classification
Y02E60/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02E60/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
C23C16/00
CHEMISTRY; METALLURGY
H01M4/1393
ELECTRICITY
H01M2250/20
ELECTRICITY
International classification
B05D5/12
PERFORMING OPERATIONS; TRANSPORTING
H01M4/1393
ELECTRICITY
Abstract
A method for making corrosion resistant carbon nanoparticles includes a step of heating a carbon powder to a predetermined temperature. The carbon powder includes carbon particles having an average spatial dimension from about 10 to 100 nanometers. The carbon powder is contacted with a vapor of a metal-containing compound. The carbon powder is then contacted with a vapor of an activating compound. These steps are repeated plurality of times to form a metal-containing layer on the carbon particles.
Claims
1. A method comprising: a) heating a carbon powder to a predetermined temperature, the carbon powder including carbon particles having an average spatial dimension from about 10 to 100 nanometers; b) contacting the carbon powder with a vapor of a metal-containing compound selected from the group consisting of tin-containing compounds, titanium-containing compounds, tantalum-containing compounds, niobium-containing compounds, and tungsten-containing compounds; c) contacting the carbon powder with a vapor of an activating compound; d) repeating steps b) and c) a sufficient number of times to form a metal-containing layer on the carbon particles having a thickness that is greater than or equal to 1 and less than or equal to 2 wherein 1 is a thickness at which the carbon corrosion current is reduced to less than 20 percent of its maximum value and 2 is a thickness at which the electrical conductivity is within 20 percent of its maximum value with 1 being less than 2; e) depositing a precious metal on the metal-containing layer; and f) incorporating the carbon particles with the metal-containing layer and the precious metal thereon into an electrocatalyst layer for a fuel cell.
2. The method of claim 1 wherein the metal-containing compound selected from the group consisting of tin-containing compounds, titanium-containing compounds, tantalum-containing compounds, niobium-containing compounds, and tungsten-containing compounds.
3. The method of claim 1 wherein the precious metal is platinum, gold, ruthenium, rhodium, palladium, osmium, iridium, or platinum.
4. The method of claim 1 wherein the metal-containing compound is a metal halide.
5. The method of claim 1 wherein the activating compound is an oxygen-containing compound having an OH group, a nitrogen-containing compound having an NH.sub.2 group, or combinations thereof.
6. The method of claim 5 wherein the metal-containing layer is a metal oxide layer.
7. The method of claim 6 wherein the metal-containing layer is titanium oxide.
8. The method of claim 5 wherein the nitrogen-containing compound is ammonia or a C.sub.1-6 primary amine.
9. The method of claim 8 wherein the metal-containing layer is a metal nitride layer.
10. The method of claim 1 wherein the carbon particles are contacted with both an oxygen-containing compound and a nitrogen-containing compound such that the metal-containing layer is a metal oxynitride.
11. The method of claim 1 wherein the metal-containing layer is tungsten carbide.
12. The method of claim 1 wherein the metal-containing layer is deposited at a pressure from 0.1 millitorr to 10 Torr.
13. The method of claim 1 further comprising purging with an inert gas after step b) prior to step c and after step c) prior to repeated step b).
14. The method of claim 1 wherein the activating compound is a C.sub.1-6 alcohol.
15. The method of claim 1 wherein the metal-containing compound selected from the group consisting of tantalum-containing compounds, niobium-containing compounds, and tungsten-containing compounds.
16. A method comprising: a) heating a carbon powder to a predetermined temperature, the carbon powder include carbon particles having an average spatial dimension from about 10 to 100 nanometers; b) contacting the carbon powder with a vapor of a titanium tetrahalide; c) contacting the carbon powder with a vapor of an activating compound having an OH group, wherein the activating compound is a C.sub.1-6 alcohol; d) repeating steps b) and c) a sufficient number of times to form a titanium oxide layer on the carbon particles having a thickness that is greater than or equal to 1 and less than or equal to 2 wherein 1 is a thickness at which the carbon corrosion current is reduced to less than 20 percent of its maximum value and 2 is a thickness at which the electrical conductivity is within 20 percent of its maximum value with 1 being less than 2; e) depositing platinum on the titanium oxide layer; and f) incorporating the carbon particles with the titanium oxide layer and platinum thereon into an electrocatalyst layer for a fuel cell.
17. A method comprising: a) heating a carbon powder to a predetermined temperature, the carbon powder include carbon particles having an average spatial dimension from about 10 to 100 nanometers; and b) contacting the carbon powder with a vapor of a metal-containing compound and a vapor of an activating compound to form a metal-containing layer on the carbon particles by chemical vapor deposition, the metal-containing compound being selected from the group consisting of tin-containing compounds, titanium-containing compounds, tantalum-containing compounds, niobium-containing compounds, and tungsten-containing compounds wherein the activating compound is a C.sub.1-6 alcohol; c) depositing a precious metal on the metal-containing layer; and d) incorporating the carbon particles with the metal-containing layer and the precious metal thereon into an electrocatalyst layer for a fuel cell wherein step b) is repeated a sufficient number of times to form a metal containing layer on the carbon particles having a thickness that is greater than or equal to 1 and less than or equal to 2 wherein 1 is a thickness at which the carbon corrosion current is reduced to less than 20 percent of its maximum value and 2 is a thickness at which the electrical conductivity is within 20 percent of its maximum value with 1 being less than 2.
18. The method of claim 17 wherein the metal-containing layer is titanium oxide or titanium oxynitride.
19. The method of claim 18 wherein the metal-containing layer is titanium titanium oxynitride.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(11) Reference will now be made in detail to presently preferred compositions, embodiments and methods of the present invention which constitute the best modes of practicing the invention presently known to the inventors. The Figures are not necessarily to scale. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for any aspect of the invention and/or as a representative basis for teaching one skilled in the art to variously employ the present invention.
(12) Except in the examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material or conditions of reaction and/or use are to be understood as modified by the word about in describing the broadest scope of the invention. Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary: percent, parts of, and ratio values are by weight; the description of a group or class of materials as suitable or preferred for a given purpose in connection with the invention implies that mixtures of any two or more of the members of the group or class are equally suitable or preferred; description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description and does not necessarily preclude chemical interactions among the constituents of a mixture once mixed; the first definition of an acronym or other abbreviation applies to all subsequent uses herein of the same abbreviation and applies mutatis mutandis to normal grammatical variations of the initially defined abbreviation; and, unless expressly stated to the contrary, measurement of a property is determined by the same technique as previously or later referenced for the same property.
(13) It is also to be understood that this invention is not limited to the specific embodiments and methods described below, as specific components and/or conditions may, of course, vary. Furthermore, the terminology used herein is used only for the purpose of describing particular embodiments of the present invention and is not intended to be limiting in any way.
(14) It must also be noted that, as used in the specification and the appended claims, the singular form a, an, and the comprise plural referents unless the context clearly indicates otherwise. For example, reference to a component in the singular is intended to comprise a plurality of components.
(15) Throughout this application, where publications are referenced, the disclosures of these publications in their entireties are hereby incorporated by reference into this application to more fully describe the state of the art to which this invention pertains.
(16) In an embodiment, the prefix nano means that the described particles have at least one spatial dimension from about 1 nanometer to about 100 nanometers. In a variation, the prefix nano means that the described particles have at least one spatial dimension from about 1 nanometers to about 20 nanometers. In another variation, the prefix nano means that the described particles have at least one spatial dimension from about 20 nanometers to about 50 nanometers.
(17) The term metal oxynitride layer refers to layers having metal atoms bonded to oxygen atoms and nitrogen atoms. In a refinement, a titanium oxynitride layer has the following formula TiO.sub.xN.sub.y where x is from 0.1 to 1.95 and y is from 0.1 to 1.4.
(18) The term metal oxide layer refers to layers having metal atoms bonded to oxygen atoms. Examples include titanium oxides having formula TiO.sub.2, tin oxides having formula SnO2, niobium oxides having formula NbO and Nb.sub.2O.sub.3, tantalum oxides having formula Ta.sub.2O.sub.5, and sub-oxides of these materials. Sub-oxides typically include non-stoichiometric amount of oxygen that may be up to 30 atomic percent lower than the stoichiometric value.
(19) The term metal Nitride layer refers to layers having metal atoms bonded to nitrogen atoms. Examples include titanium nitrides having formula TiN, niobium nitrides having formula NbN, tantalum nitrides having formula TaN, and non-stoichiometric nitrides of these materials. Non-stoichiometric nitrides typically include non-stoichiometric amounts of nitrogen that may be up to 30 atomic percent lower than the stoichiometric value.
(20) In one embodiment of the present invention, a method for making corrosion resistant carbon nanoparticles for fuel cell and battery applications is provided. The method includes a step of heating a carbon powder to a predetermined temperature. The carbon powder includes carbon particles having an average spatial dimension from about 10 to 100 nanometers. The carbon powder is contacted with a vapor of a metal-containing compound (e.g., titanium-containing compound) and a vapor of an activating compound. In one refinement, the carbon powder is simultaneously contacted with the vapors in a chemical vapor deposition process. In another refinement, the carbon powder is alternately contacted with the vapor of a metal-containing compound and the vapor of an activating compound in an atomic layer deposition process (ALD). The activating compound is a compound that reacts with the metal-containing compound to form a metal oxide, a metal nitride, a metal oxynitride, and a metal carbide (e.g., WC). In an ALD process, the contacting steps are repeated a plurality of times to form a titanium-containing layer on (e.g., contacting the surface of) the carbon particles.
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(29) As set forth above, several steps of the methods are repeated 1 to 1000 times to build up the thickness of the metal-containing layer 56 monolayer by monolayer until a desired thickness is achieved.
(30) With reference
(31) Similarly, the pressure during film formation is set at a value suitable to the properties of the chemical precursors and coatings to be formed. Vacuum system 100 is used to establish the reactor pressure and remove the reagents and purge gas. In one refinement, the pressure is from about 10.sup.6 Torr to about 760 Torr. In another refinement, the pressure is from about 0.1 millitorr to about 10 Torr. In still another refinement, the pressure is from about 1 to about 100 millitorr. In yet another refinement, the pressure is from about 1 to 20 millitorr.
(32) In another embodiment, a method for making a corrosion resistant carbon powder by chemical vapor deposition is provided. The method includes a step of heating a carbon powder to a predetermined temperature. The carbon powder includes carbon particles having an average spatial dimension from about 10 to 100 nanometers. The carbon powder with a vapor of a metal-containing compound and a vapor of an activating compound to form a metal-containing layer on the carbon particles. Platinum is then optionally deposited on the metal-containing layer. Details of the metal-containing compounds, activating compounds, and the deposed metal-containing layer are the same as those set forth above. Moreover, the depositions temperature and pressures are also the same as set forth above.
(33) The following examples illustrate the various embodiments of the present invention. Those skilled in the art will recognize many variations that are within the spirit of the present invention and scope of the claims.
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(35) While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.