Patent Grant
11142836
The technical field relates to catalyst material and method for manufacturing the same.
Seeking alternative energy is imperative now due to energy shortages, and hydrogen energy is the best choice. Hydrogen gas serving as fuel meets the requirements of environmental protection, and electrolysis of water is the easiest way to generate hydrogen and oxygen. Although electrolyzing water to generate hydrogen has many advantages, it still has a fatal flaw in that it consumes a lot of energy, resulting in too high a cost. The high energy consumption in the electrolysis of water is related to an overly high over potential, and the over potential is related to electrodes, electrolyte, and the product of the electrochemical reaction. The electrodes are critical to enhancing the electrolysis performance of water. Lowering the activity energy and increasing the reaction interface are critical factors of the electrolysis performance of water. The activity energy can be lowered by the catalyst influence on the electrode surface, which is determined by the inherent catalytic properties of the electrode material. Although noble metal IrO2 is one of the most catalytic electrode materials, it is expensive. As such, IrO2 must be replaced with other materials for lowering the cost.
Accordingly, a novel catalyst for further enhancing the activities of hydrogen evolution reaction (HER) and oxygen evolution reaction (OER) for simultaneously achieving the catalyst activity and lowering the cost is called for.
One embodiment of the disclosure provides a catalyst material, having a chemical structure of M′aM″bN2, wherein M′ is Ni, Co, Fe, Mn, Cr, V, Ti, Cu, or Zn; M″ is Nb, Ta, or a combination thereof; 0.7≤a≤1.7, 0.3≤b≤1.3, and a+b=2, wherein the catalyst material is a cubic crystal system.
In some embodiments, M′ is Ni, M″ is Nb, 0.7≤a≤1.51, and 0.49≤b≤1.30.
One embodiment of the disclosure provides a catalyst material, having a chemical structure of M′cM″dCe, wherein M′ is Ni, Co, Fe, Mn, Cr, V, Ti, Cu, or Zn; M″ is Nb, Ta, or a combination thereof; 0.24≤c≤1.7, 0.3≤d≤1.76, and 0.38≤e≤3.61, wherein the catalyst material is a cubic crystal system or amorphous.
In some embodiments, M′ is Ni, M″ is Nb, 0.53≤d≤1.10, and 0.9≤e≤1.9.
In some embodiments, M′ is Ni, M″ is Nb, 0.37≤d≤1.26, and 0.38≤e≤1.30.
In some embodiments, M′ is Co, M″ is Nb, 0.61≤d≤1.76, and 0.63≤e≤3.61.
One embodiment of the disclosure provides a method for manufacturing catalyst material, including: putting an M′ target and an M″ target into a nitrogen-containing atmosphere, wherein M′ is Ni, Co, Fe, Mn, Cr, V, Ti, Cu, or Zn, and M″ is Nb, Ta, or a combination thereof; providing power to the M′ target and the M″ target, respectively; and providing ions to bombard the M′ target and the M″ target, to sputtering deposit M′aM″bN2 on a substrate, wherein 0.7≤a≤1.7, 0.3≤b≤1.3, and a+b=2, wherein M′aM″bN2 is a cubic crystal system.
In some embodiments, the power provided to the M′ target is 10 W to 200 W, and the power provided to the M″ target is 10 W to 200 W.
In some embodiments, the nitrogen-containing atmosphere has a pressure of 1 mTorr to 30 mTorr.
In some embodiments, the nitrogen-containing atmosphere includes carrier gas, and the nitrogen and the carrier gas have a partial pressure ratio of 0.1 to 10.
In some embodiments, the substrate includes a porous conductive layer.
One embodiment of the disclosure provides a method for manufacturing catalyst material, including: putting an M′ target, an M″ target, and a carbon target into an atmosphere of carrier gas, wherein M′ is Ni, Co, Fe, Mn, Cr, V, Ti, Cu, or Zn, and M″ is Nb, Ta, or a combination thereof; providing power to the M′ target, the M″ target, and the carbon target, respectively; and providing ions to bombard the M′ target, the M″ target, and the carbon target to sputtering deposit M′cM″dCe on a substrate, wherein 0.24≤c≤1.7, 0.3≤d≤1.76, and 0.38≤e≤3.61, wherein M′cM″dCe is a cubic crystal system or amorphous.
In some embodiments, the power provided to the M′ target is 10 W to 200 W, the power provided to the M″ target is 10 W to 200 W, and the power provided to the carbon target is 10 W to 200 W.
In some embodiments, the atmosphere of carrier gas has a pressure of 1 mTorr to 30 mTorr.
In some embodiments, the substrate includes a porous conductive layer.
A detailed description is given in the following embodiments with reference to the accompanying drawings.
The disclosure can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and devices are schematically shown in order to simplify the drawing.
One embodiment of the disclosure provides a catalyst material with a chemical structure of M′aM″bN2, wherein M′ is Ni, Co, Fe, Mn, Cr, V, Ti, Cu, or Zn, M″ is Nb, Ta, or a combination thereof, 0.7≤a≤1.7, 0.3≤b≤1.3, and a+b=2, wherein the catalyst material is a cubic crystal system. In one embodiment, M′ is Ni, M″ is Nb, 0.7≤a≤1.51, and 0.49≤b≤1.30. If a is too low (e.g. b is too high), the activity of the catalyst will be poor. If a is too high (e.g. b is too low), the activity and the stability of the catalyst will be poor.
One embodiment of the disclosure provides a catalyst material of M′cM″dCe, wherein M′ is Ni, Co, Fe, Mn, Cr, V, Ti, Cu, or Zn, M″ is Nb, Ta, or a combination thereof, 0.24≤c≤1.7, 0.3≤d≤1.76, and 0.38≤e≤3.61, wherein M′cM″dCe is a cubic crystal system or amorphous. In one embodiment, M′ is Ni and M″ is Nb, 0.53≤d≤1.10, and 0.9≤e≤1.9. In one embodiment, M′ is Ni and M″ is Nb, 0.37≤d≤1.26, and 0.38≤e≤1.30. In one embodiment, M′ is Co and M″ is Nb, 0.61≤d≤1.76, and 0.63≤e≤3.61. If c is too low (e.g. d is too high), the activity of the catalyst will be poor. If c is too high (e.g. d is too low), the activity and the stability of the catalyst will be poor. If e is too low, the activity of the catalyst is poor. If e is too high, the activity and the stability of the catalyst will be poor.
One embodiment of the disclosure provides a method for forming the catalyst material, including putting an M′ target and an M″ target in a nitrogen-containing atmosphere, wherein M′ is Ni, Co, Fe, Mn, Cr, V, Ti, Cu, or Zn, and M″ is Nb, Ta, or a combination thereof. Respectively providing power to the M′ target and the M″ target, and providing ions to bombard the M′ target and the M″ target for sputtering depositing M′aM″bN2 on the substrate, wherein 0.7≤a≤1.7, 0.3≤b≤1.3, a+b=2, and M′aM″bN2 is a cubic crystal system. In one embodiment, the nitrogen-containing atmosphere has a pressure of 1 mTorr to 30 mTorr. If the pressure of the nitrogen-containing atmosphere is too low or too high, the nitridation cannot be efficiently performed. In one embodiment, the nitrogen-containing atmosphere includes carrier gas such as helium, argon, or another suitable inert gas. The nitrogen and the carrier gas have a partial pressure ratio of 0.1 to 10. If the partial pressure ratio of the nitrogen is too low or too high, the nitridation cannot be efficiently performed. The method respectively provides power to the M′ target and the M″ target. For example, the power applied to the M′ target is 10 W to 200 W. If the power applied to the M′ target is too low, the M′ ratio in the catalyst material will be too low. If the power applied to the M′ target is too high, the M′ ratio in the catalyst material will be too high. On the other hand, the power applied to the M″ target is 10 W to 200 W. If the power applied to the M″ target is too low, the M″ ratio in the catalyst material will be too low. If the power applied to the M″ target is too high, the M″ ratio in the catalyst material will be too high. The power can be direct current power of RF power.
The method also provides ions to bombard the M′ target and the M″ target for sputtering depositing M′aM″bN2 on the substrate. For example, nitrogen gas and the carrier gas can be excited by plasma to form ions, and the targets are bombarded by the ions. In one embodiment, the substrate includes a porous conductive layer, such as porous metal mesh (e.g. stainless steel mesh, Ti mesh, Ni mesh, Ni alloy mesh, niobium alloy mesh, copper mesh, or aluminum mesh). The pore size of the porous conductive layer is determined by the application of M′aM″bN2. For example, if the porous conductive layer with M′aM″bN2 thereon serves as the anode in OER to electrolyze an alkaline aqueous solution, the porous conductive layer will have a pore size of 40 micrometers to 150 micrometers.
One embodiment of the disclosure provides a method for forming the catalyst material, including putting an M′ target, an M″ target, and a carbon target in an atmosphere of carrier gas, wherein M′ is Ni, Co, Fe, Mn, Cr, V, Ti, Cu, or Zn, and M″ is Nb, Ta, or a combination thereof. Respectively providing power to the M′ target, the M″ target, and the carbon target, and providing ions to bombard the M′ target, the M″ target, and the carbon target for sputtering depositing M′cM″dCe on the substrate, wherein 0.24≤c≤1.7, 0.3≤d≤1.76, 0.38≤e≤3.61, and M′cM″dCe is a cubic crystal system or amorphous. In one embodiment, the atmosphere of carrier gas has a pressure of 1 mTorr to 30 mTorr. If the pressure of the atmosphere of carrier gas is too low or too high, an effective crystal cannot be formed. In one embodiment, the carrier gas can be helium, argon, another suitable inert gas, or a combination thereof. The method respectively provides power to the M′ target, the M″ target, and the carbon target. For example, the power applied to the M′ target is 10 W to 200 W. If the power applied to the M′ target is too low, the M′ ratio in the catalyst material will be too low. If the power applied to the M′ target is too high, the M′ ratio in the catalyst material will be too high. The power applied to the M″ target is 10 W to 200 W. If the power applied to the M″ target is too low, the M″ ratio in the catalyst material will be too low. If the power applied to the M″ target is too high, the M″ ratio in the catalyst material will be too high. On the other hand, the power applied to the carbon target is 10 W to 200 W. If the power applied to the carbon target is too low, the carbon ratio in the catalyst material will be too low. If the power applied to the carbon target is too high, the carbon ratio in the catalyst material will be too high. The power can be direct current power of RF power.
The method also provides ions to bombard the M′ target, the M″ target, and the carbon target, to sputtering deposit M′cM″dCe on the substrate. For example, the carrier gas can be excited by plasma to form ions, and the targets are bombarded by the ions. In one embodiment, the substrate includes a porous conductive layer, such as porous metal mesh (e.g. stainless steel mesh, Ti mesh, Ni mesh, Ni alloy mesh, niobium alloy mesh, copper mesh, or aluminum mesh). The pore size of the porous conductive layer is determined by the application of M′cM″dCe. For example, if the porous conductive layer with M′cM″dCe thereon serves as the anode in OER to electrolyze an alkaline aqueous solution, the porous conductive layer will have a pore size of 40 micrometers to 150 micrometers.
In one embodiment, the catalyst material can be used as a membrane electrode assembly for generating hydrogen by electrolysis. As shown in
In one embodiment, the anion exchange film 13 can be a halogen ion-containing imidazole polymer or another suitable material. For example, the anion exchange film can be FAS (commercially available from Fumatech) or X37-50 (commercially available from Dioxide materials). Because the membrane electrode assembly 100 is used to generate hydrogen by electrolyzing alkaline aqueous solution, the anion exchange film 13 rather than other ionic exchange film is adopted.
In one embodiment, each of the gas-liquid diffusion layer 11A and the gas-liquid diffusion layer 15A respectively includes a porous conductive layer. For example, the gas-liquid diffusion layer 11A can be a porous metal mesh (e.g. stainless steel mesh, Ti mesh, Ni mesh, Ni alloy mesh, niobium alloy mesh, copper mesh, or aluminum mesh). On the other hand, the gas-liquid diffusion layer 15A can be a porous metal mesh (e.g. stainless steel mesh, Ti mesh, Ni mesh, Ni alloy mesh, niobium alloy mesh, copper mesh, or aluminum mesh) or a porous carbon material (e.g. carbon paper or carbon cloth). In one embodiment, the gas-liquid diffusion layer 11A has a pore size of 40 micrometers to 150 micrometers. If the pore size of the gas-liquid diffusion layer 11A is too small, the mass transfer resistance will be increased. If the pore size of the gas-liquid diffusion layer 11A is too large, the active area will be lost. In one embodiment, the gas-liquid diffusion layer 15A has a pore size of 0.5 micrometers to 5 micrometers. If the pore size of the gas-liquid diffusion layer 15A is too small, the mass transfer resistance will be increased. If the pore size of the gas-liquid diffusion layer 15A is too large, the active area will be lost.
In other embodiments, the gas-liquid diffusion layer 11A of the anode 11 and the gas-liquid diffusion layer 15A of the cathode 15 have different pore sizes and/or different compositions if necessary. On the other hand, the elements or element ratios of the catalyst layer 11B of the anode 11 and the catalyst layer 15B of the cathode 15 may be different if necessary. For example, the catalyst layer 11B may have a chemical structure of M′aM″bN2 or M′cM″dCe, and the catalyst layer 15B may have a chemical structure of MxRuyN2 or MxRuy, wherein M is Ni, Co, Fe, Mn, Cr, V, Ti, Cu, or Zn, 0<x<1.3, 0.7<y<2, x+y=2, MxRuyN2 is a cubic crystal system or amorphous, and MxRuy is a cubic crystal system. In this embodiment, the gas-liquid diffusion layer 11A can be a porous metal mesh, and the gas-liquid diffusion layer 11B can be a porous carbon paper to further increase the durability of the membrane electrode assembly in electrolysis. Alternatively, the catalyst layer 11B has a chemical structure of M′aM″bN2 or M′cM″dCe, and the cathode 15 can be a commercially available electrode.
The membrane electrode assembly can be used for generating hydrogen by electrolysis. For example, the membrane electrode assembly can be dipped in alkaline aqueous solution. The alkaline aqueous solution can be an aqueous solution of NaOH, KOH, another suitable alkaline, or a combination thereof. In one embodiment, the alkaline aqueous solution has a pH value of greater than 14 and less than 15. If the pH value of the alkaline aqueous solution is too low, the conductivity of the alkaline aqueous solution will be poor. If the pH value of the alkaline aqueous solution is too high, the viscosity of the alkaline aqueous solution will be too high. The method also involves in applying a voltage to the anode and the cathode to electrolyze the alkaline aqueous solution to generate hydrogen by the cathode and generate oxygen by the anode.
Accordingly, the catalyst of the embodiments meets the requirement of electrolyzing alkaline aqueous solution to generate hydrogen. In OER aspect, the catalyst in the embodiments may overcome the poor catalytic effect, poor conductivity, low corrosion resistance, low anti-oxidation ability, and other problems of conventional catalysts. The catalyst should have a high conductivity and high electrochemical activity of OER. In view of the diffusion in the catalyst of the embodiments, the grain boundary diffusion coefficient is much larger than the body diffusion coefficient at low temperatures. Because the impurity atoms added into the catalyst may fill the grain boundaries, which may block the diffusion of atoms via the grain boundaries for improving the catalyst performance. The fast diffusion path of the catalyst (e.g. grain boundaries) can be filled by some material, thereby preventing the adjacent material atoms from diffusion via the grain boundaries or other defects. The diffusion of the atoms via grain boundaries is greatly reduced by introducing nitrogen atoms or carbon atoms into the seams of grain boundaries. Accordingly, the nitrogen atom and carbon atom can increase the anti-oxidation ability and stability of the catalyst material. Because the nitride and the carbide has excellent conductivity and simultaneously meet the requirements of activity and cost, the nitride or carbide of M″ (has an activity similar to Pt) can be combined with M′ to obtain the catalyst with high conductivity and electrochemical activity.
Below, exemplary embodiments will be described in detail with reference to accompanying drawings so as to be easily realized by a person having ordinary knowledge in the art. The inventive concept may be embodied in various forms without being limited to the exemplary embodiments set forth herein. Descriptions of well-known parts are omitted for clarity, and like reference numerals refer to like elements throughout.
Pt catalyst was deposited on a glass carbon electrode (5 mm OD×4 mm H) by a reactive magnetron sputter. A Pt target was put into the sputter to be applied a power. Nitrogen with a flow rate of 20 sccm was introduced into the sputter, and the pressure in the sputter was 30 mTorr. The Pt target was bombarded by argon ions to perform the sputtering at room temperature for 5 minutes to 6 minutes, thereby forming the Pt catalyst with a thickness of about 100 nm on the glass carbon electrode. The loading amount of the catalyst was 0.042 mg.
NixRuy catalysts of different element ratios were respectively deposited on glass carbon electrodes (5 mm OD×4 mm H) by the reactive magnetron sputter. A Ni target and a Ru target were put into the sputter, and powers applied to the Ni target (10 W to 200 W) and the Ru target (10 W to 200 W) were adjusted. Nitrogen with a flow rate of 20 sccm was introduced into the sputter, and the pressure in the sputter was 20 mTorr. The Ni target and the Ru target were bombarded by argon ions to perform the reactive sputtering at room temperature for 5 minutes to 6 minutes, thereby respectively forming the NixRuy catalysts with a thickness of about 100 nm on the glass carbon electrodes. The loading amount of the catalyst was 0.024 mg. The NixRuy catalysts had x of about 0.065 to 0.85 and y of about 1.935 to 1.15, which were determined by EDS. The NixRuy catalysts had surface morphology of granular, which were determined by SEM. The NixRuy catalysts were cubic crystal system, which were determined by X-ray diffraction. In addition, only the Ru target was put into the sputter to form a Ru catalyst film with a thickness of 100 nm on the glass carbon electrode by the similar conditions, and the catalyst loading amount was 0.024 mg.
NixRuyN2 catalysts of different element ratios were respectively deposited on glass carbon electrodes (5 mm OD×4 mm H) by the reactive magnetron sputter. A Ni target and a Ru target were put into the sputter, and powers applied to the Ni target (10 W to 200 W) and the Ru target (10 W to 200 W) were adjusted. Nitrogen and argon with a total flow rate of 20 sccm (e.g. nitrogen:(nitrogen+argon)=50:100) were introduced into the sputter, and the pressure in the sputter was 20 mTorr. The Ni target and the Ru target were bombarded by argon ions to perform the reactive sputtering at room temperature for 5 minutes to 6 minutes, thereby respectively forming the NixRuyN2 catalysts with a thickness of about 100 nm on the glass carbon electrodes. The loading amount of the catalyst was 0.024 mg. The NixRuyN2 catalysts had x of about 0.069 to 1.086 and y of about 1.931 to 0.914, which were determined by EDS. The NixRuyN2 catalysts had surface morphology of tetrahedron or pyramidal, which were determined by SEM. The NixRuyN2 catalysts were cubic crystal system, which were determined by X-ray diffraction. In addition, only the Ru target was put into the sputter to form a Ru2N2 catalyst film with a thickness of 100 nm on the glass carbon electrode by the similar conditions, and the catalyst loading amount was 0.024 mg.
The OER electrochemical activities of the Pt, Ru, Ru2N2, NixRuy, and NixRuyN2 catalysts were tested as below. In 0.1M KOH solution, the glass carbon electrode with the Pt, Ru, Ru2N2, NixRuy, or NixRuyN2 catalyst formed thereon served as a working electrode. Hg/HgO served as a reference electrode, and platinum served as an auxiliary electrode. The scan voltage ranged from −0.8V to 1V, the scan rate was 50 mV/s, and the number of scans was 10. Subsequently, the CV measurement of the OER was performed, in which the scan voltage ranged from −0.8V to 0.1V, the scan rate was 10 mV/s, and the number of scans was 5. The OER results are shown in
As shown in Table 1, the current densities of the Ni0.29Ru1.71 and Ni0.46Ru1.53N2 catalysts were higher than the current density of the Pt film catalyst in OER. However, the NixRuy was free of the anti-oxidation ability, it should be improper to be applied in OER. In other words, the Ni0.46Ru1.53N2 catalyst was more suitable than the Pt film catalyst in the application of OER.
The HER electrochemical activities of the Pt, Ru, NixRuy, and NixRuyN2 catalysts were tested as below. In 0.1M KOH solution, the glass carbon electrode with the Pt, Ru, Ru2N2, NixRuy, or NixRuyN2 catalyst formed thereon served as a working electrode. Hg/HgO served as a reference electrode, and platinum served as an auxiliary electrode. In measurements of the HER, the working electrode was rotated at 1600 rpm, the scan voltage ranged from 0 to 1V, the scan rate was 10 mV/s, and the number of scans was 3. The HER results are shown in
As shown above, the current densities of the Ni0.06Ru1.93 and Ni1.2Ru0.8N2 catalysts were higher than the current density of the Pt film catalyst in HER. In other words, the Ni0.06Ru1.93 and Ni1.2Ru0.8N2 catalyst was more suitable than the Pt film catalyst in the application of HER.
MnxRuyN2 catalysts of different element ratios were respectively deposited on glass carbon electrodes (5 mm OD×4 mm H) by the reactive magnetron sputter. An Mn target and a Ru target were put into the sputter, and powers applied to the Mn target (10 W to 200 W) and the Ru target (10 W to 200 W) were adjusted. Nitrogen and argon with a total flow rate of 20 sccm (e.g. nitrogen:(nitrogen+argon)=50:100) were introduced into the sputter, and the pressure in the sputter was 20 mTorr. The Mn target and the Ru target were bombarded by argon ions to perform the reactive sputtering at room temperature for 5 minutes to 6 minutes, thereby respectively forming the MnxRuyN2 catalysts with a thickness of about 100 nm on the glass carbon electrodes. The loading amount of the catalyst was 0.024 mg. The MnxRuyN2 catalysts had x of about 0.01 to 0.8 and y of about 1.2 to 1.99, which were determined by EDS.
The OER electrochemical activities of the MnxRuyN2 catalysts were tested as below. In 0.1M KOH solution, the glass carbon electrode with the MnxRuyN2 catalyst formed thereon served as a working electrode. Hg/HgO served as a reference electrode, and platinum served as an auxiliary electrode. The working electrode was rotated at 1600 rpm. The scan voltage ranged from −0.8V to 1V, the scan rate was 50 mV/s, and the number of scans was 10. Subsequently, the CV measurement of the OER was performed, in which the scan voltage ranged from −0.8V to 0.1V, the scan rate was 10 mV/s, and the number of scans was 5. The OER results are shown in
As shown in Table 3, the current density of the Mn0.323Ru1.677N2 catalyst was higher than the current density of the Pt film catalyst in OER. In other words, the Mn0.323Ru1.677N2 catalyst was more suitable than the Pt film catalyst in the application of OER.
The HER electrochemical activities of the MnxRuyN2 catalysts were tested as below. In 0.1M KOH solution, the glass carbon electrode with the MnxRuyN2 catalyst formed thereon served as a working electrode. Hg/HgO served as a reference electrode, and platinum served as an auxiliary electrode. In measurements of the HER, the working electrode was rotated at 1600 rpm, the scan voltage ranged from 0 to 1V, the scan rate was 10 mV/s, and the number of scans was 3. The HER results are shown in
As shown above, the current density of the Mn0.079Ru1.92N2 catalyst was higher than the current density of the Pt film catalyst in HER. In other words, the Mn0.079Ru1.92N2 catalyst was more suitable than the Pt film catalyst in the application of HER.
NiaNbbN2 catalysts of different element ratios were respectively deposited on glass carbon electrodes (5 mm OD×4 mm H) by the reactive magnetron sputter. A Ni target and a Nb target were put into the sputter, and powers applied to the Ni target (10 W to 200 W) and the Nb target (10 W to 200 W) were adjusted. Nitrogen and argon with a total flow rate of 10 sccm (e.g. nitrogen:(nitrogen+argon)=50:100) were introduced into the sputter, and the pressure in the sputter was 5 mTorr. The Ni target and the Nb target were bombarded by argon ions to perform the reactive sputtering at room temperature for 5 minutes to 6 minutes, thereby respectively forming the NiaNbbN2 catalysts with a thickness of about 100 nm on the glass carbon electrodes. The loading amount of the catalyst was 0.017 mg. The NiaNbbN2 catalysts had a of about 0.3128 to 1.5082 and y of about 0.5095 to 1.6872, which were determined by EDS. The NiaNbbN2 catalysts were cubic crystal system, which were determined by XRD.
NicNbdCe catalysts of different element ratios were respectively deposited on glass carbon electrodes (5 mm OD×4 mm H) by the reactive magnetron sputter. A Ni target, a Nb target, and a carbon target were put into the sputter, and powers applied to the Ni target (10 W to 200 W), the Nb target (10 W to 200 W), and the carbon target (10 W to 200 W) were adjusted. Argon with a flow rate of 10 sccm was introduced into the sputter, and the pressure in the sputter was 5 mTorr. The Ni target, the Nb target, and the carbon target were bombarded by argon ions to perform the reactive sputtering at room temperature for 5 minutes to 6 minutes, thereby respectively forming the NicNbdCe catalysts with a thickness of about 100 nm on the glass carbon electrodes. The loading amount of the catalyst was 0.017 mg. The NicNbdCe catalysts had c of about 0.58 to 1.47, d of about 0.53 to 1.42, and e of about 0.92 to 2.47, which were determined by EDS. The NicNbdCe catalysts were cubic crystal system or amorphous, which were determined by XRD. In addition, only the Nb target and the carbon target were put into the sputter to form Nb0.6556C1.3444 catalyst film with a thickness of 100 nm on the glass carbon electrode by the similar conditions, and the catalyst loading amount was 0.017 mg.
NicNbdCe catalysts of different element ratios were respectively deposited on glass carbon electrodes (5 mm OD×4 mm H) by the reactive magnetron sputter. A Ni target, a Nb target, and a carbon target were put into the sputter, and powers applied to the Ni target (10 W to 200 W), the Nb target (10 W to 200 W), and the carbon target (10 W to 200 W) were adjusted. Argon with a flow rate of 10 sccm was introduced into the sputter, and the pressure in the sputter was 5 mTorr. The Ni target, the Nb target, and the carbon target were bombarded by argon ions to perform the reactive sputtering at room temperature for 5 minutes to 6 minutes, thereby respectively forming the NicNbdCe catalysts with a thickness of about 100 nm on the glass carbon electrodes. The loading amount of the catalyst was 0.017 mg. The NicNbdCe catalysts had c of about 0.74 to 1.63, d of about 0.37 to 1.26, and e of about 0.38 to 1.30, which were determined by EDS. The NicNbdCe catalysts were cubic crystal system or amorphous, which were determined by XRD.
The OER electrochemical activities of the Pt, NiaNbbN2, NicNbdCe, and Nb0.6556C1.3444 catalysts were tested as below. In 0.1M KOH solution, the glass carbon electrode with the Pt, NiaNbbN2, NicNbdCe, or Nb0.6556C1.3444 catalyst formed thereon served as a working electrode. Hg/HgO served as a reference electrode, and platinum served as an auxiliary electrode. The working electrode was rotated at 1600 rpm. The scan voltage ranged from −0.8V to 1V, the scan rate was 50 mV/s, and the number of scans was 10. Subsequently, the CV measurement of the OER was performed, in which the scan voltage ranged from −0.8V to 0.1V, the scan rate was 10 mV/s, and the number of scans was 5. The OER results are shown in
As shown in Table 5, the current densities of the Ni1.5Nb0.5N2 and Ni1.62Nb0.37C0.39 catalysts were higher than the current density of the Pt film catalyst in OER. In other words, the Ni1.5Nb0.5N2 and Ni1.62Nb0.37C0.39 catalysts were more suitable than the Pt film catalyst in the application of OER.
CocNbdCe catalysts of different element ratios were respectively deposited on glass carbon electrodes (5 mm OD×4 mm H) by the reactive magnetron sputter. A Co target, a Nb target, and a carbon target were put into the sputter, and powers applied to the Co target (30 W to 100 W), the Nb target (35 W), and the carbon target (100 W) were adjusted. Argon with a flow rate of 10 sccm was introduced into the sputter, and the pressure in the sputter was 5 mTorr. The Co target, the Nb target, and the carbon target were bombarded by argon ions to perform the reactive sputtering at room temperature for 10 minutes to 15 minutes, thereby respectively forming the CocNbdCe catalysts with a thickness of about 100 nm on the glass carbon electrodes. The loading amount of the catalyst was 0.017 mg. The CocNbdCe catalysts had c of about 0.24 to 1.39, d of about 0.61 to 1.76, and e of about 0.63 to 3.61, which were determined by EDS. The CocNbdCe catalysts were cubic crystal system or amorphous, which were determined by XRD.
The OER electrochemical activities of the CocNbdCe and Nb0.6556C1.3444 catalysts were tested as below. In 0.1M KOH solution, the glass carbon electrode with the CocNbdCe or Nb0.6556C1.3444 catalyst formed thereon served as a working electrode. Hg/HgO served as a reference electrode, and platinum served as an auxiliary electrode. The working electrode was rotated at 1600 rpm. The scan voltage ranged from −0.8V to 1V, the scan rate was 50 mV/s, and the number of scans was 10. Subsequently, the CV measurement of the OER was performed, in which the scan voltage ranged from −0.8V to 0.1V, the scan rate was 10 mV/s, and the number of scans was 5. The OER results are shown in
Ni1.5Nb0.5N2 catalyst was deposited on stainless steel mesh (316 stainless steel, 200 mesh, 50 mm×50 mm) by the reactive magnetron sputter. A Ni target and a Nb target were put into the sputter, and powers applied to the Ni target (10 W to 200 W) and the Nb target (10 W to 200 W) were adjusted. Nitrogen and argon with a total flow rate of 10 sccm (e.g. nitrogen:(nitrogen+argon)=50:100) were introduced into the sputter, and the pressure in the sputter was 5 mTorr. The Ni target and the Nb target were bombarded by argon ions to perform the reactive sputtering at room temperature for 8 minutes, thereby forming the Ni1.5Nb0.5N2 catalysts (determined by EDS) with a thickness of about 300 nm on the stainless steel mesh. The loading amount of the catalyst per area was 0.17 mg/cm2. The Ni1.5Nb0.5N2 catalyst was cubic crystal systems, which was determined by XRD.
Commercially available PtC (HISPEC 13100, Johnson Matthey) was coated on a carbon paper H23C8 (Freudenberg) to serve as a cathode of HER, and the loading amount of the cathode catalyst per area was controlled to 1.8 mg/cm2. The Ni1.5Nb0.5N2-stainless steel mesh in Preparation Example 9 served as the anode of OER, and an anion exchange film X37-50 (commercially available from Dioxide Materials) was interposed between the catalyst layers of the cathode and the anode to obtain a membrane electrode assembly. The membrane electrode assembly was dipped in 2M KOH solution to test its electrochemical activity. The scan voltage ranged from 1.3V to 2.2V and the scan rate was 50 mV/s. The curve of current versus voltage of the membrane electrode assembly is shown in
Ni1.62Nb0.37C0.39 catalyst was deposited on stainless steel mesh (316 stainless steel, 200 mesh, 50 mm×50 mm) by the reactive magnetron sputter. A Ni target, a Nb target, and a carbon target were put into the sputter, and powers applied to the Ni target (10 W to 200 W), the Nb target (10 W to 200 W), and the carbon target (10 W to 200 W) were adjusted. Argon with a flow rate of 10 sccm was introduced into the sputter, and the pressure in the sputter was 5 mTorr. The Ni target, the Nb target, and the carbon target were bombarded by argon ions to perform the reactive sputtering at room temperature for 8 minutes, thereby forming the Ni1.62Nb0.37C0.39 catalysts (determined by EDS) with a thickness of about 300 nm on the stainless steel mesh. The loading amount of the catalyst per area was 0.17 mg/cm2. The Ni1.62Nb0.37C0.39 catalyst was cubic crystal systems or amorphous, which was determined by XRD.
Commercially available PtC (HISPEC 13100, Johnson Matthey) was coated on a carbon paper H23C8 (Freudenberg) to serve as a cathode of HER, and the loading amount of the cathode catalyst per area was controlled to 1.8 mg/cm2. The Ni1.62Nb0.37C0.39-stainless steel mesh in Preparation Example 10 served as the anode of OER, and an anion exchange film X37-50 (commercially available from Dioxide Materials) was interposed between the catalyst layers of the cathode and the anode to obtain a membrane electrode assembly. The membrane electrode assembly was dipped in 2M KOH solution to test its electrochemical activity. The scan voltage ranged from 1.3V to 2.2V and the scan rate was 50 mV/s. The curve of current versus voltage of the membrane electrode assembly is shown in
Commercially available PtC (HISPEC 13100, Johnson Matthey) was coated on a carbon paper H23C8 (Freudenberg) to serve as a cathode of HER, and the loading amount of the cathode catalyst per area was controlled to 1.8 mg/cm2. Commercially available insoluble anode (IrO2/RuO2—Ti mesh, Ultrapack Energy Co., Ltd) served as the anode of OER, and an anion exchange film X37-50 (commercially available from Dioxide Materials) was interposed between the catalyst layers of the cathode and the anode to obtain a membrane electrode assembly. The membrane electrode assembly was dipped in 2M KOH solution to test its electrochemical activity. The scan voltage ranged from 1.3V to 2.2V and the scan rate was 50 mV/s. The curve of current versus voltage of the membrane electrode assembly is shown in
Comparison of the membrane electrode assemblies in Example 7, Example 8, and Comparative Example 1 are shown in Table 6:
As shown in Table 6, the activities of the Ni1.5Nb0.5N2 catalyst and the Ni1.62Nb0.37C0.39 catalyst were greatly higher than the activity of the commercially available anode catalyst.
Ni0.75Ru1.25N2 catalyst was deposited on stainless steel mesh (316 stainless steel, 200 mesh, 50 mm×50 mm) by the reactive magnetron sputter. A Ni target and a Ru target were put into the sputter, and powers were applied to the Ni target (150 W) and the Ru target (100 W). Nitrogen and argon (e.g. nitrogen:(nitrogen+argon)=50:100) were introduced into the sputter, and the pressure in the sputter was 5 mTorr. The Ni target and the Ru target were bombarded by argon ions to perform the reactive sputtering at room temperature for 8 minutes, thereby forming the Ni0.75Ru1.25N2 catalysts (determined by EDS) with a thickness of about 300 nm on the stainless steel mesh. The loading amount of the catalyst per area was 0.17 mg/cm2. The Ni0.75Ru1.25N2 catalyst had surface morphology of tetrahedron or pyramidal, which were determined by SEM. The Ni0.75Ru1.25N2 catalyst was cubic crystal systems or amorphous, which was determined by XRD.
The Ni0.75Ru1.25N2-stainless steel mesh in Preparation Example 11 served as the cathode of HER, the Ni1.5Nb0.5N2-stainless steel mesh in Preparation Example 9 served as the anode of OER, and an anion exchange film X37-50 (commercially available from Dioxide Materials) was interposed between the catalyst layers of the cathode and the anode to obtain a membrane electrode assembly. The membrane electrode assembly was dipped in 2M KOH solution to test its electrochemical activity. The scan voltage ranged from 1.3V to 2.2V and the scan rate was 50 mV/s. The membrane electrode assembly could generate a current of 10.5 A at 1.87V, and the impedance of the entire test system was 12 mΩ. The decay rate per minute of the membrane electrode assembly was 0.0057%.
Ni0.75Ru1.25N2 catalyst was deposited on carbon paper (H23C8, Freudenberg, 50 mm×50 mm) by the reactive magnetron sputter. A Ni target and a Ru target were put into the sputter, and powers were applied to the Ni target (150 W) and the Ru target (100 W). Nitrogen and argon (e.g. nitrogen:(nitrogen+argon)=50:100) were introduced into the sputter, and the pressure in the sputter was 5 mTorr. The Ni target and the Ru target were bombarded by argon ions to perform the reactive sputtering at room temperature for 8 minutes, thereby forming the Ni0.75Ru1.25N2 catalysts (determined by EDS) with a thickness of about 300 nm on the carbon paper H23C8. The loading amount of the catalyst per area was 0.17 mg/cm2. The Ni0.75Ru1.25N2 catalyst had surface morphology of tetrahedron or pyramidal, which were determined by SEM. The Ni0.75Ru1.25N2 catalyst was cubic crystal systems or amorphous, which was determined by XRD.
The Ni0.75Ru1.25N2-carbon paper in Preparation Example 12 served as the cathode of HER, the Ni1.5Nb0.5N2-stainless steel mesh in Preparation Example 9 served as the anode of OER, and an anion exchange film X37-50 (commercially available from Dioxide Materials) was interposed between the catalyst layers of the cathode and the anode to obtain a membrane electrode assembly. The membrane electrode assembly was dipped in 2M KOH solution to test its electrochemical activity. The scan voltage ranged from 1.3V to 2.2V and the scan rate was 50 mV/s. The curve of current versus voltage of the membrane electrode assembly is shown in
Comparison of the membrane electrode assemblies in Example 7, Example 9, and Example 10 are shown in Table 7:
As shown in Table 7, the Ni0.75Ru1.25N2 catalyst serving as the catalyst layer of the cathode could greatly enhance the catalyst activity. In addition, the Ni0.75Ru1.25N2 catalyst formed on the carbon paper could further improve the durability of the membrane electrode assembly.
It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed methods and materials. It is intended that the specification and examples be considered as exemplary only, with the true scope of the disclosure being indicated by the following claims and their equivalents.
| Number | Name | Date | Kind |
|---|---|---|---|
| 3416891 | Jacques | Dec 1968 | A |
| 3492100 | Roubin et al. | Jan 1970 | A |
| 7485600 | Harutyunyan et al. | Feb 2009 | B2 |
| 8632672 | Soloveichik | Jan 2014 | B2 |
| 9287568 | Wood et al. | Mar 2016 | B2 |
| 9683300 | Noaki et al. | Jun 2017 | B2 |
| 20080029396 | Shirakura et al. | Feb 2008 | A1 |
| 20090318723 | Kortz et al. | Dec 2009 | A1 |
| 20120103829 | Tampucci et al. | May 2012 | A1 |
| 20140124360 | Funahashi | May 2014 | A1 |
| 20140373751 | Schuh et al. | Dec 2014 | A1 |
| 20150083585 | Sasaki et al. | Mar 2015 | A1 |
| 20150180046 | Serov et al. | Jun 2015 | A1 |
| 20150252484 | Chen et al. | Sep 2015 | A1 |
| 20150292095 | Haber et al. | Oct 2015 | A1 |
| 20160009574 | Hoffmann et al. | Jan 2016 | A1 |
| 20160077035 | Kanemoto et al. | Mar 2016 | A1 |
| 20160079604 | Atanasoski et al. | Mar 2016 | A1 |
| 20160160365 | Cao | Jun 2016 | A1 |
| 20170051419 | Jang et al. | Feb 2017 | A1 |
| 20170187046 | Huang et al. | Jun 2017 | A1 |
| 20170233879 | Kumta et al. | Aug 2017 | A1 |
| 20170321331 | Mitsushima et al. | Nov 2017 | A1 |
| 20180034065 | Chao et al. | Feb 2018 | A1 |
| Number | Date | Country |
|---|---|---|
| 101209424 | Jul 2008 | CN |
| 101909749 | Dec 2010 | CN |
| 102299347 | Dec 2011 | CN |
| 103422116 | Dec 2013 | CN |
| 103952719 | Jul 2014 | CN |
| 104327971 | Feb 2015 | CN |
| 105734606 | Jun 2018 | CN |
| 108884576 | Nov 2018 | CN |
| 10-2017-0022788 | Mar 2017 | KR |
| 544968 | Aug 2003 | TW |
| 201718396 | Jun 2017 | TW |
| 201837236 | Oct 2018 | TW |
| 201840907 | Nov 2018 | TW |
| WO 2017001843 | Jan 2017 | WO |
| Entry |
|---|
| Arockiasamy et al (Ductility behavior of cubic titanium niobium nitride ternary alloy: a first-principles study, Indian J Phys (2016) 90(2): 149-154 (Year: 2016). |
| Cong et al (“Tantalum Cobalt Nitride Photocatalysts for Water Oxidation under Visible Light,” Chem. Mater. 2012, 24, 579-586) (Year: 2012). |
| Taiwanese Office Action and Search Report, dated Apr. 18, 2019, for Taiwanese Application No. 107142987. |
| Taiwanese Office Action and Search Report, dated Jun. 12, 2019, for Taiwanese Application No. 107142989. |
| Taiwanese Office Action and Search Report, dated Jun. 12, 2019, for Taiwanese Application No. 107142990. |
| U.S. Office Action dated Nov. 4, 2019 for U.S. Appl. No. 16/205,349. |
| Taiwanese Notice of Allowance and Search Report dated Mar. 28, 2019 for Application No. 107142991. |
| Bouhtiyya et al., “Application of sputtered ruthenium nitride thin films as electrode material for energy-storage devices,” Scripta Materialia, vol. 68, 2013 (Available online Feb. 4, 2013), pp. 659-662. |
| Cattaruzza et al., “On the synthesis of a compound with positive enthalpy of formation: Zinc-blende-like RuN thin films obtained by rf-magnetron sputtering,” Applied Surface Science, vol. 320, 2014 (Available online Oct. 2, 2014), pp. 863-870. |
| Karimi et al., “Metal Carbide and Oxide Supports for Iridium-Based Oxygen Evolution Reaction Electrocatalysts for Polymer-Electrolyte-Membrane Water Electrolysis,” Electrochimica Acta, vol. 246, 2017 (Available online Jun. 15, 2017), pp. 654-670. |
| Li et al., “Nitrogen and Phosphorus Dual-Doped Graphene/Carbon Nanosheets as Bifunctional Electrocatalysts for Oxygen Reduction and Evolution,” ACS Catalysis, vol. 5, May 27, 2015, pp. 4133-4142. |
| Rosestolato et al., “Electrochemical properties of stoichiometric RuN film prepared by rf-magnetron sputtering: A preliminary study,” Electrochemistry Communications, vol. 49, 2014 (Available online Oct. 5, 2014), pp. 9-13. |
| Tang et al., “A Co-doped porous niobium nitride nanogrid as an effective oxygen reduction catalyst,” Journal of Materials Chemistry A, vol. 5, Jun. 12, 2017, pp. 14278-14285. |
| Chen et al., “Recent Developments in Transition Metal Carbides and Nitrides as Hydrogen Evolution Electrocatalysis,” Chem Commun., vol. 49, 2013 (Published Jul. 29, 2013), pp. 6896 8909. |
| U.S. Notice of Allowance, dated Oct. 14, 2020, for U.S. Appl. No. 16/205,341. |
| U.S. Notice of Allowance, dated Oct. 15, 2020, for U.S. Appl. No. 16/205,903. |
| Zhong et al., “Transition Metal Carbides and Nitrides in Energy Storage and Conversion,” Advanced Science, vol. 3, No. 5, PubMed Chental ID: 5067566, 2016 (Electronic Publication Date: Feb. 4, 2016), pp. 1-34. |
| Chinese Office Action and Search Report for Chinese Application No. 201910103247.9, dated Oct. 10, 2020. |
| Das et al., “In Situ Fabrication of a Nicket/Motybdenum Carbide-Anchored N-Doped Graphene/CNT Hybrid: An Efficient (Pre)catatyst for OER and HER,” Applied Materials and Interfaces, vol. 10, No. 41, Sep. 24, 2018, pp. 35025-35038. |
| Chinese Office Action and Search Report for Chinese Application No. 201911198355.5, dated Apr. 12, 2021. |
| Number | Date | Country | |
|---|---|---|---|
| 20200173042 A1 | Jun 2020 | US |
