Platinum-based catalysts dominate in fuel cells and industrial chemical reactions due to their high activity, but their cost, limited durability, and complex fabrication methods hinder scalability. For Pt-Ni porous catalysts, acid-etching methods are widely used but slow, inefficient, and often compromise performance. A faster, more scalable approach is required to produce durable catalysts that reduce platinum consumption while maintaining or improving activity.
This invention employs a gas-phase CO etching process to selectively remove nickel from PtNi₄ precursors supported on carbon, transforming them into hollow Pt₃Ni nanoframes while preserving tetrahexahedral morphology. During temperature-controlled annealing, CO reacts with nickel to form volatile Ni(CO)₄, which is removed, leaving behind a Pt-rich skin with downshifted d-band center that enhances catalytic performance. The process is complete in under 45 minutes, is compatible with standard annealing equipment, and can be extended to other bimetallic systems such as Pt-Fe or Pd-Ni.
• Rapid catalyst synthesis (~45 minutes), significantly faster than acid-based methods
• High catalytic activity for oxygen reduction and alcohol oxidation reactions
• Maintains structural integrity and performance after 5000 electrochemical cycles
• Maximizes platinum utilization with hollow frame design
• Scalable using standard thermal annealing equipment
• Adaptable to produce other bimetallic catalysts (e.g., Pt-Fe, Pd-Ni)
• US Patent 10,454,114 (Filed: 12/21/2017; Issued: 10/22/2019)
• US Patent 11,088,371 (Filed: 10/21/2019; Issued: 08/10/2021)
• US Publication US-2018-0316023-A1
Patented, Demonstrated – Catalyst fabrication method validated with proven improvements in activity, speed of synthesis, and durability. TRL ~5–6.
This technology is available for licensing.
Ideal for licensing to companies in fuel cell manufacturing, industrial catalysis, and renewable energy sectors seeking scalable, durable, and cost-efficient alternatives to platinum-heavy catalysts.
Performance data, durability test results, and synthesis scalability demonstrations available upon request.