CROSS REFERENCE TO RELATED APPLICATIONS:

This application claims priority under 35 U.S.C. § 119(e) to co-pending Provisional United States Patent Application No. 61/284,329, filed December 15, 2009, and entitled "MATERIAL PROCESSING," which is hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to the field of catalysts. More specifically, the present invention relates to methods of pinning and affixing nano-active material to a nano-support.

BACKGROUND OF THE INVENTION:

Catalysts are used to facilitate and speed up a reaction. For example, using well- known methods of wet chemistry to form a catalyst, extrudates are placed in

hexachlorplatinic acid (H ₂ PtCl ₆ ). In some embodiments, an extrudate is a cylindrical pellet made by an extrusion process. An example of an extrudate 100 is shown in FIG. 1A. The extrudate 100 is made of or is coated with alumina (A1 ₂ 0 ₃ ) and thus has available oxygen (O) atoms 105 on its surface. As illustrated in FIG. IB, the platinum (Pt) atoms 115 of the hexachlorplatinic acid 110 are chemically absorbed onto the surface of the alumina. In particular, drying and calcining, such as in an oven, allows the platinum atoms 115 to bond to the oxygen atoms 105, with HCl molecules as byproduct. However, the platinum atoms 115 are not fixed to their bonded oxygen atoms 105 and are able to move around to other available oxygen atoms 105 as illustrated in FIGS. 1C-1D. As the platinum atoms 115 move, the platinum atoms 115 begin to coalesce with other platinum atoms resulting in larger particles 120, as shown in FIG. IE, and a more energetically favorable state. It is understood that as the platinum particles become larger, it detrimentally affects the ability of the material to act as a catalyst. In high temperature applications, such as in an aged catalytic converting testing, the movement of platinum atoms is magnified. What is needed is an interface and method to prevent the platinum atoms from coalescing.

SUMMARY OF THE INVENTION:

In one aspect, an interface for pinning a nano-active material to a nano-support includes a compound configured to limit movement of the nano-active material on a surface of the nano-support. The compound is formed by a reaction of the nano-active material and the surface of the nano-support. In some embodiments, the nano-active material is platinum and the nano-support is alumina. In some embodiments, the nano-support comprises a partially reduced alumina surface. In other embodiments, the compound is a platinum alumina metallic compound. Alternatively, the compound is a platinum copper intermetallic compound.

In another aspect, a pinning method to affix nano-active materials to nano-supports uses a high temperature condensation technology. The high temperature condensation technology is eBeam, microwave, RF or DC plasma. The nano-active materials and the nano- supports are gathered. In some embodiments, starting materials, including a quantity of catalyst material and a quantity of carrier material, are loaded into a chamber. The quantity of catalyst material and the quantity of carrier material are vaporized to create the nano-active materials and the nano-supports. In some embodiments, working gas is supplied to the chamber and energy is delivered to the working gas to form a highly reactive and energetic mixture such that the quantity of catalyst material and the quantity of carrier material are vaporized. In some embodiments, a quantity of copper is also loaded into the chamber to be vaporized.

Metallic properties on surfaces of the nano-supports are then increased. An interface between each nano-active material and a nano-support is formed. The interface is configured to limit movement of the nano-active material on the surface of the nano-support. In some embodiments, each of the plurality of nano-active materials is platinum. In some

embodiments, each of the plurality of nano-supports is alumina. In some embodiments, each of the plurality of nano-supports comprises a partially reduce alumina surface. In other embodiments, the interface includes a platinum alumina metallic compound or a platinum copper intermetallic compound.

In yet another aspect, a method of affixing a nano-active material to a nano-support uses high temperature condensation technology to form a layer between the nano-active material and the nano-support material. The high temperature condensation technology is eBeam, microwave, RF or DC plasma. In some embodiments, starting materials, including catalyst material and carrier material, are loaded into a chamber and are vaporized to create the nano-active material and the nano-support. In other embodiments, copper is also loaded into the chamber to be vaporized. Typically, the layer between the nano-active material and the nano-support material is configured to limit movement of the nano-active material on a surface of the nano-support. In some embodiments, the layer includes a platinum alumina metallic compound. Alternatively, the layer includes a platinum copper intermetallic compound.

BRIEF DESCRIPTION OF THE DRAWINGS:

FIGS. 1 A- IE illustrate a wet catalyst and its properties in the prior art.

FIG. 2 illustrates a process 200 of pinning and affixing nano-active material to nano- support in accordance with the present invention.

FIGS. 3A-3B illustrate a nanoparticle in accordance with the present invention.

FIG.4 illustrates a graph of difference of activity of fresh and aged plasma catalysts versus a ratio of copper to platinum in the plasma catalyst.

DETAILED DESCRIPTION OF THE INVENTION:

Reference will now be made in detail to implementations of the present invention as illustrated in the accompanying drawings. The drawings may not be to scale. The same reference indicators will be used throughout the drawings and the following detailed description to refer to identical or like elements. In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will, of course, be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer's specific goals, such as compliance with application, safety regulations and business related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort will be a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure.

The following description of the invention is provided as an enabling teaching which includes various embodiments. One skilled in the relevant arts, including but not limited to chemistry and physics, will recognize that many changes can be made to the embodiments described, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features.

Accordingly, those who work in the art will recognize that many modifications and adaptations to the embodiments are possible and may even be desirable in certain circumstances, and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof, since the scope of the present invention is defined by the claims.

Embodiments of the present invention are directed to pinning and affixing nano-active material to nano-support using a high temperature condensation technology. In some embodiments, the high temperature condensation technology is plasma. The high

temperature condensation technology can be eBeam, microwave, RF or DC plasma, or any other high temperature condensation technology are possible. Plasma catalyst formed by using the methods described below advantageously has an interface between a nano-active material and a support. As explained in more detail below, the interface dramatically reduces the ability for the nano-active material to move around on the surface of the support, thereby prevent, or at least minimizing, agglomerations of the nano-active material.

Fig. 2 illustrates a process 200 of pinning and affixing nano-active material to nano- support in accordance with an embodiment of the present invention. At a step 210, starting materials are introduced into a plasma gun. Typically, a quantity of a catalyst material 212 is loaded into a plasma gun 215. Preferably, the catalyst material 212 comprises platinum (Pt), which has excellent catalytic properties. A quantity of carrier material 214 is also loaded into the plasma gun 215. In some embodiments, the carrier material 214 is an oxide such as alumina (A1 ₂ 0 ₃ ). Other useful oxides will be apparent to those of ordinary skill. In some embodiments, the catalyst material 212 and the carrier material 214 are loaded manually into a hopper (not shown), which automatically loads the materials into the plasma gun 215. Alternatively, an automated system is able to load the catalyst material 212 and carrier material 214 into the plasma gun 215. In some embodiments, the starting materials are in powder form when they are loaded into the plasma gun 215. Alternatively, the starting materials are loaded into the plasma gun 215 in other forms (e.g., wire, liquid and gas) are contemplated. It should be understood to one skilled in the art that the ratio of the catalyst material 212 to the carrier material 214 can be adjusted to meet particular demands of a given application. Typically, the quantity of the carrier material 214 is much greater than the quantity of the catalyst material 212.

Next, at a step 220, the plasma gun 215 vaporizes the catalyst material 212 along with the carrier material 214 to form a vapor cloud 225. In some embodiments, working gas is introduced into the plasma gun, while energy is supplied to the working gas to create plasma. A variety of different means can be employed to deliver this energy, including, but not limited to, DC coupling, capacitive coupling, inductive coupling, and resonant coupling. The combination within the plasma gun 215 of the plasma and the materials forms a highly reactive and energetic mixture, wherein the materials can be vaporized. The vapor cloud 225 comprises both vaporized catalyst material and vaporized carrier material in the ratio that was loaded into the plasma gun 215 at the step 210.

Still referring to FIG. 2, the resulting vapor cloud 225 is then put through a quenching step 230. Preferably, the quenching step occurs in a highly turbulent quench chamber to facilitate rapid, even, consistent quenching of the vapor 225 into precipitate nanoparticles 300. As the catalyst material 212 and carrier material 214 cool, they solidify into

nanoparticles 300. An example of a resulting nanoparticle 300 is shown in FIG. 3 A. As shown, the nanoparticle 300 comprises a nano-active material 320 and a nano-support 310. In some embodiments, the nano-active material 320 is a gaseous platinum atom, and the nano-support 310 is some form of alumina, such as aluminum (Al) plus oxygen (O).

Specifically, the vaporizing and quenching is performed in reducing conditions using plasma from argon H ₂ . As the vapor 225 quenches, the catalyst material 212 starts to cool down to form nano-active material 320 during quenching. Meanwhile, the carrier material 214 forms into a nano-support 310 with a partially reduced alumina surface, resulting in a more metallic and less oxygen-rich surface. At the surface, the partially reduced alumina is of A1 ₂ 0 ₃ . _X , wherein x is an integer that ranges from zero to three.

Generally the ratio of the nano-active materials 320 and the nano-supports 310 is determined by the ratio of the starting quantities of the catalyst material 212 and carrier material 214 in step 210 of FIG. 2. As such, there are many more nano-supports 310 than there are nano-active materials 320. Although nano-active materials 320 are able to collide with other nano-active materials 320, the chances are greater that the nano-supports 310 collide with other nano-supports 310. The next most likely occurrence are the nano-active materials 320 colliding with the nano-supports 310, resulting in nanoparticles 300.

FIG. 3B illustrates a cross-sectional view of the nanoparticle 300. Since the surface of the nano-support 310 is partially reduced alumina, the nano-active material 320 reacts with the aluminum metal (more so than with the aluminum oxide). As such, when a nano-active material 320 attaches to the surface 315 of a nano-support 310, an interface 325 is formed by the reaction of the nano-active material 320 and the partially reduced alumina. In some embodiments, the interface 325 thereby comprises a platinum alumina metallic compound (Pt _a Al _b ). The platinum alumina metallic compound changes dramatically the ability for the nano-active material 320 to move around on the surface 315 of the nano-support 310.

Consequently, the nano-active material 320 strongly attaches to the nano-support 310, preventing the movement and coalescing/conglomeration of the nano-active material 320 on the surface of the nano-support 310. In contrast to the plasma catalyst of the present invention, nano-active materials of a wet catalyst formed using wet chemistry are free to move and conglomerate. As discussed above, the prevention of movement and

coalescing/conglomeration is of great benefit in high temperature applications such as in an aged catalytic converting testing.

When using wet chemistry to form a wet catalyst, a problem arises in high

temperature applications, such as in the aged catalytic converting testing in which the temperature was raised to 800°C. The degree of platinum conglomeration in the wet catalyst was magnified compared to that of fresh catalytic converting testing, whereas the difference between conglomerations in aged and fresh catalytic converting testing was much lower in the plasma catalyst. This was true when the testing is done in both reducing and oxidation conditions. The increase in the amount of conglomeration of the aged plasma catalyst raised to 800° is equivalent to the amount of the wet catalyst raised to only 20° to 50°C.

In some embodiments, the effectiveness and activity of the plasma catalyst is further improved by adding a quantity of copper (Cu) into the plasma gun 215 along with the other starting materials 212, 214. FIG.4 illustrates a graph of difference of activity of fresh and aged plasma catalysts versus a ratio of copper to platinum in the plasma catalyst. With a certain copper to platinum ratio, typically 0.4, in the plasma catalyst, an increase in conglomeration is even lower, typically equivalent to only a 1°C to 5°C raise in the wet catalysts. When copper is added, the interface between the nano-active material 320 and the surface 315 of the nano-support 310 comprises a platinum copper intermetallic compound (IMC), which consequently provides a better bond than an interface containing a platinum alumina metallic compound since the tendency of platinum atoms to skip over to an available oxygen atom is further reduced.

The present invention has been described in terms of specific embodiments incorporating details to facilitate the understanding of principles of construction and operation of the invention. Such reference herein to specific embodiments and details thereof is not intended to limit the scope of the claims appended hereto. A person skilled in the art would appreciate that various modifications and revisions to the pinning and affixing nano- active material. Consequently, the claims should be broadly construed, consistent with the spirit and scope of the invention, and should not be limited to their exact, literal meaning.