IP Library › Granted Patent US 12,226,835
Granted Patent B2
US 12,226,835 · App. 17/445,687 · Granted Feb 18, 2025

Methods of forming metal nanomaterials

Inventors: Bin Hua (Ammon, ID); Meng Li (Ammon, ID); Dong Ding (Idaho Falls, ID)
Assignee: Battelle Energy Alliance, LLC
B22F9/26B22F1/054B22F2201/013B22F2301/25B22F2301/45B22F2302/25B22F2304/054B22F2304/056B22F2304/058B82Y30/00B82Y40/00H01M4/9041
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Quick Facts
Patent No.
US 12,226,835
App. No.
17/445,687
Granted
Feb 18, 2025
Kind
B2
Abstract

A method of forming a metal nanomaterial comprises forming a precursor solution comprising a metal precursor and a metal oxide precursor. A complexing agent is added to the precursor solution, and the metal precursor and the metal oxide precursor are hydrolyzed to form a sol. The sol is heated to form a gel, which is calcined to incorporate metal cations from the metal precursor into a metal oxide lattice from the metal oxide precursor. The calcined gel is exposed to a reducing agent to exsolve the metal from the metal oxide lattice and to form a metal nanomaterial comprising a metal and a metal oxide is formed. Additional methods of forming a metal nanomaterial are also disclosed.

Claims (63)

1. A method of forming a metal nanomaterial, comprising;

forming an aqueous precursor solution comprising a metal precursor and a metal oxide precursor, the metal precursor comprising a metal salt including ruthenium and the metal oxide precursor comprising samarium nitrate and cerium nitrate;

adding a complexing agent to the aqueous precursor solution;

hydrolyzing the metal precursor and the metal oxide precursor to form a sol;

heating the sol to form a gel;

calcining the gel to incorporate metal cations from the metal precursor into a metal oxide lattice from the metal oxide precursor;

exposing the calcined gel to a reducing agent to exsolve the metal from the metal oxide lattice; and

forming a metal nanomaterial comprising a metal of the metal salt and a metal oxide of the metal oxide precursor, a particle size of the metal in the metal nanomaterial determined by an amount of the complexing agent added to the aqueous precursor solution and the amount of the complexing agent controlling a hydrolysis rate of the metal cations in the aqueous precursor solution, the metal of the metal nanomaterial exhibiting a substantially uniform particle size.

2. The method of claim 1 , wherein forming an aqueous precursor solution comprises forming the aqueous precursor solution comprising water, the metal salt including ruthenium, and two or more of the samarium nitrate, the cerium nitrate, and other lanthanide element salts.

3. The method of claim 1 , wherein adding a complexing agent to the aqueous precursor solution comprises adding citric acid, ethylene glycol, ethylenediaminetetraacetic acid (EDTA), ethylene glycol tetraacetic acid (EGTA), nitrilotriacetic acid, n-hydroxyethylethylenediamine-triacetic acid (HEDTA), a polycarboxylate, a polyol, a phosphate, a sulfate or a combination thereof to the aqueous precursor solution.

4. The method of claim 1 , wherein adding a complexing agent to the aqueous precursor solution comprises adding citric acid and ethylene glycol to the aqueous precursor solution.

5. The method of claim 1 , wherein forming a metal nanomaterial comprises forming the metal of the metal nanomaterial exhibiting single atoms exhibiting the substantially uniform particle size.

6. The method of claim 1 , wherein forming a metal nanomaterial comprises forming the metal of the metal nanomaterial comprising nanoclusters comprising from 2 metal atoms to 100 metal atoms and exhibiting the substantially uniform particle size.

7. The method of claim 1 , wherein forming a metal nanomaterial comprises forming the metal of the metal nanomaterial comprising nanoparticles exhibiting a particle size of from about 1 nm to about 999 nm and exhibiting the substantially uniform particle size.

8. A method of forming a metal nanomaterial, comprising;

forming an aqueous precursor solution comprising a metal precursor and a metal oxide precursor;

adding a complexing agent to the aqueous precursor solution;

hydrolyzing the metal precursor and the metal oxide precursor to form a sol;

heating the sol to form a gel;

calcining the gel to incorporate metal cations from the metal precursor into a metal oxide lattice from the metal oxide precursor;

exposing the calcined gel to a reducing agent to exsolve the metal from the metal oxide lattice; and

forming the metal nanomaterial comprising an iridium/samarium-doped ceria material, a particle size of the metal in the metal nanomaterial being substantially uniform and determined by an amount of the complexing agent added to the aqueous precursor solution and the amount of the complexing agent controlling a hydrolysis rate of the metal cations in the aqueous precursor solution.

9. A method of forming a metal nanomaterial, comprising;

forming an aqueous precursor solution comprising a metal precursor and a metal oxide precursor;

adding a complexing agent to the aqueous precursor solution;

hydrolyzing the metal precursor and the metal oxide precursor to form a sol;

heating the sol to form a gel;

calcining the gel to incorporate metal cations from the metal precursor into a metal oxide lattice from the metal oxide precursor;

exposing the calcined gel to a reducing agent to exsolve the metal from the metal oxide lattice; and

forming the metal nanomaterial comprising a ruthenium/lanthanum-doped ceria material, a particle size of the metal in the metal nanomaterial being substantially uniform and determined by an amount of the complexing agent added to the aqueous precursor solution and the amount of the complexing agent controlling a hydrolysis rate of the metal cations in the aqueous precursor solution.

10. The method of claim 1 , wherein forming a metal nanomaterial comprises forming the metal in the metal nanomaterial comprising a predetermined particle size.

11. A method of forming a metal nanomaterial, comprising;

providing an aqueous precursor solution comprising a metal precursor, a metal oxide precursor, and a complexing agent, the metal oxide precursor comprising a samarium salt and a cerium salt;

hydrolyzing the metal precursor and the metal oxide precursor to form a sol;

incorporating metal cations of the metal precursor into a metal oxide of the metal oxide precursor; and

exsolving the metal cations to form a metal nanomaterial comprising a metal and the metal oxide, the metal of the metal nanomaterial exhibiting a substantially uniform size, a particle size of the metal in the metal nanomaterial determined by an amount of the complexing agent added to the aqueous precursor solution and the amount of the complexing agent controlling a hydrolysis rate of the metal cations in the aqueous precursor solution.

12. The method of claim 11 , wherein providing an aqueous precursor solution comprising a metal precursor, a metal oxide precursor, and a complexing agent comprises providing a nitric salt, a chloride salt, an ammonium salt, an amine salt, or combinations thereof of the metal precursor and a samarium nitrate salt and a cerium nitrate salt of the metal oxide precursor.

13. The method of claim 11 , wherein hydrolyzing the metal precursor and the metal oxide precursor comprises adding a concentration of the complexing agent sufficient to form the metal of the substantially uniform size.

14. The method of claim 11 , wherein providing an aqueous precursor solution comprising a metal precursor, a metal oxide precursor, and a complexing agent comprises providing the metal precursor, the metal oxide precursor, citric acid, and ethylene glycol, wherein a molar ratio of metal cations:citric acid:ethylene glycol is 1:2:2.

15. The method of claim 11 , further comprising removing water after incorporating metal cations of the metal precursor into a metal oxide of the metal oxide.

16. The method of claim 11 , wherein exsolving the metal cations to form a metal nanomaterial comprises forming the metal nanomaterial comprising iron, cobalt, nickel, copper, ruthenium, rhodium, palladium, silver, iridium, platinum, or gold.

17. The method of claim 11 , wherein exsolving the metal cations to form a metal nanomaterial comprises calcining the metal cations in air.

18. A method of forming a metal nanomaterial, comprising;

adding a complexing agent to an aqueous precursor solution comprising a metal precursor and a metal oxide precursor, the metal precursor comprising a metal salt including iridium;

hydrolyzing the metal precursor and the metal oxide precursor to form a sol;

incorporating metal cations of the metal precursor into a metal oxide of the metal oxide precursor; and

calcining the metal cations to form a metal nanomaterial comprising the metal and the metal oxide, the metal comprising a predetermined substantially uniform particle size, a particle size of the metal in the metal nanomaterial determined by an amount of the complexing agent added to the aqueous precursor solution and the amount of the complexing agent controlling a hydrolysis rate of the metal cations in the aqueous precursor solution.

19. The method of claim 18 , wherein calcining the metal cations to form a metal nanomaterial comprises forming the metal nanomaterial comprising the metal substantially homogeneously dispersed therein.

20. The method of claim 18 , wherein calcining the metal cations to form a metal nanomaterial comprises exposing the metal cations and the metal oxide to hydrogen gas.

21. The method of claim 18 , wherein adding a complexing agent to an aqueous precursor solution comprising a metal precursor and a metal oxide precursor comprises adding the complexing agent to the aqueous precursor solution at a molar ratio of metal ions:complexing agent of from about 1.0:0.2 to about 1.0:6.0.

22. A method of forming a metal nanomaterial, comprising:

forming an aqueous precursor solution comprising a metal precursor and a metal oxide precursor;

adding a complexing agent to the aqueous precursor solution;

hydrolyzing the metal precursor and the metal oxide precursor to form a sol;

heating the sol to form a gel;

calcining the gel to incorporate metal cations from the metal precursor into a metal oxide lattice from the metal oxide precursor, the metal oxide lattice comprising ceria (CeO 2 ), samarium doped ceria (SDC), or lanthanum doped ceria (LDC);

exposing the calcined gel to a reducing agent to exsolve the metal from the metal oxide lattice; and

forming a metal nanomaterial comprising a metal and a metal oxide, a particle size of the metal in the metal nanomaterial determined by an amount of the complexing agent added to the aqueous precursor solution and the amount of the complexing agent controlling a hydrolysis rate of the metal cations in the aqueous precursor solution, the metal exhibiting a substantially uniform particle size.

23. The method of claim 22 , wherein adding a complexing agent to the aqueous precursor solution comprises adding citric acid and ethylene glycol to the precursor solution.

24. The method of claim 22 , wherein adding a complexing agent to the aqueous precursor solution comprises adding a higher concentration of the complexing agent relative to the metal cations to form the metal in the metal nanomaterial exhibiting a size of from single atoms to metal nanoclusters comprising from 2 metal atoms to 100 metal atoms, the metal exhibiting the substantially uniform particle size.

25. The method of claim 22 , wherein adding a complexing agent to the aqueous precursor solution comprises adding a lower concentration of the complexing agent relative to the metal cations to form the metal in the metal nanomaterial exhibiting a particle size of from about 1 nm to about 999 nm, the metal exhibiting the substantially uniform particle size.

26. The method of claim 22 , wherein adding a complexing agent to the aqueous precursor solution comprises adding citric acid and ethylene glycol to the aqueous precursor solution in a ratio of metal cations:citric acid:ethylene glycol of 1:2:2.

27. The method of claim 22 , wherein adding a complexing agent to the aqueous precursor solution comprises adding citric acid and ethylene glycol to the aqueous precursor solution in a ratio of metal cations:citric acid:ethylene glycol of 1.0:0.1:0.1.

Assignments (1)
CONFIRMATORY LICENSE Recorded Mar 2, 2022
From: BATTELLE ENERGY ALLIANCE/IDAHO NAT'L LAB
To: UNITED STATES DEPARTMENT OF ENERGY
Reel/Frame 059143/0735 →
Continuity (2)
Provisional Application 63124193 · Dec 11, 2020
Related Publication 20220184702A1 · Jun 16, 2022
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