This invention introduces a one-pot synthesis of Mn-based spinel nanocrystals with {101} facets, delivering high ORR efficiency and durability as a cost-effective, non-platinum catalyst for fuel cells.
Platinum-based catalysts dominate proton exchange membrane (PEM) fuel cells but are costly and scarce. Alkaline fuel cells provide an alternative pathway, yet their development is constrained by the lack of effective, low-cost oxygen reduction reaction (ORR) catalysts. Existing non-PGM catalyst synthesis methods often yield irregular particle shapes with poor facet exposure, leading to low activity and scalability issues. A new catalyst solution that combines precise facet control, high activity, and cost-effectiveness is critical for advancing alkaline fuel cells and energy storage technologies.
This invention introduces a one-pot colloidal synthesis method to create uniform ~9 nm octahedral nanocrystals of CoMn₂O₄ or CuMn₂O₄ spinels. Using chloride-based precursors (CoCl₂·6H₂O or CuCl₂·2H₂O) with manganese acetate, oleylamine, oleic acid, and xylene, rapid water injection at 90°C triggers controlled nucleation and facet-specific growth. The resulting nanocrystals expose exclusive {101} facets, which are highly active for electron transfer. After annealing, these nanocrystals demonstrate high ORR activity, long-term stability, and mass activity approaching platinum benchmarks, making them scalable and cost-effective alternatives to platinum catalysts.
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• Achieves high ORR mass activity (~60.0 A/g), outperforming nanosphere variants
• Exclusively exposed {101} facets optimize electron transfer kinetics
• Significantly lower material cost using abundant Co, Cu, and Mn oxides
• Facile, scalable one-pot synthesis process
• High durability with minimal E½ decay after 10,000 cycles
• Improved reaction kinetics with low Tafel slope (~42.1 mV/decade)
• High-performance alkaline fuel cell cathodes
• Electrodes for rechargeable zinc-air batteries
• Catalysts for industrial alkaline electrocatalytic processes
• Large-scale non-PGM catalyst production for energy storage systems
• US Provisional Application 63/310,230 – Filed February 15, 2022
• US Utility Application 18/081,485 – Filed December 14, 2022
• US Published Application 2023-0261211 A1 – Published April 23, 2023
Prototype – Synthesis method and catalyst performance validated at lab scale with demonstrated ORR efficiency and durability in alkaline systems. TRL ~4.
This technology is available for licensing.
This invention is an attractive alternative for companies developing alkaline fuel cells, zinc-air batteries, and large-scale electrocatalytic systems, offering platinum-level performance at a fraction of the cost.
Performance data, structural characterization, and long-term ORR cycling test results available upon request.