Atomic layer deposition (ALD) is an enabling technology for the fabrication of performance materials with precise surface functionalities. It involves an alternating, self-terminated, gas-phase reaction sequence scheme and is well-suited for coating all types of complex-structured materials, including powders. The nanoCARBS (nanostructured CAtalysts as Rational Bio-conversion Systems) project main aim was to probe the innovation potential of ALD for rationally-designed nanostructured catalysts. The knowledge gained can be implemented for the realization of novel, high-performance catalytic conversion systems.
The latest scientific breakthroughs made in the framework of my ERC-StG (AggloNanoCoat) had a significant impact on the current understanding of the structural properties of the deposited coatings, further strengthening the position of my team in the rapidly-evolving landscape of ALD for powder modification. In the last years we expanded our coatings portfolio, exploring different material configurations metal (e.g. Pt, Pd) and metal-oxide (e.g. Al2O3, TiO2, SiO2) inorganic materials (ALD), organic coatings (molecular layer deposition, MLD, the organic equivalent of ALD) and hybrid organic/inorganic (e.g. alucone) materials (MLD/ALD). While doing so, we also gained mechanistic understanding on the main processes influencing the structural properties of the grown structures allowing us to impose additional control on the deposited features (e.g. size distribution, spatial density).
Moreover, the commercialization potential of the technique was successfully evaluated under the auspices of our previous ERC-PoC grant (CONiA) resulting to the launch of our spin-out company Delft IMP (Delft Intensified Materials Production) from early 2015. With one of the primary market penetration routes identified in the catalyst industry, the company quickly moved-in to initiate industrial research collaborations with several relevant industrial stakeholders both in EU and overseas. These initiatives focus both on the material innovation aspects but also on the process scale-up potential.
With nanoCARBS we filled a significant gap identified in our previous market analysis, related to the modification of carbon-based powder materials by ALD for both metal (nanoparticles) and metal-oxide (ultrathin films, core/shell structures) growth. We demonstrated the advantages that the technology offers for the rational fabrication of materials with clear structure/performance relationships. Although we explored the possibilities for utilizing these in bio-conversion systems, we discovered that the market demand currently is more on the side of high-metal-loading catalytic conversion systems e.g. for automotive applications. On that aspect, we focused especially in the synthesis of materials relevant to fuel cell systems. Integrating this approach, Delft IMP is expected to introduce to the market its series of rationally-designed carbon-based proprietary catalysts by the beginning of 2018.
