Zinc-Air Batteries,  Portable Power Solutions
  Manufacturing Process

QuantumSphere’s award winning platform technology is an adaptation of the gas phase condensation (GPC) vacuum production method covered by proprietary trade secrets and multiple issued patents. Metal is vaporized using resistance heat at a temperature beyond the boiling point of the material, until a sufficient rate of vaporization is achieved. Through automated computer control of the metal flux, chamber pressure, temperature and gas flow, metal and metal alloy nanoparticles are manufactured with the desired size and particle distribution.

Based on customer feedback and third party expert validation, QSI’s resistance heated vapor condensation method delivers the highest quality metal and metal alloy nanoparticles with the lowest level of agglomeration and fewest impurities in the marketplace. This method is the clear choice for low-cost commercial production of uniform, reproducible, advanced nano catalysts for multiple electro and thermo chemical applications.

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Intellectual Property
The platform technology patent for QuantumSphere’s Gas Phase Condensation process was awarded in October 2007 and includes seventy-three broad claims on a fully automated, ISO certified manufacturing system that produces QSI’s award winning, high performance nanoscale catalysts. Several additional patents have been issued over the past few years and multiple patent applications are pending covering various catalytic compositions including nanoscale bi-metallic alloys (with controlled metal core/oxide shell) for enhanced electro and thermo chemical applications, dispersions and formulations, integrated process chemistries, several commercial electrochemical devices and components (batteries and fuel cells), and high efficiency thermo chemical processes (ammonia, hydrogen, methane, CO production) as well as multiple other clean-energy applications enabled by the use of QSI’s advanced catalyst and integrated components.

Competing Technologies
Synthetic or man-made nano scale materials were first created in the 1970’s using the gas phase condensation method. Today, there are dozens of processes for producing nano scale materials worldwide, including chemical vapor deposition, physical vapor deposition, reactive sputtering, laser pyrolysis, plasma gun spray conversion, mechanical alloying, grinding and sol gel. These processes are expensive and require sophisticated and complex equipment and labor-intensive maintenance. They may also result in products with inconsistent particle size, distribution, shape and impurities with little ability to scale up to commercial quantities at reasonable prices. QSI’s

Because QSI’s patented process is safe, environmentally friendly and fully automated, it requires minimal supervision and suffers little down time for reactor maintenance. The unique process literally removes the potential for human error and expensive labor from the manufacturing equation. Increased production rates combined with lower labor and conversion costs enable commercial application of these advanced materials by industry leading companies for multiple consumer and industrial products. The ability to deliver high quality nano scale catalysts in commercial quantities at reasonable prices allows QSI and its partners to attain mass market penetration and accelerated commercialization of these new advanced materials.

ISO Certified Quality Control & Customization
Our primary focus is to produce ultra-fine advanced catalysts that enhance the performance of our customers’ electro and thermo chemical end-use products and processes. We manufacture our award winning nano scale catalysts according to ISO 9001:2008 certification and strict customer specifications, maintaining a very narrow particle size distribution, low agglomeration, high purity, and consistent particle morphology. In order to ensure the quality of our product, we analyze each batch before it is shipped using analytical techniques such as: BET surface area measurement, TGA thermal analysis for oxide shell thickness, x-ray diffraction, elemental analysis, and electron microscopy. Batch sizes can be adjusted to the requirements of our customers.

Environmentally Friendly
QSI manufactures the highest quality and quantity of nano scale metal catalysts in the industry without compromising its commitment, either to employee safety or the environment. Our manufacturing facility and production process personnel follow strict NIOSH best practice guidelines for handling nanomaterials. Accordingly, no hazardous chemicals or toxic gases are used in our manufacturing process, and no solid, liquid or hazardous waste stream is generated. By utilizing electricity and helium gas, the result is a greater than 85% yield of high quality nano scale catalysts from feedstock; unprocessed raw metals are completely recyclable.


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Founded: 2002
Santa Ana, CA.
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