Method for producing a catalyst filter, catalyst filter, use of a catalyst filter, air treatment device comprising a catalyst filter

Abstract

According to the invention, in a method for producing a catalyst arrangement (1) which has a support structure (2), wherein the catalyst arrangement (1) is designed to break down decontamination residues (3), in particular hydrogen peroxide (4), in a controlled containment (5), in particular an isolator (6), it is proposed that the support structure (2) of the catalyst arrangement (1) is additively manufactured, wherein the support structure (2) consists of a support material (8) which is provided with an adhesion promoter (7), said support material being in particular homogeneously and / or uniformly mixed, wherein the support structure (2) of the catalyst arrangement (1) is formed from layers (11, 11') consisting of preferably linear filament structures (10), wherein each layer (11) is criss-crossingly overlaid (15) over a next layer (11') and wherein the catalyst arrangement (1) is designed in particular as a component of an air treatment device (22).

Description

[0001] PC 25 1136 C 30 July 2025

[0002] Method for manufacturing a catalyst filter, catalyst filter, use of a catalyst filter, air treatment device comprising a catalyst filter

[0003] The invention relates to a method for producing a catalyst arrangement comprising a support structure, wherein the catalyst arrangement for the degradation of decontamination residues, in particular hydrogen peroxide and / or ozone, is formed in a controlled containment, in particular an isolator.

[0004] The invention further relates to a catalyst arrangement comprising a preferably multilayered support structure, which is formed from a support material provided with an adhesion promoter, in particular a mixture, and a catalyst applied to the support material.

[0005] The invention further relates to the use of a previously described catalyst arrangement for the degradation of decontamination residues, in particular for the degradation of hydrogen peroxide, within a controlled containment, in particular within an isolator, during a recirculating air and / or exhaust air process.

[0006] The invention relates to an air preparation device which has a catalyst arrangement already described.

[0007] The catalyst arrangement and the manufacturing processes are known from practice. For example, catalysts are used for gas purification or gas processing.

[0008] The invention is based on the objective of simplifying the manufacture of a catalyst arrangement for controlled containments, in particular for isolators, and thus, for example, for PC 25 1136 C 2 / 39 30. July 2025 protected spaces for the manipulation of pharmaceuticals.

[0009] To solve the aforementioned problem, the features of claim 1 are provided according to the invention. In particular, to solve the aforementioned problem in a method for producing a catalyst arrangement of the type described above, it is proposed according to the invention that the support structure of the catalyst arrangement is additively manufactured using a support material provided with an adhesion promoter, in particular a mixed one.

[0010] Controlled containment can be, for example, a controlled environment, particularly an isolator, in which drug manipulation is preferably carried out. In such containments, it is essential that they meet appropriate hygiene requirements to prevent drug contamination. For this purpose, these containments are decontaminated with decontamination agents before and after drug manipulation. However, to also prevent a reaction between the product being manipulated in the containment and the decontamination agent, this agent is passed over the appropriate catalyst assembly, particularly within the framework of recirculating and / or exhaust air systems, after a decontamination step has been completed, and decomposed by the chemically active surface of the catalyst assembly.This has the advantage that the (decontamination agent-free) exhaust air can be safely released into the environment, where people may be present, and / or that materials not resistant to decontamination agents need not be used in the exhaust air area. PC 25 1136 C 3 / 39 30. July 2025.

[0011] This catalyst arrangement consists of a support structure, which in turn comprises a support material that can be processed using an additive manufacturing process and is provided with, in particular mixed with, the adhesion promoter. This advantageously results in a favored bonding of a catalyst layer applied to the support material of the support structure.

[0012] The adhesion promoter can, for example, correspond to the material of a catalyst coating subsequently applied to the support structure, such as the one already mentioned. Furthermore, substances that increase the surface roughness and / or abrasion resistance of the support material, for example through ceramic and / or mineral and / or metallic particles with similar rough structures, can be used as adhesion promoters, additionally or alternatively. The adhesion promoter can be, for example, a metal (e.g., platinum), a metal oxide, a transition metal oxide, a metal-organic compound, and / or a metal-organic framework compound, in particular a manganese oxide, such as manganese dioxide.

[0013] All known additive manufacturing processes can be considered as additive manufacturing processes, such as 3D printing processes and / or bath-based and / or photolithographic processes.

[0014] In a further advantageous embodiment of the invention, it can be provided that the connection between the adhesion promoter and the carrier material is homogeneous and / or uniform.

[0015] For example, it may be stipulated that the

[0016] The adhesion promoter is mixed homogeneously and / or uniformly with the carrier material PC 25 1136 C 4 / 39 30 . July 2025. It is particularly advantageous in this way that the adhesion promoter does not remain on the surface of, for example, an extruded filament of the carrier framework.

[0017] In particular, it can be provided that the bond is materially bonded. This can be particularly advantageous, for example, in preventing the adhesion promoter from detaching from the carrier material.

[0018] In a further advantageous embodiment of the invention, the adhesion promoter can be added to the substrate material prior to the additive manufacturing process. This enables application in the same process step as the additive manufacturing and / or in a homogeneous material.

[0019] Alternatively or additionally, the adhesion promoter can be added to the substrate during the additive process. This allows, for example, separate feeding of the adhesion promoter and the substrate. Pretreatment of the substrate is unnecessary.

[0020] Since, in additive manufacturing processes such as fused deposition modeling (FDM) and fused filament fabrication (FFM), the substrate material is heated, and in resin printing processes such as stereolithography and digital light processing (DLP), the substrate material is polymerized, adding an adhesion promoter before and / or during the additive process can, for example, achieve a simultaneous fusion of both components and promote a material-coherent bond. This would result, for example, in a PC 25 1136 C 5 / 39 30. July 2025 produced by the additive process.

[0021] The filament already contains both components, preferably homogeneously and / or uniformly.

[0022] A further advantageous embodiment of the invention may provide that the additive manufacturing process by which the support structure is formed is a melt layer printing process and / or a resin printing and / or a selective laser sintering process.

[0023] Due to the spatial design of the containment structures, melt flow printing processes offer the advantage that support structures with large cross-sections can be easily produced. Resin printing processes, on the other hand, offer the advantage that layers can be produced faster and in greater detail, thus enabling the printing of fine structures.

[0024] Another advantageous embodiment of the invention may provide that the carrier material is coated with a catalyst after additive manufacturing.

[0025] The applied catalyst coating thus allows for the highly advantageous chemical degradation of the containment decontamination residues as soon as they come into contact with the catalyst-coated support structure. The catalyst can be, for example, a metal (platinum), a metal oxide, a transition metal oxide, a metal-organic compound, and / or a metal-organic framework compound, in particular a manganese oxide, such as manganese dioxide. Furthermore, platinum or silver compounds, for example, can also be used.

[0026] In a further advantageous embodiment, it may be provided that the adhesion promoter is logically connected to a catalyst, for example, the aforementioned catalyst (PC 25 1136 C 6 / 39 30 . July 2025).

[0027] This can be particularly advantageous, for example, in achieving a homogeneous and insoluble bond between the catalyst and the adhesion promoter.

[0028] In a further advantageous embodiment of the invention, it can be provided that the support structure is formed in multiple layers during additive manufacturing by linear filament structures of the support material, in particular wherein at least two layers are applied offset from each other and / or each layer is applied offset from each other and / or from at least a preceding and / or subsequent layer.

[0029] For example, it may be provided that a first layer is offset to a next layer or at least to at least one previously applied layer.

[0030] In the exhaust air and / or recirculation process described above, a fluid stream containing the decontamination agent, in particular an air stream, flows through the catalyst assembly. Due to the catalyst applied to the support structure, the decontamination agent can then be chemically degraded upon contact with the catalyst. Therefore, for example, to degrade the decontamination agent within the containment, it is important to achieve the highest possible contact density between the fluid stream and the catalyst. Such a multilayered and staggered structure of the support framework can thus advantageously achieve the highest possible surface contact between the fluid stream and the catalyst applied to the support structure. PC 25 1136 C 7 / 39 30 July 2025

[0031] For example, it can be designed so that pores of, for example, 0.2 mm are achieved between finely extruded filament structures of, say, 0.4 mm during the extrusion process. An air permeability of 50% can be particularly advantageous here.

[0032] Resin printing, for example, is extremely advantageous for producing significantly smaller and / or more detailed structures, which in turn increases the contact area.

[0033] Furthermore, the filament structures can be designed to have a layer height of, for example, 0.1 mm to 0.2 mm, so that preferably 10 to 20 layers can be stacked on top of each other. This allows, for example, the simulation of porosity s.

[0034] In a further advantageous embodiment, it can be provided that a surface of the carrier material is chemically treated after manufacturing in such a way that the adhesion promoter added to the carrier material is exposed.

[0035] For example, the surface of the additively manufactured support structure coated with the adhesion promoter can be treated by etching to expose the adhesion promoter. This is particularly advantageous for creating contact points for the catalyst coating and ensuring good adhesion of the catalyst coating.

[0036] Alternatively or additionally, the features according to claim 8 are provided to solve the aforementioned problem according to the invention. In particular, it is thus proposed according to the invention that, for setting a desired PC 25 1136 C 8 / 39 30 . July 2025

[0037] The degradation rate and / or pressure loss of a fluid flow containing the decontamination residues and passing through the catalyst arrangement is a measure for at least one plane and / or at least one mesh that is individually selected.

[0038] Particularly advantageous is the ability to vary, for example, the number and / or height of levels, the offset of unidirectional meshes, the mesh width, and / or the mesh spacing, depending on the application. Since these parameters correlate with the number of channels, the channel width, and / or the channel length, the desired degradation rate and / or pressure drop can be adjusted accordingly.

[0039] Alternatively or additionally, the features of claim 7 are provided to solve the aforementioned problem. According to the invention, it is proposed that a layer providing a filtering and / or catalytic effect is produced in an additive process, wherein at least one fold region is formed and wherein the layer is folded in the fold region according to the additive process. Thus, three-dimensional arrangements can be produced in a simple manner, in particular without the need for a third-dimensional extension to fit into a 3D printer.

[0040] The fold area can, for example, be formed by a crease. It can be provided, for instance, that at least two layers are additively manufactured through the fold area, such as the crease, whereby the layers can then be folded in such a way as to form a support structure, in this case a two-layer structure. This can extend to a large number of further layers. The fold area can thus, for example, be printed directly along with the layers, for instance, within the framework of a process such as the aforementioned melt layer printing process and / or resin printing process and / or selective laser sintering process.

[0041] Lamellar or pleated arrangements for catalysts and / or filters can be easily designed. This allows for a larger, and in particular significantly larger, effective catalyst and / or filter area than the clear flow cross-section in which the catalyst and / or filter is or will be installed.

[0042] It is particularly advantageous if the folding area, especially in the form of a fold line, extends over the entire layer.

[0043] It is advantageous to form several fold zones, preferably parallel or longitudinally aligned. These can then be folded alternately, for example, as mountain and valley folds. This allows for the creation of a Z-shaped profile.

[0044] Alternatively, the folds can all be formed in the same direction (as mountain folds or valley folds). This also makes it easy to produce catalyst and / or filter cartridges with a polygonal base shape, especially if the layer is completely closed by the folds.

[0045] Mixed forms with any sequence of mountain folds and valley folds can also be created, depending on the desired application.

[0046] In general, a mountain fold can be described, for example, as a fold where the inflection point is closest to an observer (the observer sees a mountain), PC 25 1136 C 10 / 39 30 July 2025, while a valley fold can be described, for example, as a fold located farther from the observer (the observer sees a valley). Valley and mountain folds can alternatively or additionally be characterized by different signs of curvature in their respective profiles.

[0047] Particularly advantageous is the ability to additively manufacture the support structure along its entire length, for example by printing, whereby the various layers are then folded over or bent, creating a multi-layered catalyst arrangement.

[0048] Furthermore, this makes it particularly advantageous to produce a lamellar filter in a simple additive process and, in addition, to achieve an increased filter area for the removal of decontamination residues.

[0049] In a further advantageous embodiment of the invention, it can be provided that at least one connection area for the, in particular modular, linking of several layers is formed on the layer.

[0050] In this context, it may be provided, for example, that basic modules, such as layers, of the catalyst arrangement are connected in series in a modular fashion in order to advantageously multiply the degradation rate for the removal of decontamination residues.

[0051] In a further advantageous embodiment of the invention, the catalyst assembly can be manufactured together with a frame and / or a connection. PC 25 1136 C 11 / 39 30 July 2025

[0052] The connection can be, for example, a fluid-tight, especially gas-tight, connection that is connected to the frame and / or the catalyst assembly.

[0053] This can be particularly advantageous, for example, in achieving shape stability of the entire catalyst arrangement.

[0054] Furthermore, the connection can, for example, be a seal for sealing against elements of the catalyst assembly located in front of, beside, and / or behind it. These elements can be, for example, fasteners and / or attachment points for fastening and / or transport devices, etc.

[0055] Alternatively or additionally, the features of dependent claim 9 are provided according to the invention to solve the aforementioned problem. According to the invention, it is thus proposed in a method for producing, for example, a catalyst arrangement already mentioned, that the support structure is formed from a support material and is materially bonded to a filter material.

[0056] The filter material can, for example, be a component of a HEPA filter. Furthermore, the filter material can be, for example, a fibrous sheet structure made of different materials. Additionally, the filter material can be, for example, woven or non-woven.

[0057] Particularly advantageous is the achievement of a materially bonded connection between the carrier material and the filter material, which, in addition to the catalytic cleaning of the airflow, also provides filtration of the airflow, and which can be achieved by a composite material PC 25 1136 C 12 / 39 30 . July 2025 between the filter material and the carrier material.

[0058] Furthermore, the carrier material can be designed to form a filtering effect, such as the one already mentioned, and / or a catalytically effective layer, such as the one already mentioned, which in turn is bonded to the filter material. If the layer has a bending zone, such as the one already mentioned, it is particularly advantageous to allow the filter material to be bent together with the carrier material.

[0059] Alternatively or additionally, it may be provided that the carrier material is applied additively to the filter material.

[0060] For example, it may be possible to apply the carrier material directly to the filter material during additive manufacturing, which in turn allows for a particularly time- and cost-efficient realization of catalytic cleaning and simultaneous filtration of the airflow.

[0061] In a further advantageous embodiment of the invention, it can be provided that the filter material is placed on a carrier material that is additively manufactured, for example, the one already mentioned.

[0062] This can be particularly advantageous, for example, in achieving a detachable connection between the support material and the filter material, allowing the filter to be changed and / or removed independently of the support material. PC 25 1136 C 13 / 39 30 July 2025

[0063] In general, it can also be provided that the carrier material is in front of and / or behind the filter material, or that the filter material is formed in front of and / or behind the carrier material.

[0064] Alternatively or additionally, the features of the dependent claim, which relates to a catalyst arrangement, are provided according to the invention to solve the aforementioned problem. In particular, to solve the aforementioned problem in a catalyst arrangement comprising a preferably multilayered support structure formed from a support material provided with an adhesion promoter, in particular a mixture thereof, and a catalyst applied to the support material, it is proposed according to the invention that the support structure of the catalyst arrangement is produced in an additive process.

[0065] When manufacturing the catalyst assembly support structure with the adhesion promoter using an additive process, particularly fast and automated process flows can be generated. Furthermore, additive processes, such as melt printing, resin printing, and / or selective laser sintering, offer diverse and adaptable design options for the support structure. For example, if the catalyst assembly support structure with the adhesion promoter is manufactured using an additive process in which the support material is heated to its melting point, a strong, bonded connection between the two components can be achieved particularly advantageously if the adhesion promoter is added to the support material, such as the one already mentioned, before and / or during the additive process. PC 25 1136 C 14 / 39 30 July 2025

[0066] In particular, the support structure of the catalyst assembly is manufactured using a previously claimed method. Thus, the aforementioned advantages can be achieved.

[0067] Alternatively or additionally, it is proposed according to the invention that a layer of the support structure consisting of a preferably linear filament structure is superimposed in a crossing manner to at least one subsequent next layer.

[0068] A particularly advantageous aspect of such an intersecting layering of the support structure is the creation of a highly compact support structure. Furthermore, the predominantly linear filament structures allow for the realization of large cross-sections. The intersecting layering also increases the contact area, which is necessary, for example, to largely neutralize and chemically degrade a fluid stream (such as an air stream) passing through the catalyst assembly, preferably containing decontamination residues, using the catalyst applied to the support structure. This fluid stream can be generated within a recirculating and / or exhaust air process.

[0069] The layers can be, for example, particularly progressive, printing layers, for example with different dimensions to each other, and / or object layers.

[0070] In a further advantageous embodiment of the invention, it can be provided that various superimposed and / or offset layers are formed at least partially congruently on top of one another, thereby forming a base layer. PC 25 1136 C 15 / 39 30 July 2025

[0071] For example, it can be stipulated that the sections in which the layers are congruent and overlapping are predetermined. Thus, it can be determined, for instance, that the layers are designed and / or manufactured in such a way that the sections in which the layers are congruent repeat after every second layer (not limited to this).

[0072] In a further advantageous embodiment, it can be provided that the intersecting superposition creates an offset of the layers, whereby channels are formed in each cross-section of the catalyst arrangement.

[0073] It can therefore be particularly advantageous, for example, for a fluid flow containing residues to be neutralized, such as the one already mentioned, to pass through the channels of the entire catalyst arrangement.

[0074] In particular, baffle-like channels form in each cross-section of the catalyst assembly. These baffle-like channels are particularly advantageous in increasing the contact area of ​​the catalyst assembly and thus increasing the probability that a fluid flow, such as the one already mentioned, passing through and / or through the catalyst assembly will contact the catalyst.

[0075] In a further advantageous embodiment of the invention, it can be provided that the support structure forms channels which have changes in direction along a flow direction of a gas flowing through the channels.

[0076] These changes in direction can, for example, be used to create a controlled deflection and / or turbulence of the flowing PC 25 1136 C 16 / 39 30 . July 2025

[0077] The gas can be reached. This can also advantageously increase (surface) contact between the flowing gas and the catalyst of the catalyst assembly, as it forces the flowing gas to "impact" itself at points of change of direction(s) in the catalyst assembly. The flowing gas can be, for example, a fluid stream, especially an air stream, such as the one already mentioned, which contains decontamination residues, especially hydrogen peroxide, that can be chemically degraded by the catalyst assembly, for example, in a controlled containment.

[0078] Preferably, the support structure forms channels which have changes in direction of at least 80°, in particular at least 90°, along the flow direction of the gas flowing through the channels.

[0079] As already mentioned, such abrupt changes in direction advantageously lead to a correspondingly abrupt change in the flow direction of the flowing gas, so that as many gas particles as possible of the flowing gas contact the catalyst arrangement.

[0080] In a further advantageous embodiment of the invention, it can be provided that one sign of the offset of the layers along the cross-section is reversed at least once.

[0081] Particularly advantageous is the ability to easily fabricate changes in the direction of the channels of the support structure along the flow direction of the gas flowing through the channels, for example, using melt layer and / or resin and / or selective laser sintering processes. A "reversal of the sign of the layer offset" can be understood, for example, as a PC 25 1136 C 17 / 39 30 July 2025 along a changing flow cross-sectional narrowing of a channel section, corresponding to the flow direction of the gas flowing through the channels, followed by a flow cross-sectional widening of an adjacent channel section.This means that, since the flow of the gas follows the changes in direction of the channels, the direction of flow of the gas is also influenced, for example, compared to a straight flow direction, and / or vice versa.

[0082] In a further advantageous embodiment, it can be provided that the support material is resistant to reactance, preferably resistant to hydrogen peroxide and / or ozone.

[0083] A particular advantage is that the support material, for example when hydrogen peroxide is to be broken down using the catalyst arrangement, remains undamaged and the entire catalyst arrangement, especially the support framework of the catalyst arrangement, is therefore more durable.

[0084] Another advantageous embodiment of the invention may provide that the adhesion promoter and the carrier material form a multi-component material.

[0085] The adhesion promoter can, for example, be a substance that increases the surface roughness of the substrate material, while the substrate material is, for example, a material that can be processed using additive manufacturing. It is advantageous if the adhesion promoter is added to the substrate material, for example, before and / or during the additive manufacturing process for the substrate structure, thus forming a multi-component material that, in turn, forms the basis of the substrate material. The substrate structure produced from this multi-component material ultimately offers the combined advantages of both material properties. The material properties of the substrate structure can therefore be adapted to different requirements, for example, by varying the weight percentages of the components.

[0086] In a further advantageous embodiment of the invention, it can be provided that the support structure is manufactured by means of melt layer printing and / or resin printing and / or selective laser sintering printing.

[0087] These additive manufacturing processes offer the significant advantage that, for example, different support structure cross-sections and / or adaptations of the cross-sections to changing requirements can be implemented without critical issues. Furthermore, these additive manufacturing processes also offer the advantage that the support structures can be manufactured from different materials.

[0088] In a further advantageous embodiment of the invention, it can be provided that the support material of the support structure is coated with the catalyst.

[0089] The catalyst forms the main component of the entire catalyst assembly. Once the catalyst is applied to the support material of the support structure, or the support material of the support structure is coated with the catalyst, the aforementioned advantages for the degradation of various residues, for example, the degradation of hydrogen peroxide from a flowing gas, such as the one already mentioned and / or claimed, can be realized. PC 25 1136 C 19 / 39 30 July 2025

[0090] Another advantageous embodiment of the invention may provide that the catalyst is a metal oxide.

[0091] For example, hydrogen peroxide-containing decontamination residues can be chemically degraded using metal oxides. Advantageously, hydrogen peroxide can be degraded within a controlled containment, particularly insulators, which, prior to the manipulation of a drug, especially during a decontamination step, have been treated with a flowing gas, particularly hydrogen peroxide, to decontaminate various components within the containment. This degradation can occur, for example, using a recirculating and / or exhaust air process. This has the advantage that the (decontamination agent-free) exhaust air can be safely released into the environment, where people may be present, and / or that materials not resistant to decontamination agents need to be used in the exhaust air area.Additionally or alternatively, a reaction of a drug, for example the one already mentioned, with hydrogen peroxide is prevented.

[0092] In particular, it may be provided that the catalyst is a manganese oxide.

[0093] In a further advantageous embodiment of the invention, it can be provided that the adhesion promoter increases the surface roughness of the carrier material.

[0094] This can be achieved, for example, by ceramic and / or mineral and / or metallic particles or similar structures, and offers the advantage that a catalyst coating applied to the support material adheres better to the support material of the support structure. PC 25 1136 C 20 / 39 30 July 2025

[0095] In a further advantageous embodiment, it can be provided that at least one layer forms a connection area.

[0096] This allows for the particularly advantageous realization of the benefits already described above, such as a modular linking of different basic modules, for example the already mentioned one, where a basic module can be formed by a layer.

[0097] In a further advantageous embodiment of the invention, the support structure can be connected to a frame and / or clamped into the frame. This allows for simple assembly as a module.

[0098] This can be particularly advantageous in increasing the shape stability of the catalyst arrangement.

[0099] In a further advantageous embodiment of the invention, the catalyst assembly can be connected to the frame via a fluid-tight, in particular gas-tight, connection. This allows for a simple reduction or prevention of unwanted leakage of unpurified substances.

[0100] This makes it particularly advantageous, for example, to connect various components directly to the connection.

[0101] Alternatively or additionally, the features of dependent claim 18 are provided according to the invention to solve the aforementioned problem. In particular, it is thus proposed according to the invention to solve the aforementioned problem in a catalyst arrangement of the type described at the outset that a layer additively produced, which has a filtering effect and / or catalytic effect, PC 25 1136 C 21 / 39 30. July 2025, forms at least one kink region.

[0102] The bending area could, for example, be the bending area already described. It is particularly advantageous for the catalyst assembly to be bent in this way, which in turn advantageously increases the contact area between the airflow and the catalyst assembly.

[0103] Alternatively or additionally, the features of dependent claim 19 are provided according to the invention to solve the aforementioned problem. In particular, it is thus proposed according to the invention, to solve the aforementioned problem in a catalyst arrangement of the type described at the outset, that the support structure is formed from a support material and is materially connected to a filter material.

[0104] It is particularly advantageous, for example, to achieve that the carrier material can be folded together with the filter material if the carrier material forms a layer that has a folding area, such as the one already mentioned.

[0105] Furthermore, it is advantageous that a composite material is created between the carrier material and the filter material, through which an airflow, for example the one already mentioned, can not only be catalyzed but also filtered.

[0106] In a further advantageous embodiment of the invention, the carrier material can be additively applied to, for example, the aforementioned filter material. PC 25 1136 C 22 / 39 30 July 2025

[0107] The advantages already described can thus be achieved particularly effectively.

[0108] In a further advantageous embodiment of the invention, it can be provided that a filter material, for example the one already mentioned, is placed on a carrier material, for example the one already mentioned, additively manufactured.

[0109] For example, it may be provided that the support material is in front of and / or behind the filter material, or that the filter material is formed in front of and / or behind the support material.

[0110] Alternatively or additionally, to solve the aforementioned problem, the features of the subsidiary claim, which is directed to the use of an already claimed catalyst arrangement for the degradation of decontamination residues within a controlled containment, in particular an isolator and / or a sterilization device, in particular an electron beam sterilization device, during a recirculating air and / or exhaust air process, are provided according to the invention.

[0111] The electron beam sterilization device can, for example, be an "E-beam". It is preferred if, for example, the "E-beam" and / or the insulator includes a filling device, in particular for filling pharmaceutical containers, syringes, etc.

[0112] The catalyst arrangement can preferably be located in a recirculating air and / or exhaust air duct of the controlled containment.

[0113] This can be particularly advantageous for the aforementioned

[0114] Advantages of the catalyst arrangement are realized. PC 25 1136 C 23 / 39 30. July 2025

[0115] Recirculating air and / or exhaust air processes also offer the advantage that the decontamination residues are driven and / or directed towards the catalyst assembly and can thus be broken down by it. This results in a flowing fluid stream containing the decontamination residues, for example, a flowing gas containing the decontamination residues.

[0116] In particular, the previously claimed catalyst arrangement is used for the degradation of hydrogen peroxide.

[0117] Alternatively or additionally, the features of the dependent claim, which relates to an air treatment device, are provided according to the invention to solve the aforementioned problem. In particular, to solve the aforementioned problem in an air treatment device that has a catalyst arrangement already claimed, it is proposed according to the invention that the air treatment device is configured to pass a fluid flow containing decontamination residues through the catalyst arrangement during a recirculation and / or exhaust air process.

[0118] This allows the advantages of the catalyst arrangement already described to be realized particularly effectively.

[0119] In particular, the air preparation device is designed to pass a fluid stream containing hydrogen peroxide through the catalyst arrangement during the recirculation and / or exhaust air process.

[0120] Thus, the hydrogen peroxide, especially if the catalyst of the catalyst assembly is a metal oxide, can be degraded and released into the air within a controlled containment, for example, the one already mentioned, in particular PC 25 1136 C 24 / 39 30 July 2025.

[0121] I solators, for example for the manipulation of drugs, are processed.

[0122] The invention will now be described in more detail with reference to exemplary embodiments, but is not limited to these. Further exemplary embodiments result from combining the features of one or more claims with each other and / or with one or more features of the exemplary embodiment. It shows, in each case in a highly simplified representation,

[0123] Fig. 1 shows a two-dimensional top view of a catalyst arrangement according to the invention.

[0124] Fig. 2 shows a two-dimensional representation of a catalyst arrangement according to Fig. 1 in a bottom view.

[0125] Fig. 3 shows a controlled containment with an air preparation device having a multilayer catalyst arrangement according to the invention and a cross-sectional profile of the multilayer catalyst arrangement.

[0126] Fig. 4 shows a three-dimensional representation of a multilayer support structure of a catalyst arrangement according to the invention with a cross-sectional view.

[0127] Fig. 5 shows a representation of intersecting superpositions of layers of a support framework of a catalyst arrangement according to the invention.

[0128] Fig. 6 shows an exploded view of a multilayer support structure of a catalyst arrangement according to the invention, PC 25 1136 C 25 / 39 30. July 2025

[0129] Fig. 7 shows a two-dimensional sectional view of superimposed layers of a support structure of a catalyst arrangement according to the invention with baffle-like channels and a gas flowing through them.

[0130] Fig. 8 shows a three-dimensional representation of a layer of the catalyst arrangement with three kink regions.

[0131] Fig. 9 shows a three-dimensional representation of a layer of the catalyst arrangement according to Fig. 8 in a bent state.

[0132] Fig. 10 shows a three-dimensional representation of a layer of the catalyst arrangement with two kink regions.

[0133] Fig. 11 shows a three-dimensional representation of a layer of the catalyst arrangement according to Fig. 10 in a bent state.

[0134] Fig. 12 shows a two-dimensional sectional view of a support material and filter material formed in front of the support material.

[0135] Fig. 13 shows a two-dimensional sectional view of a support material and filter material formed behind the support material.

[0136] Fig. 14 shows a two-dimensional sectional view of a carrier material with filter material formed in front of and behind the carrier material.

[0137] Fig. 15 shows a two-dimensional sectional view of a filter material with support material formed in front of and behind the filter material. PC 25 1136 C 26 / 39 30 July 2025

[0138] Figures 1 and 2 show a catalyst assembly, designated as a whole by 1, in a top view (Figure 1) and a bottom view (Figure 2). In the exemplary embodiments, the catalyst assembly 1 has a multilayer support structure 2 manufactured by an additive manufacturing process. This support structure consists of a hydrogen peroxide-resistant and ozone-resistant support material 8, provided with an adhesion promoter 7 (here mixed), and a catalyst 9 applied to the support material 8, in this case coated after additive manufacturing. The adhesion promoter 7 is metallurgically bonded to the catalyst 9.

[0139] In the illustrated embodiments, the catalyst 9 is formed from a metal oxide, but is not limited to this. The same applies to the adhesion promoter 7 and the support material 8, which in the illustrated embodiments form a multi-component material.

[0140] In the illustrated embodiments, the support structure 2 of the catalyst arrangement 1 is additively manufactured such that a homogeneous and uniform bond exists between the adhesion promoter 7 and the support material 8. For this purpose, the adhesion promoter 7 is added to the support material 8 before and / or during additive manufacturing, for example, during a fused deposition modeling (FDM) process, a resin printing process, and / or a selective laser sintering (SLS) process.

[0141] To achieve good dimensional stability, the support structure 2 is clamped in a frame 24. Furthermore, the support structure 2 of the catalyst arrangement 1 has a pattern 27, which is created by a linear

[0142] The filament structure 10 of the existing layer 11 (see Fig. 3) to PC 25 1136 C 27 / 39 July 30, 2025 is superimposed 15 at least on a subsequent layer 11' (see Fig. 3 ff.). It can therefore be said that the support structure 2 is formed in multiple layers during additive manufacturing by linear filament structures 10 of the support material 8, with each layer 11 being deposited offset from the others.

[0143] Fig. 3 shows a two-dimensional schematic representation of a controlled containment 5, which in this embodiment is designed as an insulator 6. Components and functional units that are functionally and / or structurally similar or identical to those in the preceding embodiments are designated with the same reference numerals and are not described separately again.

[0144] It can be seen that the catalyst arrangement 1 is designed as part of an air treatment device 22 within the controlled containment 5, or the insulator 6. Thus, a flowing gas 20 or fluid stream 23, which in turn contains decontamination residues 3 (in the illustrated embodiment, hydrogen peroxide 4) from the controlled containment 5, is passed over the catalyst arrangement 1 by the air treatment device 22 and broken down by reaction of the decontamination residues 3 with the catalyst 9 of the support structure 2, as specified in the description for Fig. 7.

[0145] Furthermore, a cross-section 17 of the support structure 2 of the catalyst arrangement 1 is shown, including the layers 11, 11' and the surfaces 12 of the support structure 2. These surfaces

[0146] 12 are chemically treated after the additive manufacturing of the support structure 2 in such a way that the adhesion promoter 7, which, as already mentioned in PC 25 1136 C 28 / 39 30 July 2025, is added to the support material 8, is exposed and thus increases the surface roughness of the support material 8.

[0147] Fig. 4 and Fig. 5 show, in contrast to the preceding embodiment, a three-dimensional cross-section 17 (Fig. 4) of the support framework 2 of the catalyst arrangement 1 consisting of the linear filament structures 10, as well as a more detailed representation of the pattern 27 of the support framework 2.

[0148] In the illustrated embodiment, it is again clearly visible that an offset 16 is formed between the layers 11, 11' by the intersecting superposition 15 of these layers 11, 11', resulting in the formation of channels 18, here baffle-like channels 18', in each cross-section 17 of the catalyst arrangement, through which the gas 20, or the fluid flow 23, shown in Fig. 3, flows. It is further evident that the sign of the offset 16 of the layers 11, 11' reverses at least once along the cross-section 17.

[0149] The channels 18, 18' of the support structure 2 exhibit, as further illustrated in the embodiment according to Fig. 7, changes of direction 21 along the flow direction 19 of the gas 20 flowing through the channels 18, 18', in the embodiment shown changes of direction 21 of at least 80°.

[0150] Furthermore, Figures 4 and 5 show meshes 14 formed by the filament structure 10. The meshes 14 are characterized by their individually selectable mesh width 25, the individually selectable mesh spacing 26, and / or by the offset 16 of the meshes 14. These dimensions of the meshes 14, as well as at least one PC 25 1136 C 29 / 39 30 July 2025

[0151] The dimensions of the planes 13 shown in Fig. 6, formed by the layers 11, 11', allow for the adjustment of a desired degradation rate and / or pressure drop of the fluid flow 23 (compare Figs. 3 and 7) guided through the support structure 2 of the catalyst assembly 1. In the illustrated embodiment, the offset 16 of a unidirectional mesh 14 is 200 pm, the mesh width 25 and the mesh spacing 26 are 400 pm, but are not limited to these individually selected dimensions.

[0152] In contrast to the preceding embodiments, Fig. 6 shows an exploded view of a catalyst arrangement with 10 levels 13, each level 13 being formed by a layer 11. In the embodiment shown, the height of a level is 200 pm.

[0153] Finally, Fig. 7 shows a two-dimensional representation of a cross-section 17 of the support structure 2 of the catalyst assembly, in which baffle-like channels 18' are formed by the offset 16 of the layers 11, 11'. A fluid stream 23, or a flowing gas 20, flows through these baffle-like channels 18' along a flow direction 19 as part of a recirculation and / or exhaust air process (see Fig. 3). This flowing gas 20, or the fluid stream 23, undergoes changes in direction 21 due to the offset 16 of the layers 11, 11', thereby ensuring that the fluid stream 23 containing the decontamination residues 3 (see Fig. 3) always contacts the support structure 2. Thus, these decontamination residues 3, such as hydrogen peroxide 4, as already mentioned in the description of Fig. 3, are produced due to the reaction of the decontamination residues 3 with the catalyst 9 (see Fig.3) , which is applied to the carrier material 8 of the support structure 2 provided with the bonding agent 7, is removed. PC 25 1136 C 30 / 39 30 July 2025.

[0154] Fig. 8 shows a three-dimensional representation of a layer 11 of the catalyst arrangement 1. In the embodiment shown, the layer 11 has three bending areas 18, over which the layer 11 can be bent after additive manufacturing, as shown schematically in Fig. 9.

[0155] It can therefore be said that a layer 11, which has a filtering effect and / or a catalytic effect, is produced in an additive process, wherein at least one kinking area 28, here three kinking areas 28 in the form of folds 29, are formed and wherein the layer 11 is kinked in the kinking area according to the additive process, as illustrated in Fig. 9.

[0156] Furthermore, at least one connection area 31 is formed on layer 11 for the, in particular modular, linking of several layers 11, 11'.

[0157] Figs. 10 and 11, in contrast to the embodiments according to Figs. 8 and 9, show a layer 11 with only one bending area 28.

[0158] Figs. 12-15 show a schematic, two-dimensional sectional view of a materially bonded connection between a filter material 30 and the support material 8.

[0159] Fig. 12 shows that the carrier material 8 is placed and / or applied behind the filter material 30. Fig. 13 shows that the carrier material 8 is placed and / or applied in front of the filter material 30. Fig. 14 shows that the filter material 30 is applied and / or placed both in front of and behind the carrier material 8. Fig. 15 shows that the carrier material 8 is applied and / or applied both in front of and behind the filter material 30. PC 25 1136 C 31 / 39 30 . July 2025

[0160] In exemplary embodiments not shown, the catalyst arrangement 1 is manufactured together with a frame 24 and / or a connection that defines a connection interface for various components. Furthermore, in an exemplary embodiment not shown in detail, the support structure 2 is connected to the frame 24 via a fluid-tight, in particular gas-tight, connection and / or clamped in the frame 24.

[0161] According to the invention, in a method for producing a catalyst assembly 1 comprising a support structure 2, wherein the catalyst assembly 1 is designed for the degradation of decontamination residues 3, in particular hydrogen peroxide 4, in a controlled containment 5, in particular an insulator 6, it is proposed that the support structure 2 of the catalyst assembly 1 is additively manufactured, wherein the support structure 2 consists of a support material 8 provided with an adhesion promoter 7, in particular homogeneously and / or uniformly mixed, wherein the support structure 2 of the catalyst assembly 1 is formed from layers 11, 11' consisting preferably of linear filament structures 10, wherein each layer 11 is superimposed on a subsequent layer 11' in a crosswise manner 15, and wherein the catalyst assembly 1 is designed in particular as a component of an air preparation device 22.

[0162] / Reference list PC 25 1136 C 32 / 39 30 July 2025

[0163] Reference symbol list

[0164] 1 Catalyst arrangement

[0165] 2 support frame

[0166] 3 decontamination residues

[0167] 4 Hydrogen peroxide

[0168] 5 Containment

[0169] 6 I solator

[0170] 7 liability mediators

[0171] 8 Carrier material

[0172] 9 catalyst

[0173] 10 Filament structure

[0174] 11 shift

[0175] 11 ' subsequent shift

[0176] 12 surface

[0177] Level 13

[0178] 14 stitches

[0179] 15 intersecting superimpositions

[0180] 16 Offset

[0181] 17 Cross section

[0182] 18 channels

[0183] 18 'harassing canals

[0184] 19 Flow direction

[0185] 20 flowing gas

[0186] 21. Change of direction

[0187] 22 Air preparation device

[0188] 23 Fluid flow

[0189] 24 frames

[0190] 25 mesh width

[0191] 26 mesh spacing

[0192] 27 patterns

[0193] 28 Folding area

[0194] 29 folds

[0195] 30 filter materials

[0196] 31 Connection area claims

Claims

PC 25 1136 C 33 / 39 July 30, 2025 Claims 1. Method for producing a catalyst arrangement (1) comprising a support structure (2), wherein the catalyst arrangement (1) is used for the degradation of decontamination residues (3) , in particular hydrogen peroxide (4) and / or ozone, in a controlled containment (5) , in particular an insulator (6) , characterized in that the support structure (2) of the catalyst arrangement (1) is additively manufactured by a support material (8) provided with an adhesion promoter (7), in particular a mixed, carrier material (8).

2. Method according to the preceding claim, characterized in that a connection, in particular a materially bonded connection, between adhesion promoter (7) and carrier material (8) is homogeneous and / or uniform and / or that the adhesion promoter (7) is added to the carrier material (8) before and / or during the additive process.

3. Method according to one of the preceding claims, characterized in that the additive manufacturing process by which the support structure (2) is formed is a fused deposition modeling process and / or a resin printing process and / or a selective laser sintering process and / or that the support material (8) is coated with a catalyst (9) after additive manufacturing.

4. Method according to one of the preceding claims, characterized in that the adhesion promoter (7) is bonded to the catalyst (9) and / or that the support structure (2) is formed multilayered during additive manufacturing by linear filament structures (10) of the support material (8), in particular wherein PC 25 1136 C 34 / 39 30 July 2025 at least two layers (11) are applied offset from each other and / or each layer (11) is applied offset from each other and / or from at least a preceding and / or subsequent layer (11').

5. Method according to one of the preceding claims, characterized in that a surface (12) of the carrier material (8) is chemically treated after production in such a way that the adhesion promoter (7) added to the carrier material (8) is exposed.

6. Method for producing a catalyst arrangement (1) according to the preamble of claim 1 or according to one of the preceding claims, characterized in that, in order to adjust a desired degradation rate and / or pressure drop of a fluid flow (23) containing the decontamination residues (3) and passing through the catalyst arrangement (1), a measure for at least one plane (13) and / or at least one mesh (14) is individually selected.

7. Method for producing a catalyst arrangement (1) , in particular according to the preamble of claim 1 or according to one of the preceding claims, wherein a layer (11) having a filtering effect and / or catalytic effect is produced in an additive process, wherein at least one kink region (28) is formed and wherein the layer (11) is kinked in the kink region (28) according to the additive process.

8. Method for producing a catalyst arrangement (1) according to one of the preceding claims, characterized in that at least one connection area (31) for the, in particular modular, linking of several layers (11, 11') is formed on the layer (11). PC 25 1136 C 35 / 39 30 July 2025 and / or that the catalyst assembly (1) is manufactured together with a frame (24) and / or a connector.

9. Method for producing a catalyst arrangement (1) according to the preamble of claim 1 or according to one of the preceding claims, characterized in that the support structure (2) is formed from a support material (8) and is metallurgically connected to a filter material (30).

10. Method according to one of the preceding claims, characterized in that the carrier material (8) is additively applied to the filter material (30) and / or that the filter material (30) is placed on the or an additively manufactured carrier material (8).

11. Catalyst arrangement (1) comprising a preferably multilayer support structure (2) formed from a support material (8) provided with an adhesion promoter (7), in particular a mixture thereof, and a catalyst (9) applied to the support material (8), characterized in that the support structure (2) of the catalyst arrangement (1) is produced in an additive process, in particular according to claim 1 and / or that a layer (11) of the support structure (2) consisting of a preferably linear filament structure (10) is superimposed (15) in a crosswise manner to at least one subsequent layer (11').

12. Catalyst arrangement (1) according to the preceding claim directed to a catalyst arrangement (1), characterized in that the intersecting superposition (15) creates an offset (16) of the layers (11, 11'), whereby channels (18) are formed in each cross-section (17) of the catalyst arrangement (1), in particular baffle-like channels (18) PC 25 1136 C 36 / 39 July 30, 2025 channels (18') , form and / or that differently superimposed and / or offset layers (11, 11') are formed at least sectionally congruent and thereby form a starting layer (11'').

13. Catalyst arrangement (1) according to one of the preceding claims directed to a catalyst arrangement (1), characterized in that the support structure (2) forms channels (18) which have changes of direction (21) along a flow direction (19) of a gas (20) flowing through the channels (18), preferably changes of direction (21) of at least 80°, in particular at least 90°, and / or that a sign of the offset (16) of the layers (11, 11') along the cross-section (17) is reversed at least once.

14. Catalyst arrangement (1) according to one of the preceding claims directed to a catalyst arrangement (1), characterized in that the support material (8) is reactance-resistant, preferably hydrogen peroxide-resistant and / or ozone-resistant, and / or that the adhesion promoter (7) and the support material (8) form a multi-component material.

15. Catalyst arrangement (1) according to one of the preceding claims directed to a catalyst arrangement (1), characterized in that the support structure (2) is manufactured by means of fused deposition modeling and / or resin printing and / or selective laser sintering printing and / or that the support material (8) of the support structure (2) is coated with the catalyst (9) and / or that the catalyst (9) is a metal oxide, in particular a manganese oxide . PC 25 1136 C 37 / 39 July 30, 2025 16. Catalyst arrangement (1) according to one of the preceding claims directed to a catalyst arrangement (1), characterized in that the adhesion promoter (7) increases a surface roughness of the support material (8) and / or that at least one layer (11, 11') forms a connection area (31).

17. Catalyst arrangement (1) according to one of the preceding claims directed to a catalyst arrangement (1), characterized in that the support structure (2) is connected to a frame (24) and / or clamped in the frame (24) and / or that the catalyst arrangement (1) is connected to the frame (24) via a fluid-tight, in particular gas-tight, connection.

18. Catalyst arrangement (1) according to the preamble of claim 11 or according to one of the preceding claims, characterized in that an additively produced layer (11) that has a filtering effect and / or catalytic effect forms at least one kink region (28).

19. Catalyst arrangement (1) according to the preamble of claim 11 or according to one of the preceding claims, characterized in that the support structure (2) is formed from a support material (8) and is metallurgically connected to a filter material (30).

20. Catalyst arrangement according to one of the preceding claims, characterized in that the support material (8) is additively applied to the filter material (30) and / or that the filter material (30) is placed on the additively manufactured carrier material (8).

21. Use of a catalyst arrangement (1) according to one of the PC 25 1136 C 38 / 39 July 30, 2025 Claims 11 to 20 for the degradation of decontamination residues (3), in particular for the degradation of hydrogen peroxide (4) and / or ozone, within a controlled containment (5), in particular an isolator (6) and / or a sterilization device, in particular an electron beam sterilization device, during a recirculating air and / or exhaust air process.

22. Air preparation device (22) comprising a catalyst arrangement (1) according to one of claims 11 to 20, characterized in that the air preparation device (22) is configured to pass a fluid stream (23) containing decontamination residues (3), in particular a fluid stream (23) containing hydrogen peroxide (4), through the catalyst arrangement (1) during a recirculation and / or exhaust air process. / Summary

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