3D-Printed Catalyst Filter for Hydrogen Peroxide Exhaust Breakdown
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing catalyst arrangements for decontamination residues in controlled environments, such as isolators, are complex and inefficient, leading to potential drug contamination and the need for materials resistant to decontamination agents.
Innovation Solution
A catalyst arrangement is produced using additive manufacturing with a support structure coated by an adhesion promoter, allowing for a homogeneous bond between the catalyst and support material, and featuring a multilayer design with staggered layers and channels to enhance contact with decontamination residues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing methods are used for catalyst arrangements, then the structure can be produced, but the manufacturing process is complex and the bond between catalyst and support material is insufficient
Solution Approach 1:
The patent applies additive manufacturing technology to produce the support structure with modified parameters including porous internal structure, staggered layer arrangement, and integrated channels. This manufacturing method simplifies production while creating complex geometries that enhance catalyst contact area and improve bond strength through material interlocking
Solution Approach 2:
The patent uses composite materials by coating the additively manufactured support structure with catalyst material. The support structure itself may incorporate multiple materials with different properties to achieve both mechanical strength and catalytic functionality, resolving the contradiction between manufacturing simplicity and structural complexity
2Productivity
If the catalyst contact area with decontamination residues is increased, then degradation efficiency improves, but the structural complexity and manufacturing difficulty increase
Solution Approach 1:
The patent employs a porous support structure manufactured by additive manufacturing, which provides high surface area for catalyst coating while maintaining structural integrity. The porous architecture increases contact area between decontamination residues and catalyst without requiring complex external structures
Solution Approach 2:
The patent utilizes three-dimensional staggered layer arrangement and internal channels created through additive manufacturing to maximize catalyst exposure to gas flow from multiple directions. This dimensional approach increases effective contact area without proportionally increasing external dimensions or manufacturing complexity
3Reliability
If materials resistant to decontamination agents are used throughout the system, then protection against corrosion is improved, but cost and material limitations increase
Solution Approach 1:
The patent applies corrosion-resistant properties locally where needed - the catalyst arrangement and support structure are designed to be resistant to decontamination agents like hydrogen peroxide and ozone, while other system components can use standard materials. This localized approach maintains reliability where critical while preserving material selection flexibility elsewhere
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method ensures efficient degradation of decontamination agents like hydrogen peroxide within isolators, allowing safe release of exhaust air and reducing the need for resistant materials, while maintaining structural integrity and enhancing contact area for effective residue removal.
Implementation Method 1
a support structure (2), wherein the support structure (2) consists of a support material (8) provided with an adhesion promoter (7)
Implementation Method 2
the catalyst arrangement (1) for the degradation of decontamination residues (3), in particular hydrogen peroxide (4)
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
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 (15) on a next layer (11') in a crosswise manner, and wherein the catalyst assembly (1) is designed in particular as a component of an air preparation device (22) (Fig. 1).