Base Metal Catalyst Layer for Ozone and VOC Air Purification
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Solution Overview
Problem
Current aircraft cabin air catalyst converters rely on costly precious metals like palladium and platinum for ozone and VOC reduction, and existing ground-level pollution control methods are inefficient and costly, necessitating a more cost-effective and long-term solution for air purification.
Innovation Solution
A catalyst device with a base metal catalyst layer, comprising copper oxide and manganese oxide supported on a high surface area support material like ceria, is used to convert ozone and VOCs into less harmful compounds, reducing the reliance on precious metals and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precious metal catalysts (palladium and platinum) are used for ozone and VOC reduction, then catalytic performance is improved, but production cost increases significantly
Solution Approach 1:
The patent replaces expensive precious metal catalysts with base metal catalysts (such as copper, manganese, zinc, or iron oxides) that are significantly cheaper. While base metals may have shorter operational lifetimes compared to precious metals, they provide cost-effective catalytic performance for ozone and VOC reduction, making the system economically viable for widespread deployment in aircraft ECS and ground-level applications
Solution Approach 2:
The patent modifies the catalytic system by changing the material composition from precious metals to base metals, and adjusts operational parameters such as temperature ranges (50-200°C for ozone conversion) and catalyst formulation (combinations of metal oxides with supports like alumina or ceria) to optimize performance while reducing costs
2Ease of manufacture
If base metal catalysts are used instead of precious metals, then production cost is reduced, but long term performance stability may be compromised
Solution Approach 1:
The patent employs composite catalyst formulations combining multiple base metal oxides (e.g., copper oxide with manganese oxide, or zinc oxide with iron oxide) supported on high-surface-area materials like alumina, ceria, or titania. This composite structure enhances the stability and longevity of base metal catalysts by preventing metal sintering, maintaining active sites, and improving resistance to poisoning, thereby achieving long-term performance comparable to precious metal catalysts
Solution Approach 2:
The patent introduces support materials (alumina, ceria, titania) as intermediaries that stabilize the base metal catalyst particles, prevent aggregation, and maintain catalytic activity over extended periods. These supports act as mediators that protect the base metals from deactivation while enabling sustained catalytic performance for ozone and VOC conversion
3Object-affected harmful factors
If ground-level pollution control methods are used, then ozone treatment is achieved, but efficiency and cost-effectiveness are insufficient
Solution Approach 1:
The patent develops a universal base metal catalyst system that effectively treats multiple pollutants simultaneously - converting ozone to oxygen while also oxidizing volatile organic compounds (VOCs) to carbon dioxide and water. This multi-functional catalyst can be deployed in both aircraft environmental control systems and ground-level pollution control applications, providing efficient and cost-effective treatment for mixed pollutant streams that conventional single-function systems cannot handle
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
The base metal catalyst system effectively converts ozone and VOCs into oxygen and carbon dioxide, maintaining high performance over extended periods while reducing production costs, outperforming traditional precious metal catalysts in aircraft and ground-level applications.
Implementation Method 1
a catalyst layer disposed on the substrate. The catalyst layer includes a first base metal catalyst at a first mass percent, a second base metal catalyst at a second mass percent, and a support material impregnated with at least one of the first base metal catalyst or the second base metal catalyst
Implementation Method 2
The base metal catalyst system effectively converts ozone and VOCs into oxygen and carbon dioxide
Data Source
AI summary
Disclosed herein are base metal catalyst devices for removing ozone, volatile organic compounds, and other pollutants from an air flow stream. A catalyst device includes a housing, a solid substrate disposed within the housing, and a catalyst layer disposed on the substrate. The catalyst layer includes a first base metal catalyst at a first mass percent, a second base metal catalyst at a second mass percent, and a support material impregnated with at least one of the first base metal catalyst or the second base metal catalyst.