Porous Catalyst Membrane With Surface-Loaded Particles and Strong Adhesion
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Solution Overview
Problem
Existing catalyst-supporting films with high surface areas have limited catalytic effects due to reduced adhesion and increased fragility when attempting to increase the number of catalyst particles, leading to inefficient catalytic performance.
Innovation Solution
A catalyst-supporting porous film with unevenly distributed titanium oxide particles, forming a moth-eye structure, where the number of catalyst particles per unit volume is higher in a porous section than in a supporting section, enhancing catalytic effects while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of catalyst particles is increased to enhance catalytic effect, then the catalytic performance improves, but the adhesion between catalyst particles decreases leading to film fragility
Solution Approach 1:
The patent applies local quality by creating regions with different catalyst particle concentrations. The uneven distribution pattern ensures that catalyst-rich regions provide high catalytic activity while catalyst-sparse regions maintain adequate adhesion and structural integrity, thus resolving the contradiction between quantity and strength
Solution Approach 2:
The patent utilizes a porous film structure that provides three-dimensional space for catalyst particle distribution. This porous architecture allows high catalyst loading in certain pores while maintaining open pathways and structural connectivity, preventing film fragility even with increased catalyst particle quantity
2Area of moving object
If the surface area of the catalyst-supporting film is increased to enhance catalytic effect, then the catalytic performance improves, but the structural integrity and adhesion deteriorate
Solution Approach 1:
The patent transitions from two-dimensional surface area expansion to three-dimensional porous structure development. This dimensional change allows the film to achieve high effective surface area for catalysis while maintaining structural integrity through the interconnected porous framework that distributes mechanical stresses
3Productivity
If catalyst particles are uniformly distributed in the film, then the film structure remains simple, but the catalytic efficiency is limited due to insufficient surface presence
Solution Approach 1:
The patent employs preliminary action by using a phase-separated resin structure formed during the drying process to pre-establish regions that will attract and concentrate catalyst particles. This preliminary phase separation creates the uneven distribution pattern before catalyst application, enhancing catalytic efficiency without requiring complex post-processing
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 film achieves a high catalytic effect with increased surface area and improved adhesion, effectively degrading organic substances and preventing deterioration, suitable for air cleaning devices.
Implementation Method 1
Photocatalysts are capable of decomposition of organic substances and hydrophilization of a film surface
Data Source
AI summary
A catalyst-supporting porous film includes: a resin layer; and catalyst particles dispersed in the resin layer. The catalyst particles are unevenly distributed so as to be present at a surface of the resin layer. Preferably, the catalyst-supporting porous film includes a porous section and a supporting section for supporting the porous section. The number of catalyst particles per unit volume in the porous section is greater than the number of catalyst particles per unit volume in the supporting section. Thus, a catalyst-supporting porous film which has a high catalytic effect can be provided.