# US 11,078,821 B2 · Catalytic composite

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- Number: US 11,078,821 B2
- Document ID: US11078821B2
- Status: Granted
- Kind: B2
- Application number: 16/869,296
- Filed: 2020-05-07
- Published: 2020-08-20
- Granted: 2021-08-03
- Earliest claimed: 2017-11-17
- Assignees: W. L. Gore & Associates, Inc.
- Applicants: W. L. Gore & Associates, Inc.
- Inventors: Robert Eves; Tarun Poddar; John A. Tomanovich
- Web page: https://patentgrep.com/patent/US11078821B2

## CPC

- B01D 69/1213: {Laminated layers}
- B01D 67/0025: {by mechanical treatment, e.g. pore-stretching}
- B01D 67/00791: {Different components in separate layers}
- B01D 67/00793: {Dispersing a component, e.g. as particles or powder, in another component}
- B01D 69/02: characterised by their properties
- B01D 69/1071: {Woven, non-woven or net mesh}
- B01D 69/1216: {Three or more layers}
- B01D 69/145: {containing embedded catalysts}
- B01D 69/148: {Organic/inorganic mixed matrix membranes}
- B01D 71/022: {Metals}
- B01D 71/024: {Oxides}
- B01D 71/36: Polytetrafluoroethylene
- B01J 31/06: containing polymers {(organometallic polymers B01J31/123; polymer-bound organometallic complexes B01J31/165; coordination polymers B01J31/1691)}
- F01N 3/105: {General auxiliary catalysts, e.g. upstream or downstream of the main catalyst}
- F01N 3/2835: {fibrous}
- F01N 3/2839: {Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration}
- F01N 3/2892: {Exhaust flow directors or the like, e.g. upstream of catalytic device}
- B01D 67/0027: {by stretching}
- B01D 71/025: {Aluminium oxide}
- B01D 2325/0283: Pore size
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16)

## Abstract

A catalytic composite is formed of a catalytic layered assembly including a porous catalytic fluoropolymer film and one or more felt batts connected with the porous catalytic fluoropolymer film. At least one felt batt is positioned adjacent the upstream side of the porous catalytic fluoropolymer film to form the catalytic composite. The fluoropolymer film is perforated to allow for enhanced airflow therethrough while retaining the capability of catalyzing the reduction or removal of chemical species in fluid flowing through the catalytic composite.

## Claims

### Claim 1

A catalytic composite, comprising:
a catalytic layered assembly comprising:
a porous catalytic fluoropolymer film having an upstream side and a downstream side,
wherein the porous catalytic fluoropolymer film includes a material comprising pores; and one or more felt batts comprising a first felt batt positioned adjacent the upstream side of the porous catalytic fluoropolymer film;
wherein the porous catalytic fluoropolymer film comprises a plurality of perforations,
wherein each of the plurality of perforations is a straight passageway from an entrance surface at the upstream side of the porous catalytic fluoropolymer film to an exit surface at the downstream side of the porous catalytic fluoropolymer film,
i) wherein the straight passageway is configured to enhance flow therethrough as compared to flow via the pores of the material, and
ii) wherein the straight passageway has a diameter of 0.1 mm to 3 mm;
wherein a percent open area of the porous catalytic fluoropolymer film is from 0.14% to 50%.

### Claim 2 (depends on 1)

The catalytic composite of claim 1, wherein the one or more felt batts comprises fleece wherein the fleece comprises PTFE staple fiber.

### Claim 3 (depends on 1)

The catalytic composite of claim 1, wherein the catalytic layered assembly is connected together by the plurality of perforations.

### Claim 4 (depends on 1)

The catalytic composite of claim 1, further comprising a porous protective layer disposed on an upstream side of the first felt batt, wherein the porous protective layer is configured to block particulate ingress.

### Claim 5 (depends on 1)

The catalytic composite of claim 1, wherein the porous catalytic fluoropolymer film comprises an expanded polytetrafluoroethylene (ePTFE) film.

### Claim 6 (depends on 1)

The catalytic composite of claim 1, wherein the porous catalytic fluoropolymer film comprises catalytic particles suspended in an ePTFE matrix.

### Claim 7 (depends on 1)

The catalytic composite of claim 1, wherein the one or more felt batts comprises a fluoropolymer.

### Claim 8 (depends on 1)

The catalytic composite of claim 1, wherein the catalytic composite has an air permeability corresponding to a flow rate in the range of 0.6 to 21.3 m/min at 124.5 Pa.

### Claim 9 (depends on 1)

A filter comprising the catalytic composite of claim 1.

### Claim 10 (depends on 1)

The catalytic composite of claim 1, wherein the porous catalytic fluoropolymer film has a perforation density of 1 to 64 perforations per cm2 of the porous catalytic fluoropolymer film.

### Claim 11 (depends on 1)

The catalytic composite of claim 1, wherein the porous catalytic fluoropolymer film has a perforation density of 185 to 558 perforations per cm2 of the perforated porous catalytic fluoropolymer film.

### Claim 12 (depends on 1)

The catalytic composite of claim 1 comprising two or more felt batts, the two or more felt batts comprising: the first felt batt positioned adjacent the upstream side of the porous catalytic fluoropolymer film; and a second felt batt positioned on a downstream side of the porous catalytic fluoropolymer film.

### Claim 13 (depends on 12)

The catalytic composite of claim 12, further comprising a scrim positioned on the downstream side of the porous catalytic fluoropolymer film between the porous catalytic fluoropolymer film and the second felt batt.

### Claim 14 (depends on 13)

The catalytic composite of claim 13, wherein the scrim is perforated and comprises the plurality of perforations.

### Claim 15 (depends on 13)

The catalytic composite of claim 13, wherein the first felt batt and the scrim are perforated and comprise the plurality of perforations.

### Claim 16 (depends on 1)

The catalytic composite of claim 1, wherein multiple layers of the catalytic composite are perforated and comprise the plurality of perforations.

### Claim 17 (depends on 1)

The catalytic composite of claim 1, wherein the first felt batt is perforated and comprises the plurality of perforations.