# US 11,896,967 B2 · Large particle, high performance catalytic tape > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,896,967 B2 - Document ID: US11896967B2 - Status: Granted - Kind: B2 - Application number: 17/594,180 - Filed: 2020-04-09 - Published: 2022-07-07 - Granted: 2024-02-13 - Earliest claimed: 2019-04-12 - Assignees: W. L. Gore & Associates, Inc. - Applicants: W. L. Gore & Associates, Inc. - Inventors: Jeffrey A. Knopf; Franz J. Shelley; Zhuonan Song - Web page: https://patentgrep.com/patent/US11896967B2 ## CPC - B01D 53/865: {characterised by a specific catalyst} - B01J 35/59: Membranes - B01D 53/8628: {Processes characterised by a specific catalyst} - B01D 53/9413: {Processes characterised by a specific catalyst} - B01D 53/945: {characterised by a specific catalyst} - B01J 21/063: {Titanium; Oxides or hydroxides thereof} - B01J 23/22: Vanadium - B01J 31/06: containing polymers {(organometallic polymers B01J31/123; polymer-bound organometallic complexes B01J31/165; coordination polymers B01J31/1691)} - B01D 2255/20723: Vanadium - B01D 2255/902: Multilayered catalyst - B01D 2255/915: Catalyst supported on particulate filters - B01D 2255/9202: Linear dimensions - B01D 2255/9205: Porosity - B01D 2255/9207: Specific surface - B01D 2258/02: Other waste gases - B01J 35/50: characterised by their shape or configuration - B01J 2235/30: Scanning electron microscopy; Transmission electron microscopy - Y02T 10/12: Improving ICE efficiencies - 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 - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract The present disclosure is directed to a catalytic composite that comprises porous supported catalyst particles durably enmeshed in a porous fibrillated polymer membrane. The supported catalyst particles are composed of at least one metal or metal oxide catalyst dispersed on a porous support substrate. In some embodiments, the porous fibrillated polymer membrane is perforated or otherwise contains mechanically formed holes therein. The supported catalyst particles have a large particle population based, at least in part, a d90 value greater than 100 microns. The catalytic membrane composite may be used in filtration applications to remove air polluting substances such as Sox, NOx, dioxin/furan, CO, and others and convert them into non-polluting or less-polluting gas components. Additionally, the catalytic article may be in the form of a filter bag, a honeycomb, a monolith or any other suitable geometrically structured forms. ## Claims ### Claim 1 A catalytic article comprising: a porous fibrillated polymer membrane that includes supported catalyst particles non-covalently immobilized within a node and fibril microstructure of the porous fibrillated polymer membrane, wherein the supported catalyst particles have a particle size distribution defined by a D90 value of at least 60 microns, wherein the porous fibrillated membrane includes supported catalyst particles in a range from about 30% to about 98%. ### Claim 2 (depends on 1) The catalytic article of claim 1, wherein the supported catalyst particles have a particle size distribution defined by a D90 value of at least 100 microns. ### Claim 3 (depends on 1) The catalytic article of claim 1, wherein a mean particle size of the supported catalyst particle is greater than or equal to 20 microns. ### Claim 4 (depends on 1) The catalytic article of claim 1, wherein the supported catalyst particles have a mean particle size greater than about 20 microns. ### Claim 5 (depends on 1) The catalytic article of claim 1, wherein the supported catalyst particles comprise at least one metal or metal oxide catalyst dispersed on a porous support substrate. ### Claim 6 (depends on 1) The catalytic article of claim 1, wherein the porous fibrillated polymer membrane has a porosity from about 20% to about 90%. ### Claim 7 (depends on 6) The catalytic article of claim 6, wherein at least 40% of the porosity comprises a pore size greater than 9 microns. ### Claim 8 (depends on 1) The catalytic article of claim 1, wherein the porous fibrillated polymer membrane comprises polytetrafluorethylene (PTFE), poly(ethylene-co-tetrafluoroethylene) (ETFE), ultra-high molecular weight polyethylene (UHMWPE), polyparaxylylene (PPX), polylactic acid, and any combination or blend thereof. ### Claim 9 (depends on 1) The catalytic article of claim 1, wherein the supported catalyst particles have a particle population with a D50 value of 7 microns or more. ### Claim 10 (depends on 1) The catalytic article of claim 1, wherein the porous fibrillated polymer membrane contains perforations therein. ### Claim 11 (depends on 1) The catalytic article of claim 1, wherein the catalytic article is in the form of a filter bag, a honeycomb, monolith or any other suitable geometrically structured forms. ### Claim 12 (depends on 1) The catalytic article of claim 1, wherein the supported catalyst particle is located throughout a thickness of the fibrillated polymer membrane. ### Claim 13 (depends on 1) A catalytic filter material comprising the catalytic article of claim 1. ### Claim 14 (depends on 1) A method to reduce NOx from a gas stream comprising: a) providing a gas stream comprising a concentration of NOx; and b) contacting the gas stream with the catalytic article of claim 1, whereby the NOx concentration is reduced. ### Claim 15 (depends on 1) The catalytic article of claim 1, wherein the supported catalyst particles have a particle size distribution defined by a D90 value from 60 microns to 500 microns.