# US 12,109,557 B2 · Catalyst module for removing harmful gas and manufacturing method therefor, catalyst system comprising same for removing harmful gas, harmful substance removing apparatus comprising catalyst module for removing residual ozone and manufacturing method therefor, and harmful substance removing system comprising same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,109,557 B2 - Document ID: US12109557B2 - Status: Granted - Kind: B2 - Application number: 18/007,064 - Filed: 2020-10-19 - Published: 2023-08-31 - Granted: 2024-10-08 - Earliest claimed: 2020-08-07 - Assignees: Korea Institute of Materials Science - Applicants: Korea Institute of Materials Science - Inventors: Joon Hwan Choi; Giyeong Kim - Web page: https://patentgrep.com/patent/US12109557B2 ## CPC - B01J 35/19: {Catalysts containing parts with different compositions} - B01D 53/86: Catalytic processes - B01D 53/88: Handling or mounting catalysts - B01J 21/04: Alumina - B01J 23/22: Vanadium - B01J 23/28: Molybdenum - B01J 23/40: of the platinum group metals - B01J 23/44: Palladium - B01J 23/48: Silver or gold - B01J 23/70: of the iron group metals or copper - B01J 35/33: Electric or magnetic properties - B01J 35/56: Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths - B01J 35/60: characterised by their surface properties or porosity - B01J 37/0217: {Pretreatment of the substrate before coating} - B01J 37/0228: {in several steps} - B01J 37/024: {Multiple impregnation or coating} - B01J 37/0244: {Coatings comprising several layers} - A61L 9/16: using physical phenomena - A61L 9/20: Ultraviolet radiation - B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS - 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) - A61L: METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES (preservation of bodies or disinfecting characterised by the agents employed A01N; preserving, e.g. sterilising, food or foodstuffs A23; preparations for medical, dental or toiletry purposes A61K) ## Abstract The present invention provides a catalyst module for removing harmful gas, wherein an oxidation reaction or reduction reaction of harmful gas is carried out in a self-heating heating carrier. According to an embodiment of the present invention, the catalyst module for removing harmful gas comprises: a heating carrier composed of an electrically heatable heating body, including one or more flow channels inside, and having a porous structure with pores; and a catalyst region formed on at least a portion of the surface of the heating carrier including the flow channels and containing a catalyst material for promoting a decomposition reaction of harmful gas passing through the flow channels, wherein the catalyst region comprises: a first catalyst layer having a first catalyst material loading amount in the pores of the heating carrier; and a second catalyst layer applied on the inner surface of the heating carrier. ## Claims ### Claim 1 A catalyst module for removing harmful gas, comprising: a heating carrier comprising an electrically heatable heating body, the heating carrier including one or more flow channels inside, and having a porous structure with pores; and a catalyst region formed on at least a portion of the surface of the heating carrier including the flow channels and containing a catalyst material for promoting a decomposition reaction of harmful gas passing through the flow channels, wherein the heating carrier includes a plurality of flow channels extending from one end to an opposite end thereof, wherein the one end of the flow channel is an inlet through which a fluid is introduced and the opposite end is an outlet through which the fluid is discharged, wherein the heating carrier has the resistance in the range of 0.5Ω to 500Ω, has a porosity in a range of 20% by volume to 70% by volume, and comprises SiC-based compound, wherein the catalyst region comprises: a first catalyst layer having a first catalyst material loading amount, the first catalyst layer formed in the pores of the heating carrier; and a second catalyst layer applied on an inner surface of the first catalyst layer formed in the pores of the heating carrier, second catalyst layer having a second catalyst material loading amount higher than the first catalyst material loading amount. ### Claim 2 (depends on 1) The catalyst module of claim 1, wherein the first catalyst material loading amount is in the range of greater than 0 g/L to 50 g/L. ### Claim 3 (depends on 1) The catalyst module of claim 1, wherein the second catalyst material loading amount is in the range of 10 g/L to 220 g/L. ### Claim 4 (depends on 1) The catalyst module of claim 1, wherein the first catalyst layer is applied on the inner surface of the heating carrier. ### Claim 5 (depends on 1) The catalyst module of claim 1, further comprising an electrode connected to a portion of the heating carrier. ### Claim 6 (depends on 1) The catalyst module of claim 1, wherein the first and second catalyst materials include a metal including at least one of Pt, Pd, Rh, Ru, Fe, Cu, Ni, Mn, Co, Ag, Au, V, Ti, or Mo, a compound containing one or more of the above metals, or an oxide containing one or more of the above metals. ### Claim 7 (depends on 1) The catalyst module of claim 1, wherein the first and second catalyst materials include at least one of MnO2, Mn2O3, MnO, Mn3O4, CeO2, TiO2, CuO, V2O5, ZnO, SnO2, SiO2, zeolite, or Al2O3. ### Claim 8 (depends on 7) The catalyst module of claim 7, wherein the first and second catalyst materials further include a doped element. ### Claim 9 (depends on 1) The catalyst module of claim 1, wherein the catalyst region further comprises a cocatalyst for accelerating catalytic activity and a binder for providing adhesion to the heating carrier. ### Claim 10 (depends on 1) A catalyst system for removing harmful gas, comprising: the catalyst module for removing harmful gas of claim 1; a power supply source configured to supply power to the catalyst module for removing harmful gas; and a power control unit configured to control a waveform of the power input from the power supply source to the catalyst module for removing harmful gas. ### Claim 11 (depends on 10) The catalyst system of claim 10, wherein the power control unit further comprises a temperature control module configured to receive a temperature of the catalyst module for removing harmful gas and control a power value or waveform of the power to be input to the catalyst module for removing harmful gas according to the received temperature. ### Claim 12 (depends on 1) A manufacturing method of a catalyst module for removing harmful gas of claim 1, comprising: providing a heating carrier composed of an electrically heatable heating body, including one or more flow channels therein, and having a porous structure with pores; forming a first catalyst layer filled in at least part of the pores of the heating carrier and having a first catalyst material loading amount; and forming a second catalyst layer applied on an inner surface of the heating carrier and having a second catalyst material loading amount higher than the first catalyst material loading amount, wherein the heating carrier includes a plurality of flow channels extending from one end to an opposite end thereof, wherein the one end of the flow channel is an inlet through which a fluid is introduced and the opposite end is an outlet through which the fluid is discharged, wherein the heating carrier has a resistance in the range of 0.5Ω to 500Ω, has a porosity in the range of 20% by volume to 70% by volume, and comprises SiC-based compound, wherein the forming of the first catalyst layer is performed by immersing the heating carrier in a first catalyst solution having the first catalyst material loading amount, wherein the forming of the second catalyst layer comprises coating an inner surface of the flow channel with a second catalyst solution by introducing the second catalyst solution having the second catalyst material loading amount and placed outside the flow passage into the flow channel using a pressure difference between the one end and the opposite end of the flow channel; and forming the second catalyst layer on the inner surface of the flow channel by drying the coated second catalyst solution. ### Claim 13 (depends on 1) A manufacturing method of a catalyst module for removing harmful gas of claim 1, comprising: providing a heating carrier composed of an electrically heatable heating body, including one or more flow channels therein, and having a porous structure with pores; filling at least a portion of the pores formed on an inner surface of the flow channel with a fluid; coating the inner surface of the flow channel with a catalyst solution by introducing the catalyst solution placed outside the flow channel into the flow channel by means of a pressure difference between one end and an opposite end of the flow channel; and forming a catalyst layer on the inner surface of the flow channel by drying coated catalyst solution, wherein the heating carrier includes a plurality of flow channels extending from the one end to the opposite end thereof, wherein the one end of the flow channel is an inlet through which a fluid is introduced and the opposite end is an outlet through which the fluid is discharged, wherein the heating carrier has a resistance in the range of 0.5Ω to 500Ω, has a porosity in the range of 20% by volume to 70% by volume, and comprises SiC-based compound.