# US 2019/0314760 A1 · Filtration articles and methods of making and using the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0314760 A1 - Document ID: US20190314760A1 - Status: Published application - Kind: A1 - Application number: 16/343,921 - Filed: 2017-10-20 - Published: 2019-10-17 - Earliest claimed: 2016-10-20 - Assignees: Corning Incorporated - Applicants: Corning Incorporated - Inventors: Francis Martin Behan; Amit Halder; Benedict Yorke Johnson; Edward Zhmayev - Web page: https://patentgrep.com/patent/US20190314760A1 ## CPC - B01D 53/8668: {Removing organic compounds not provided for in B01D53/8603 - B01D53/8665} - B01D 2255/104: Silver - B01D 2255/2065: Cerium - B01D 2255/2073: Manganese - B01D 2257/708: Volatile organic compounds V.O.C.'s - B01D 2258/06: Polluted air - Y02A 50/20: Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters - 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) - Y02A: TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE ## Abstract A substrate including a conversion catalyst for removing a volatile organic compound from ambient air. The substrate includes at least one porous wall. The conversion catalyst is within the pores of the at least one substrate porous wall. ## Claims ### Claim 1 An article comprising: a honeycomb substrate comprising a plurality of porous partition walls defining a plurality of adjacent flow-through channels, the porous partition walls comprise a surface area from about 1500 m2/m3 to about 3000 m2/m3 and a porosity from about 45% to about 70%, a conversion catalyst within the pores of the porous partition walls of the honeycomb substrate, and the conversion catalyst removes a volatile organic compound from a target gas. ### Claim 2 (depends on 1) The article of claim 1 wherein 95 wt. % or more of the conversion catalyst is within the pores of the porous partition walls. ### Claim 3 (depends on 1) The article of claim 1 wherein less than 5 wt. % of the conversion catalyst is on the walls of the porous partition walls. ### Claim 4 (depends on 1) The article of claim 1, wherein at least one of the porous partition walls has a thickness of about 177 microns or greater between adjacent flow-through channels. ### Claim 5 (depends on 1) The article of claim 1, wherein the porous partition walls have a thickness from about 254 microns to about 635 microns between adjacent flow-through channels. ### Claim 6 (depends on 1) The article of claim 1, wherein the honeycomb substrate comprises cordierite, mullite, or combinations thereof. ### Claim 7 (depends on 1) The article of claim 1, wherein the conversion catalyst is essentially free of a precious metal or precious metal oxide. ### Claim 8 (depends on 1) The article of claim 1, wherein the honeycomb substrate includes from about 100 to about 400 flow-through channels per square inch. ### Claim 9 (depends on 1) The article of claim 1, wherein the pores within the porous partition walls have a mean pore size from about 10 microns to about 50 microns. ### Claim 10 (depends on 1) The article of claim 1, wherein the conversion catalyst has a mean particle size from about 20 microns to about 50 microns. ### Claim 11 (depends on 1) The article of claim 1, wherein the volatile organic compound is formaldehyde. ### Claim 12 (depends on 1) The article of claim 1, wherein the conversion catalyst comprises an oxide of at least one of: manganese, molybdenum, tin, cerium, scandium, titanium, vanadium, chromium, iron, cobalt, nickel, and combinations thereof. ### Claim 13 (depends on 1) The article of claim 1, wherein the porous partition walls include a porosity from about 35% to about 60% when the conversion catalyst is loaded within the pores of the porous partition walls. ### Claim 14 (depends on 1) The article of claim 1, wherein a cross-sectional area of the plurality of flow-through channels is from about 60% to about 90% of a total cross-sectional area of the honeycomb substrate. ### Claim 15 A formaldehyde filtration article comprising: a substrate comprising a plurality of porous partition walls defining a plurality of flow-through channels, the porous partition walls comprise a surface area, a formaldehyde conversion catalyst loaded within the pores of the porous partition walls of the substrate, the porous partition walls comprise a porosity when the catalyst is loaded within the pores of the porous partition walls, and wherein a ratio of the porosity of the porous partition walls when the catalyst is loaded within the pores of the porous partition walls to the surface area of the porous partition walls is greater than about 0.017. ### Claim 16 (depends on 15) The article of claim 15 wherein the porous partition walls include an unloaded porosity from about 45% to about 70% prior to loading with the conversion catalyst. ### Claim 17 (depends on 15) The article of claim 15 wherein the porous partition walls include a surface area from about 1500 m2/m3 to about 3000 m2/m3. ### Claim 18 (depends on 15) The article of claim 15, wherein at least 95 wt. % or more of the catalyst is within the pores of the porous partition walls of the substrate. ### Claim 19 (depends on 15) The article of claim 15, wherein less than 5 wt. % of the catalyst is on the walls and outside of the pores of the porous partition walls of the substrate. ### Claim 20 (depends on 15) The article of claim 15, wherein the catalyst comprises an oxide of at least one of: manganese, molybdenum, tin, cerium, and combinations thereof. ### Claim 21 (depends on 15, 16, 17, 18, 19, 20) The article of claim 15, claims 15-20 wherein the catalyst is essentially free of a precious metal or precious metal oxide. ### Claim 22 (depends on 15) The article of claim 15, wherein the pores within the porous partition walls have a mean pore size from about 10 microns to about 50 microns. ### Claim 23 (depends on 15) The article of claim 15, wherein the pores within at least one of the porous partition walls are tortuously interconnected to form at least one flow path through the wall. ### Claim 24 (depends on 15, 16, 17, 18, 19, 20, 21, 22, 23) The article of claim 15, claims 15-23 wherein the catalyst has a mean particle size from about 20 microns to about 50 microns. ### Claim 25 (depends on 15) The article of claim 15, wherein the porous partition walls have a thickness about 177 microns to about 635 microns between adjacent flow-through channels. ### Claim 26 (depends on 15) The article of claim 15, wherein the substrate includes from about 100 to about 400 flow-through channels per square inch of the cross-section of the substrate. ### Claim 27 (depends on 15) The article of claim 15, wherein the loaded porous partition walls include from about 0.01 to about 0.10 grams of catalyst per cubic centimeter of the substrate. ### Claim 28 (depends on 1) A method of making the article of claim 1 comprising: contacting the substrate with a precursor solution comprising a catalyst salt, and firing the contacted substrate to form a conversion catalyst within the pores of the porous partition walls. ### Claim 29 (depends on 1) A method of using the article of claim 1 comprising: contacting the article with a target gas to remove at least a portion of any formaldehyde from the target gas.