Ozone converters and methods of producing the same by additive manufaturing

A method for producing an ozone converter for an aircraft, comprising:

• performing an additive manufacturing process to produce a network structure of a core of the ozone converter, wherein the additive manufacturing process includes depositing a material layer-by-layer to form the network structure that has a three-dimensional (3D) self-supporting geometry, wherein the network structure includes a plurality of passage walls that define passages therebetween, wherein the passage walls of the network structure include concentric primary walls disposed about a common central axis of the network structure, wherein adjacent pairs of the primary walls define a fluid domain therebetween, wherein the primary walls have varying diameters between ends of the network structure;
• covering the passage walls of the network structure with a slurry to form a washcoat thereon;
• and
• impregnating the washcoat with a catalyst material to define the core of the ozone converter, wherein the catalyst material is configured to react with ozone to form oxygen,
• wherein the ozone converter includes a header assembly configured to receive a gas in an inlet thereof and expel the gas at an outlet thereof, and the core is disposed within the header assembly.

An ozone converter for an aircraft, comprising:

• a header assembly configured to receive a gas in an inlet thereof and expel the gas at an outlet thereof;
• and
• a single monolithic core disposed within the header assembly, wherein the core includes a network structure having a plurality of passage walls that define passages therebetween, wherein the core is configured to receive the gas within the passages thereof, wherein a catalyst material disposed on surfaces of the passage walls is configured to chemically react with the gas and thereby reduce a concentration of ozone in the gas as the gas passes through the passages, wherein the core is produced by an additive manufacturing process that deposits a material layer-by-layer to form the passage walls have a three-dimensional (3D) self-supporting geometry, wherein the passage walls of the network structure include concentric primary walls disposed about a common central axis of the core, wherein adjacent pairs of the primary walls define a fluid domain therebetween, wherein the primary walls have varying diameters between ends of the network structure, wherein the diameters of the primary walls are defined by limits of corresponding diametric functions, wherein the passage walls of the network structure include secondary walls extending between the adjacent pairs of the primary walls to subdivide the fluid domain therebetween and thereby define fluid passages, wherein the secondary walls vary in spacing and orientation relative to each other within the corresponding fluid domain and/or between fluid domains, wherein each of the secondary walls has varying radial positions between the ends of the network structure that are defined by corresponding radial functions.