Ceramic catalytic filter, filtering system including the same, and manufacturing method thereof

Patent metadata

Field	Value
Publication number	US-12569830-B2
Application number	US-202117460609-A
Country	US
Kind code	B2
Filing date	Aug 30, 2021
Priority date	Mar 19, 2021
Publication date	Mar 10, 2026
Grant date	Mar 10, 2026

Abstract

A ceramic catalyst filter, a filtering system including the same, and a method of manufacturing the same. The ceramic catalyst filter includes: a single body ceramic filter including a first surface for blocking a first material and a second surface for removing the second material passing through the first surface; and a photocatalyst thin film including nanometer-scale grains coated on a surface of the ceramic filter.

First claim

What is claimed is:

1 . A method of manufacturing a ceramic catalyst filter comprising a single body ceramic filter comprising a first surface for blocking a first material and a second surface for removing a second material passing through the first surface, and a photocatalyst thin film comprising nanometer-scale grains coated on a surface of the ceramic filter, the method comprising:
preparing a coating solution comprising a self-assembly polymer and a photocatalyst precursor; coating the ceramic filter with the coating solution by dipping the ceramic filter in the coating solution; and drying and then heat-treating the ceramic filter coated with the coating solution, wherein the drying is performed in a vacuum oven at a temperature of 70 to 100° C.

2 . The method of claim 1 ,
wherein the self-assembly polymer self-assembles to form a nano arrangement structure after being coated on the ceramic filter.

3 . The method of claim 1 ,
wherein the self-assembly polymer comprises: i) a copolymer comprising a polyethylene oxide block, a polypropylene oxide block, a polystyrene block, a polybutylene block, or a combination thereof; ii) a polymer comprising an acrylate polymer, a cellulose polymer, polystyrene, or a combination thereof; or iii) a combination thereof.

4 . The method of claim 1 ,
wherein the self-assembly polymer comprises a polyethylene oxide-polypropylene oxide block, a polyethylene oxide-polypropylene oxide-polyethylene oxide block, a polypropylene oxide-polyethylene oxide-polypropylene oxide block, a polystyrene-polyethylene oxide-polystyrene block, a polystyrene-polybutylene-polystyrene block, or a combination thereof.

5 . The method of claim 1 ,
wherein the dipping of the ceramic filter is performed using a one-pot method.

6 . The method of claim 1 ,
wherein the heat-treating is performed in a furnace at a temperature of 400 to 800° C.

7 . A ceramic catalyst filter manufactured according to the method of claim 1 ,
wherein the nanometer-scale grains have assembled nano-alignment structure.

8 . The ceramic catalyst filter of claim 7 , wherein the nanometer-scale grains form a worm-like alignment structure.

9 . The ceramic catalyst filter of claim 7 , wherein the nanometer-scale grains have an average grain size of about 1 nanometer to about 1,000 nanometers.

10 . The ceramic catalyst filter of claim 7 ,
wherein the photocatalyst thin film has a specific surface area of about 1 to about 300 square meters per gram, pores having a diameter of about 1 to about 100 nanometers, and a pore volume in a range of about 1×10 −3 to about 1 cubic centimeters per gram.

11 . The ceramic catalyst filter of claim 7 ,
wherein the photocatalyst thin film comprises a metal oxide photocatalyst.

12 . The ceramic catalyst filter of claim 11 ,
wherein the metal oxide photocatalyst comprises TiO 2 , WO 3 , BiVO 4 , ZnO, SiO 2 , BaTiO 3 , Fe 2 O 3 , Fe 3 O 4 , or a combination thereof.

13 . The ceramic catalyst filter of claim 11 ,
wherein the photocatalyst thin film further comprises a cocatalyst for improving photolysis characteristics or pyrolysis characteristics of the metal oxide photocatalyst, wherein the cocatalyst comprises: i) a metal compound capable of performing an oxygen generation reaction or an oxygen reduction reaction; ii) a metal compound capable of performing an oxidation reaction at about 200° C. or less; or iii) a combination thereof.

14 . The ceramic catalyst filter of claim 13 ,
wherein the cocatalyst comprises CoO x wherein 0<x<2, MnO 2 , ZnO 2 , BiOBr, BiOI, Au oxide, Ag oxide, Ir oxide, Rh oxide, Pt oxide, Ce oxide, Cu, Co, Ni, Mn, Fe, Al, Si, a noble metal, or a combination thereof.

15 . The ceramic catalyst filter of claim 7 ,
wherein the single body ceramic filter is porous.

16 . The ceramic catalyst filter of claim 7 ,
wherein the first surface and the second surface of the single body ceramic filter comprise surfaces that are parallel to each other.

17 . The ceramic catalyst filter of claim 7 ,
wherein the single body ceramic filter comprises: a plurality of first grooves each having an inlet at a first side of the ceramic filter through which the first and second materials enter; and a plurality of second grooves each having an inlet at a second side of the ceramic filter through which the second material is discharged.

18 . The ceramic catalyst filter of claim 17 ,
wherein a bottom of each of the second grooves is between the inlets of adjacent first grooves, and a bottom of each of the first grooves is between the inlets of adjacent second grooves.

19 . The ceramic catalyst filter of claim 17 ,
wherein bottoms of the first grooves have a structure for blocking the second material.

20 . The ceramic catalyst filter of claim 17 ,
further comprising a wall between the first grooves and the second grooves wherein the wall between the first grooves and the second grooves has air permeability, and the wall is configured to allow the second material to permeate therethrough.

21 . The ceramic catalyst filter of claim 7 ,
wherein the first material comprises fine dust, and the second material comprises a volatile organic compound.

22 . A filtering system comprising:
the ceramic catalyst filter according to claim 7 ; and an energy supply source arranged in the ceramic catalyst filter to supply energy for catalyst activation.

23 . The filtering system of claim 22 ,
wherein the energy supply source is configured to supply photo energy, electric energy, ion energy, thermal energy, or a combination thereof.

24 . A method of manufacturing a ceramic catalyst filter comprising a single body ceramic filter comprising a first surface for blocking a first material and a second surface for removing a second material passing through the first surface, and a photocatalyst thin film comprising nanometer-scale grains coated on a surface of the ceramic filter, the method comprising:
preparing a coating solution comprising a self-assembly polymer and a photocatalyst precursor; coating the ceramic filter with the coating solution by dipping the ceramic filter in the coating solution; and drying and then heat-treating the ceramic filter coated with the coating solution, wherein the self-assembly polymer is a block copolymer comprising 50 to 90 weight percent of a polyethylene oxide block and 10 to 50 weight percent, of a polypropylene oxide block, each based on a total weight of the block copolymer.

25 . A ceramic catalyst filter comprising:
a single body ceramic filter comprising a first surface for blocking a first material and a second surface for removing a second material passing through the first surface; and a photocatalyst thin film comprising nanometer-scale grains coated on a surface of the ceramic filter, wherein the photocatalyst thin film comprises a self-assembly polymer comprising a block copolymer comprising 50 to 90 weight percent of a polyethylene oxide block and 10 to 50 weight percent, of a polypropylene oxide block, each based on a total weight of the block copolymer.

Assignees

• Samsung Electronics Co Ltd

Inventors

• Kuk Sukeun
• Koo Minseok
• Kwon Hyukjae
• Yang Dongsik
• Oh Sehyeong
• Lee Hyun Chul
• Ji Sangmin

Classifications

• B01J2235/15

  X-ray diffraction · CPC title

• B01J35/45

  Nanoparticles · CPC title

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title

• B01J35/651

  50-500 nm · CPC title

• B01J35/647

  2-50 nm · CPC title