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Run your analysis now →https://www.patsnap.com/resources/blog/rd-blog/catalysis-and-reactor-design-structured-monolith-catalysts-patent-landscape-patent-landscape/ · Patsnap · data cut-off 2026-07-31 · downloaded from the live page
Patent Landscape · Catalysis & Reactor DesignStructured-Monolith Catalyst Patents: Who Holds the Claims
- Concentrated at the top. The five leading assignees account for 275 of 781 records in scope (35.2%), and the ten leading assignees for 399 (51.1%) — over half the field sits with a small group of filers.
- Filing has cooled sharply. Filings fell from 13 in 2021 to 1 in 2024, a 92% drop over that span, after a peak of 74 records in 2020 — publication lag means 2025-2026 figures will still fill in.
- B01J dominates, but hydrocarbon and emissions classes overlap heavily. 68.2% of records sit in B01J catalysis processes, while C07C, C01B, C10G and F01N each carry a substantial share, showing most filings straddle catalyst chemistry and downstream process application.
781
Published Records
35%
Top-5 Share of All Records
-92%
Filing Growth 2021→2024
US
Leading Jurisdiction
Filing growth compares 2021 (13 records) with 2024 (1) — a three-year span. 2024 is the most recent year we treat as complete: publication lags filing by roughly 18 months, so 2025 onwards are still filling in and any growth rate that ends there would understate the field. Top-5 share is the combined record count of the five largest assignees divided by all 781 records in scope (CR5), not by the ranked leaders only.
Published byPatsnap Research··7 min readSourced from Patsnap Eureka
Overview
What the structured-monolith catalyst patent record shows
Structured-monolith and honeycomb catalyst reactors sit at the intersection of catalyst chemistry and reactor engineering: claims cover the substrate, the washcoat formulation, the reactor geometry, and the process it enables, from Fischer-Tropsch synthesis to exhaust after-treatment. The 781 records in this dataset span 2015 to mid-2026 and cluster heavily around B01J catalytic process claims, with substantial overlap into hydrocarbon processing, inorganic compound chemistry, separation, and exhaust treatment classes.
Filing activity peaked in 2020 and has since declined sharply, a pattern consistent with a technology area where core reactor and substrate architectures were claimed early and subsequent activity has shifted toward narrower process and formulation variants. The concentration of filings among a small group of assignees suggests that new entrants face a dense prior-art landscape around the foundational monolith and honeycomb reactor claims, even as specific application niches remain open.
Filing activity and technology composition, 2015-2026
Source: Patsnap Eureka. Assignee ranking and totals. Derived from a Patsnap search on Catalysis & Reactor Design — Structured-Monolith Catalysts Patent Landscape covering 2015–2026, data cut-off 2026-07-31. Counts reflect published records only and shift as new filings publish.Run this in Eureka MCP
The Data
Filing trends and technology composition
The following breaks down publication volume over time and the IPC subclasses that structured-monolith catalyst filings most often carry.
Filing trend, 2015-2026
Publications rose to a peak of 74 records in 2020, then fell steadily; 2021 to 2024 alone shows a 92% decline (13 to 1 record). Because publication typically lags filing by around 18 months, the 2025-2026 figures are still incomplete and should not be read as confirming a continued fall.
Technology composition by IPC subclass
B01J (chemical/physical processes and catalysis) appears in 68.2% of the 781 records in scope, far ahead of any other subclass. C07C (acyclic and carbocyclic compounds, 29.3%), C01B (non-metallic elements and inorganic compounds, 25.9%), B01D (separation processes, 25.5%), C10G (hydrocarbon oil refining, 18.4%) and F01N (exhaust treatment, 16.0%) each account for a meaningful share, and because records can carry multiple classes these figures sum to well over 100%.
Shares are the percentage of the 781 records in scope. A patent can carry several IPC classes, so the shares add up to more than 100%.
Source: Patsnap Eureka. Filing trend and technology composition. Derived from a Patsnap search on Catalysis & Reactor Design — Structured-Monolith Catalysts Patent Landscape covering 2015–2026, data cut-off 2026-07-31. Counts reflect published records only and shift as new filings publish.
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The most-cited records in the field
Representative Filing
Structured catalyst bed and method for conversion of feed materials to chemical products and liquid fuels
BATTELLE MEMORIAL INSTITUTE
The invention describes a structured monolith reactor and method for controlled Fischer-Tropsch synthesis that manages mass transport limitations to raise CO conversion and lower methane selectivity. Over 95 wt% of total liquid hydrocarbon product falls in the C5-C18 carbon range, achieved by controlling olefin readsorption within the monolithic catalyst structure to narrow the product distribution around a preselected chain length.Filed by Battelle Memorial Institute, published 2009-08-27 as US20090215911A1.
Highest-cited structured-monolith catalyst patents
| # | Publication no. | Patent title | Citations |
|---|---|---|---|
| 1 | US6262131B1 | Structured fischer-tropsch catalyst system and method | 229 |
| 2 | US6616909B1 | Method and apparatus for obtaining enhanced production rate of thermal chemical reactions | 219 |
| 3 | US6211255B1 | Fischer-tropsch synthesis | 164 |
| 4 | US6777370B2 | SOx tolerant NOx trap catalysts and methods of making and using the same | 138 |
| 5 | US6447745B1 | Catalytic oxidation process | 134 |
| 6 | US20030021745A1 | SOx tolerant NOx trap catalysts and methods of making and using the same | 133 |
| 7 | US6558634B1 | Catalyst structure and method of fischer-tropsch synthesis | 126 |
| 8 | US5232357A | Multistage process for combusting fuel mixtures using oxide catalysts in the hot stage | 124 |
| 9 | US5461864A | Cooled support structure for a catalyst | 118 |
| 10 | US6506361B1 | Gas-liquid reaction process including ejector and monolith catalyst | 116 |
Citation counts inside this corpus favour older filings and should be read as a signal of influence within the searched literature, not as a measure of current commercial relevance.
Each row carries its publication number; clicking a row searches Eureka by that number.
Source: Patsnap Eureka. Citation counts and representative records. Derived from a Patsnap search on Catalysis & Reactor Design — Structured-Monolith Catalysts Patent Landscape covering 2015–2026, data cut-off 2026-07-31. Counts reflect published records only and shift as new filings publish.Run this in Eureka MCP
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What the numbers mean for strategy
Three patterns stand out once filing counts, citation weight and IPC composition are read together.
Concentration
51.1% of 781 records
held by ten assignees
The field is a small group's territory
Ten assignees account for 399 of the 781 records in scope, and the top five alone hold 275 (35.2%). A new entrant is not filing into open ground; they are filing around claims already staked by a handful of established players in catalysis and reactor engineering.
Ranking covers 100 assignees total
Filing momentum
-92% (2021-2024)
filings 13 to 1
Core architecture claims look largely settled
The drop from 74 records at the 2020 peak down to single digits by 2024 suggests the foundational monolith and honeycomb reactor designs were claimed early in this window. Remaining activity concentrates on narrower formulation and process variants rather than new reactor geometries.
2025-2026 figures still incomplete due to publication lag
Technology overlap
68.2% in B01J
of 781 records
Claims straddle chemistry and process
B01J catalysis claims dominate, but heavy overlap with C07C, C01B, C10G and F01N shows most filings are not pure substrate patents — they tie the monolith design to a specific downstream process such as Fischer-Tropsch synthesis or exhaust treatment.
Classes overlap; shares exceed 100% by design
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Co-filing patterns
| Assignee | Co-assignee | Shared families |
|---|---|---|
| Catalytica Inc. | Tanaka Kikinzoku Kogyo K.K. | 32 |
| BP Chemicals Ltd. | Laser Catalyst Systems Ltd. | 24 |
| Catalytica Inc. | DALLA BETTA RALPH A | 6 |
| Tanaka Kikinzoku Kogyo K.K. | DALLA BETTA RALPH A | 6 |
| Catalytica Inc. | TSURUMI KAZUNORI | 2 |
| Catalytica Inc. | EZAWA NOBUYASU | 2 |
| Tanaka Kikinzoku Kogyo K.K. | TSURUMI KAZUNORI | 2 |
| Tanaka Kikinzoku Kogyo K.K. | EZAWA NOBUYASU | 2 |
Ten co-assignee pairs appear in the dataset, with the strongest pairing linked by 32 shared records — evidence of joint development programmes between catalyst formulators and reactor system integrators rather than purely independent filing.
Source: Patsnap Eureka. Co-assignee relationships and derived observations. Derived from a Patsnap search on Catalysis & Reactor Design — Structured-Monolith Catalysts Patent Landscape covering 2015–2026, data cut-off 2026-07-31. Counts reflect published records only and shift as new filings publish.Run this in Eureka MCP
Players
Who holds the strongest positions
The assignee ranking spans 100 companies; a handful of names anchor the field, with citation-heavy foundational filings from institutional and industrial catalysis specialists.
Leader
78 records
documented filings
The top-ranked assignee's position
The leading assignee holds 78 records in this dataset, well ahead of the field, reflecting sustained investment across substrate design, washcoat chemistry and reactor configuration claims over the coverage period.
Ranked #1 of 100 assignees
Mid-field
35 records
fifth-ranked assignee
A dense second tier
The fifth-placed assignee holds 35 records and the tenth-placed holds 23, showing the drop-off from leader to mid-field is steep but the mid-field itself remains competitive with meaningful filing volume.
Top 10 hold 399 of 781 records
Momentum
0 in latest year
across named leaders
Leading filers have gone quiet recently
Several of the most prolific historical assignees show zero filings in the latest year, consistent with the field-wide decline in publication volume rather than a single company's retreat — publication lag means this understates true recent activity.
Recent-year momentum, all leading assignees
Recent-year filing momentum by assignee
| Assignee | Recent year | YoY |
|---|---|---|
| Battelle Memorial Institute | 0 | — |
| Eni S.p.A. | 0 | -100% |
| Corning Inc. | 0 | — |
| Air Products and Chemicals, Inc. | 0 | — |
| Catalytica Inc. | 0 | — |
| Tanaka Kikinzoku Kogyo K.K. | 0 | — |
| Umicore AG & Co. KG | 0 | — |
| BP Chemicals Ltd. | 0 | — |
Source: Patsnap Eureka. Assignee-level momentum. Derived from a Patsnap search on Catalysis & Reactor Design — Structured-Monolith Catalysts Patent Landscape covering 2015–2026, data cut-off 2026-07-31. Counts reflect published records only and shift as new filings publish.Run this in Eureka MCP
What's Next
Where to take this analysis
The dataset points to specific next steps depending on whether you are clearing a filing or scouting acquisition targets.
Map claims against your own reactor design
Run your specific monolith geometry, substrate material and washcoat chemistry against the most-cited records to see which foundational claims you sit closest to before drafting.
Explore in EurekaTrack the quiet leaders
Several top assignees show zero filings in the latest year; monitor whether this reflects portfolio maturity or a shift toward trade-secret protection for newer formulations.
Set up monitoring in EurekaTest the under-claimed branches
Additive-manufactured geometries and non-noble-metal washcoats show comparatively thin filing density inside a crowded core — worth a freedom-to-operate check before committing R&D spend.
Run a white space search in EurekaSource: Patsnap Eureka. Forward-looking reading of the same dataset. Derived from a Patsnap search on Catalysis & Reactor Design — Structured-Monolith Catalysts Patent Landscape covering 2015–2026, data cut-off 2026-07-31. Counts reflect published records only and shift as new filings publish.Run this in Eureka MCP
FAQ
Common questions on structured-monolith catalyst patents
The dataset ranks 100 assignees by record count, with the leading company holding 78 of the 781 records in scope. The top five assignees combined hold 275 records (35.2% of the field), and the top ten hold 399 (51.1%), showing that a small group of industrial and institutional catalysis specialists controls over half the documented filings. This concentration means a new entrant should expect to file around, rather than into, open space near the core reactor and substrate claims.
No — filing peaked at 74 records in 2020 and has declined sharply since, falling from 13 records in 2021 to just 1 in 2024, a 92% drop over that span. This does not necessarily mean the technology is losing relevance; it more likely reflects that foundational reactor and substrate architecture claims were staked early in the period. Publication typically lags filing by around 18 months, so the 2025-2026 figures are still incomplete and should not be read as a continuing decline.
The dominant class is B01J (chemical and physical processes including catalysis), appearing in 68.2% of the 781 records in scope. Substantial overlap also exists with C07C (acyclic and carbocyclic compounds, 29.3%), C01B (inorganic compounds, 25.9%), B01D (separation processes, 25.5%), C10G (hydrocarbon refining, 18.4%) and F01N (exhaust treatment, 16.0%). Because a single record can carry multiple IPC classes, these shares add up to well over 100%, reflecting that most filings tie a monolith design to a specific downstream chemical process.
This Battelle Memorial Institute filing, published 2009-08-27, describes a structured monolith reactor for controlled Fischer-Tropsch synthesis that manages mass transport to raise CO conversion and lower methane selectivity. It claims a method where over 95 wt% of the liquid hydrocarbon product falls in the C5-C18 range, achieved by controlling olefin readsorption within the monolithic catalyst to narrow the product chain-length distribution. Anyone designing a monolith reactor for Fischer-Tropsch or similar syngas conversion should check their olefin-readsorption control mechanism and product-distribution claims against this filing.
The core B01J catalysis cluster is dense, but adjacent branches carry comparatively thin filing density, including non-noble-metal washcoat formulations, additive-manufactured monolith geometries, in-situ catalyst regeneration monitoring, and monolith substrate end-of-life recycling. These are technically specific niches rather than broad open categories, so a freedom-to-operate search on the exact claim language is still needed before relying on any of them as clear space. The overall decline in recent filings across leading assignees also suggests some room may be opening as older portfolios mature.
Answers are grounded in the same dataset. Derived from a Patsnap search on Catalysis & Reactor Design — Structured-Monolith Catalysts Patent Landscape covering 2015–2026, data cut-off 2026-07-31. Counts reflect published records only and shift as new filings publish.Run this in Eureka MCP
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Disclaimer. This page is generated from Patsnap Eureka data drawn from a limited snapshot of global patent and scientific-literature records, and is provided for general information and reference only.
Patent data carries inherent limitations: recent filings (typically the most recent 18–24 months) are under-counted due to standard publication lag; counts may be reported at either a patent-family or a patent-record basis and are not always directly comparable; classification, applicant-name, and citation data may contain errors, duplicates, or omissions; and the underlying search query defines and constrains the scope shown. As a result, the analysis may be incomplete or inaccurate and may not reflect the full technology landscape.
Nothing on this page constitutes an exhaustive prior-art, novelty, freedom-to-operate, or validity search, nor does it constitute legal, financial, investment, or professional advice, and it should not be relied upon as such. Any patent, commercial, or strategic decision should be verified independently and reviewed with qualified patent, legal, and domain professionals. Patsnap makes no warranties, express or implied, as to the accuracy, completeness, or fitness for any particular purpose of the information presented.
Machine translation. Assignee and organisation names originally recorded in Chinese, Japanese or Korean have been rendered into English by an AI translation step so that the tables stay readable. These renderings are best-effort and may not match a company's registered English name; the original name is what the underlying patent record carries, and it is what any Eureka query launched from this page uses.