SYSTEM AND METHOD FOR PHOTOCATALYTIC OXIDATION AIR FILTRATION USING A SUBSTRATE WITH PHOTOCATALYST PARTICLES POWER COATED THEREON

• US 20080286163A1
• Filed: 05/17/2007
• Published: 11/20/2008
• Est. Priority Date: 05/17/2007
• Status: Active Grant

• Current Assignee: Scientific Health Development, Ltd.
• Original Assignee: Garfield Industries Inc.
• Inventors: Potter, John, Garfield, Kirk
• Granted Patent: US 7,820,100 B2
• Time in Patent Office: Days
• US Class Current: 422/120
• CPC Class Codes: A61L 2209/134 Distributing means, e.g. baffles, valves, manifolds, nozzles
• CPC Class Codes: A61L 2209/14 Filtering means
• CPC Class Codes: A61L 9/205 using a photocatalyst or photosensitiser
• CPC Class Codes: B01D 2255/802 Photocatalytic
• CPC Class Codes: B01J 21/063 Titanium; Oxides or hydroxides thereof
• CPC Class Codes: B01J 35/39 Photocatalytic properties
• CPC Class Codes: B01J 35/40 characterised by dimensions, e.g. grain size in a colloidal state B01J35/23; crystallite size B01J35/77
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B01J 37/0217 Pretreatment of the substrate before coating
• CPC Class Codes: B01J 37/0219 the coating containing organic compounds
• CPC Class Codes: B01J 37/0225 of metal substrates
• CPC Class Codes: B01J 37/023 using molten compounds
• CPC Class Codes: B01J 37/04 Mixing B01J37/0009, B01J37/0018 take precedence
• CPC Class Codes: B01J 37/08 Heat treatment B01J37/0009, B01J37/0018 take precedence
• CPC Class Codes: B01J 37/347 Ionic or cathodic spraying; Electric discharge
• CPC Class Codes: F04D 29/701 especially adapted for elastic fluid pumps
• CPC Class Codes: F24F 8/108 using dry filter elements
• CPC Class Codes: F24F 8/167 using catalytic reactions

Abstract

The present invention relates to an air filtration system and a method for making a photocatalytic oxidation substrate by powder coating a photocatalyst onto a metal substrate.

Claims

1. A method for applying a photocatalyst onto a substrate useful in a photocatalytic oxidation air filtration system comprising the steps of:

a. mixing a metal oxide photocatalyst with a polymeric resin to form a photocatalyst-resin mixture;

b. electrically charging the photocatalyst-resin mixture;

spraying the photocatalyst mixture onto the substrate to form a metal oxide powder-coated substrate; and

c. heating the photocatalyst powder-coated substrate.

2. The method of claim 1, further comprising the step of heating the substrate for a time and at a temperature sufficient to cure the photocatalyst mixture on the substrate.

3. The method of claim 1, wherein the photocatalyst further comprises titanium dioxide.

4. The method of claim 1, wherein the substrate further comprises aluminum.

5. The method of claim 1, wherein the photocatalyst mixture is comprised of about 70% by weight of titanium dioxide and about 30% by weight of polymer resin.

6. The method of claim 5, wherein the polymer resin further comprises a terephthalate ester-based resin.

7. An air filtration system comprising:

a. a particulate filter;

b. a motor fan for propelling airflow;

c. a substrate powder coated with a photocatalyst; and

d. a UV light source for irradiating UV light on the substrate.

8. The air filtration system of claim 7, wherein the substrate is formed of aluminum.

9. The air filtration system of claim 8, wherein the substrate is woven.

10. The air filtration system of claim 9, wherein the photocatalyst is titanium dioxide.

11. The air filtration system of claim 10, wherein the titanium dioxide is P25 titanium dioxide having an average particle size of about 134 μ

m on the substrate.

12. The air filtration system of claim 7, further comprising a control panel that comprises an infrared motion detector and an air quality sensor.

13. The air filtration system of claim 12, wherein the control panel further comprises a negative ion generator.

14. An air filtration system comprising:

a. a particulate filter;

b. a substrate powder coated with a photocatalyst;

c. at least one UV light source for irradiating UV light on the substrate; and

d. at least one reflector positioned adjacent the at least one UV light source for reflecting UV light toward the substrate.

15. The air filtration system of claim 14, wherein the particulate filter is a MERV 8 or higher pleated filter.

16. The air filtration system of claim 14, wherein the substrate has a structure selected from the group consisting of:

a honeycomb, fins, a mesh, a fibrous structure, or a filamentous structure.

17. The air filtration system of claim 14, wherein the photocatalyst further comprises titanium dioxide.

18. The air filtration system of claim 14, wherein the titanium dioxide is P25 titanium dioxide having an average particle size of about 134 μ

m on the substrate.