WO2004009219A1

WO2004009219A1 - Air sanitizer-purifier

Info

Publication number: WO2004009219A1
Application number: PCT/US2003/021484
Authority: WO
Inventors: Dale Taylor
Original assignee: Ceramatec, Inc.
Priority date: 2002-07-09
Filing date: 2003-07-09
Publication date: 2004-01-29
Also published as: AU2003248905A1

Abstract

The present invention discloses an air sanitizer-purifier (10) which has a substrate material (15) having a surface area, and a catalyst material (16) associated with at least a portion of the substrate material (15) wherein the catalyst materials (16) are in the form of A(1-X)B(X)C(1-Y)D(Y), where A, B, C and D are oxide materials. Alternatively, the catalyst material (16) could simply comprise a ceramic oxygen generator. The air sanitizer-purifier (10) may further be placed into a sanitizing system, along with an air moving device (12) capable of directing air from a surrounding environment, into and through the system, an air heating device (23), and a heat exchanger (22) placing the directed air and the system air into thermal contact. A method for using the device and system is also disclosed.

Description

TITLE OF THE INVENTION AIR SAMITZER-PURIFIER BACKGROUND OF THE INVENTION

1. FIELD OF THE INVENTION The present invention is generally related to air purification methods and devices, and specifically to a device and method for the improved purification of pathogens and chemicals found in contaminated air.

2. STATE OF THE PRIOR ART

Air purification systems have been known in the art, and used in commercial and residential applications for some time. These systems generally include one of two conventional methods for improving air quality, namely mechanical filtration, and chemical filtration. The two methods are similar and related, but operate quite differently.

In a mechanical filtration system, a micro-mesh screen or filter is placed in direct contact with airflow so that all air must pass through the screen or filter. The screen comprises any number of materials that have small to microscopically sized mesh holes, such as microfibres and the like, which allow the passage of air, but trap particulate within the screen or filter. A commonly known and typical mechanical filtration system is the HEPA filter. A HEPA filter (High-Efficiency Particulate Air filters) provides a high-efficiency filter for removing particulate from the air, and has been used in such critical installations as the ventilation systems for nuclear plants. These filters, however, still have their limitations due to their utilization of a mechanical screen/filtration method.

A chemical filtration system, on the other hand, utilizes adsorption properties of certain chemical compounds and materials to remove particulate from the air via chemisorption. As with the mechanical filtration systems, chemical filtration systems are placed in direct contact with airflow, allowing air to pass through the filter itself. Once in contact with the air, the chemical makeup of the filter itself removes particulate from the air by adsorption, actually drawing the particulate out and onto the filter surface. One common type of chemical absoφtion material includes activated carbon, which acts as a high-efficiency, high-surface area adsorbent.

Additionally, it is not uncommon to see a single filtration product that incoφorates both types of filtration methods.

Both of these filtration method types operate in the same manner, and therefore are both burdened by the same drawbacks. One particularly negative drawback of filters of these types is that the filtration method causes a buildup of particulate on the filter, decreasing the efficiency of the filter over time, and giving the entire filtration device a limited life, requiring replacement. It is therefore an object of this invention to provide an improved filtration system that operates without the need for continued replacement of filtration parts, and without decreased system efficacy over time.

These objects and others will become apparent to one of ordinary skill in the art in view of the specification, claims and drawings appended hereto.

SUMMARY OF THE INVENTION

An air sanitizer-purifier is disclosed herein, which includes a substrate material having a surface area, and a catalyst material associated with at least a portion of the substrate material, wherein the catalyst materials include A (1-X) B (X) C (1-Y) D , where A and B are chemicals selected from the group consisting of La, Sr, Ca, Mg, Ba, Y, and Yb, and C and D comprise chemicals selected from the group consisting of Mn, Fe, Co, Ni, Cu, Ga, Ce, Pt, Bi, Sm, Gd, Y, Yb, and Zr. Alternatively, the sanitizer-purifier could include A (1-X) B (X) C (1- Y) D 00, where A, B, C and D are alloys of or pure chemicals selected from the group consisting of Ti, V, Ni, Cu, Co, Cr, Zn, Fe, Mn, Mo, Re, Ru, Rh, Pd, Ag, Cd, Sn, W, Ta, h, Pt, Au, and Pb. In still another embodiment, the catalyst could simply include a ceramic oxygen generator. h one preferred embodiment, the catalyst materials comprise an oxide material capable of at least one of transporting oxygen ions, transporting oxygen molecules, adsorbing oxygen and absorbing oxygen. The substrate material utilized in the purifier preferably is constructed from one or more of a metal and a ceramic material. If a metal material is utilized, preferred materials include alloyed metal material selected from at least two metals from the group consisting of Fe, Ni, Cr, Mn, Co, Ti, Ta, Al, Ru, Rh, Pd, Ag, Cd, Sn, Ta, W, Re, Ir, Pt, Au, Pb, Zr, Mo, and Mg. If a ceramic material is utilized, preferred ceramic materials include an oxide material including at least one material selected from the group consisting of Ce, Zr, Mn, Mg, Ti, V, Fe, Co, Ni, Cu, Zn, Ga, Si, Al, and W. The oxide material could be a doped or an undoped material. Oilier preferred ceramic materials include at least one of a carbide and a nitride selected from the group consisting of Si, Al, W, Ti, Ca, and Mg.

In another preferred embodiment, the substrate material has an electronic conductivity. Alternatively, the device could include a conductive material associated with the catalyst material, such as a coating of conductive material associated with the catalyst material, or intermixed with the catalyst material.

If conductive materials are utilized, it may be preferable to include a voltage coupling in the purifier, wherein the voltage coupling allows for a voltage drop to be placed across the purifier. In such a case, it is beneficial to include one of a D.C. or an A.C. current source, or an oscillating electric charge source associated with the voltage coupling.

The substrate material can be formed into a variety of shapes, including a honeycomb, or a flat sheet in the form of one of the group consisting of a planar sheet, a corrugated sheet, and a mountainous sheet. Preferably, the above-described sanitizer is included within a system for the sanitizing/purification of air, which includes the sanitizer along with an air moving device capable of directing air from a surrounding environment, into and through the system, an air heating device, and a heat exchanger placing the directed air and the system air into thermal contact. Through the above device, air can be sanitized and/or purified by (1) contacting contaminated air with an air purification/sanitation device, and (2) sanitizing the contaminated air upon placement of that air within a proximate distance to the catalyst material. Generally, sanitizing the air may be accomplished by oxidizing at least a portion of a contaminated material contained in the contaminated air, and thus purifying it. Other steps may additionally be included, such as (3) heating the contaminated air before the step of contacting, preferably by heating the catalyst material of the sanitizing device. The method may be most effective if the air is heated several hundred degrees Celsius above its initial temperature, and preferably above 300 degrees Celsius. In doing so, both the air and the catalyst material may be heated several hundred degrees Celsius above its initial temperature, and well above 300 degrees Celsius. BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 comprises a plan view of a sanitizing system according to the present invention;

Fig. 2 comprises another, alternative plan view of an alternative embodiment of the sanitizing system; Fig. 3 comprises one perspective view of a preferred structure for substrate structure; Fig. 4A comprises another perspective view of a preferred substrate structure; Fig. 4B comprises another perspective view of a preferred substrate structure; and Fig. 4C comprises another perspective view of a preferred substrate structure.

DETAILED DESCRD7TION OF THE INVENTION

While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will be described in detail, specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments illustrated.

The present invention is shown and described herein in relation to the figures attached hereto. In Fig. 1, Air purifier 10 is shown as comprising air moving device 12, sanitizing member 14, ducts 19, and power supply 20. Together, these elements allow contaminated air and/or other similar fluids to be introduced into air purifier 10, and purified through contact with sanitizing member 14.

Air moving device 12 of device operates to draw contaminated air into purifier 10 from an external source, such as the environment surrounding device 12. In order to do so, air- moving device 12 must be in fluidic contact with the environment air, or with a conduit of some sort that connects a source of contaminated air with the air purifier 10. Air moving device 12 generally comprises any number of fluid-moving devices, such as bladed fluid-moving machines, like fans, and may be positioned either upstream or downstream of sanitizing member 14. Of course, other similar devices could also be used, depending upon the fluid and flow rate needed. For example, device 12 could comprise a blower or compressor. Air moving device 12 will bring the contaminated fluid into purifier 10, and thereafter into contact with sanitizing member 14. In order to maintain the contaminated air within the purifier 10, purifier 10 additionally includes ducts 19. Ducts 19 comprise any number of conventional fluid conduits that connect the region between device 12 and sanitizing member 14. Preferably, ducts 19 comprise a material having a high thermal conductivity in order to allow for the incoming contaminated air to be heated. hi a preferred embodiment shown in Fig. 2, purifier 10 additionally includes heat exchange apparatus 22. Heat exchange apparatus comprises air heating device 23 and exchange plate 24. Air heating device 23 is capable of heating system air, preferably externally obtained pure air, to several hundreds of degrees higher than ambient temperature. This heated air is passed by exchange plate 24, which is in thermal conduct with ducts 19 of purifier 10. The proximity of exchange plate 24 and ducts 19 allows for thermal transfer across that wall, heating the incoming, contaminated air. Preferably, such an exchange will allow an increase in temperature of the incoming contaminated air several hundred degrees, and more preferably to above 300 degrees Celsius. The contaminated air is thereafter brought into contact with sanitizing member 14.

Sanitizing member 14, shown in more detail in Fig. 3, generally comprises substrate material 15, with catalyst material 16 configured thereon. Substrate material 15 comprises any of a number of known materials having rigid or semi-rigid structures that can act as a support structure for catalyst material 16. Preferably, substrate material 15 is in a honeycomb-like shape having a number of repeating cells 17 (Fig. 3 A) therein, the honeycomb shape enabling fluid to flow over and through the structure of the material 15. Cells 17 may be any polygonal shape having a generally open central area.

Substrate material 15 may also be formed into other shapes, including planar (Fig. 4A), corrugated (Fig. 4B), mountainous (Fig. 4C), or any other similar structure which allows for the free flow of fluid through and/or over material 15, while exposing some surface area thereto. Preferred substrate materials 15 comprise metal or ceramic materials so as to provide rigidity and form to the substrate. If a metal substrate material 15 is selected, it is preferred that the substrate be selected from an alloy of two of the group of Fe, Ni, Cr, Mh, Bi, Co, Ti, Ta, Al, Ru, Rh, Pd, Ag, Cd, Sn, Ta, W, Re, Ir, Pt, Au, Pb, Zr, Mo, and Mg. Alternatively, if a ceramic is selected, it is preferred that the ceramic be an oxide material including at least one material selected from the group consisting of Ce, Zr, Mn, Mg, Ti, V, Fe, Co, Ni, Cu, Zn, Ga, Si, Al, and W.

Substrate material 15 may additionally have an electronic conductivity so as to allow for an electrical current to be run through the substrate. The electronic conductivity may be achieved through the selection of the substrate material 15 themselves, or through the combination of the substrate material with a conductive substance. For example, substrate may be coated with a conductive material, or substrate material may be intermixed with a conductive material, creating a conductive composite.

Catalytic material 16 is deposited on substrate material 15 in a fixed fashion in such a way as to maximize the surface area exposed to catalytic material 16. Catalytic material 16 comprises a combination of chemical materials that oxidize contaminants and pollutants to which it is exposed. Preferably, catalytic material 16 comprises A (1-X) B (X) C (1-Y) D (Y), where A and B comprise chemicals selected from the group consisting of La, Sr, Ca, Mg, Ba, Y, and Yb, and C and D comprise chemicals selected from the group consisting of Mn, Fe, So, Ni, Cu, Ga, Ce, Pt, Bi, Sm, Gd, Y, Yb, and Zr. Additionally, A, B, C and D could comprise alloys of or pure chemicals selected from the group consisting of Ti, V, Ni, Cu, Cr, Co, Zn, Fe, Mh, Mo, Re, Ru, Rh, Pd, Ag, Cd, Sn, W, Ta, ir, Pt, Au, and Pb. Preferably, the selected catalyst materials 16 comprise an oxide material capable of at least one of transporting oxygen ions, transporting oxygen molecules, adsorbing oxygen and absorbing oxygen. As described above, in a preferred embodiment of the invention, again shown in Fig. 1, substrate material 15 is capable of conducting electricity. Additionally, as can be noted above, a number of the materials included as possible selections for the catalyst material 16 are additionally conductive and/or semi-conductive. Therefore, it is preferred that purifier 10 additionally include a voltage coupling 26 for connecting a voltage source to purifier 10. Voltage coupling 26 may be associated with just the catalyst 16, or just the substrate 15, as desired. Voltage coupling 26 should be capable of receiving a DC electrical charge, an AC electrical charge, or an oscillating electrical charge, as needed, turning the entire structure into an electro catalyst. The combination of the electrical charge with the materials selected above increases the oxidizing activity of the catalyst. This electrical power can be supplied by power source 20.

In operation, the present device is placed in a location where fluidic communication with contaminated air/water is possible. For example, purifier 10 could be placed within the heating duct system of an office building, such as honeycomb substrates and the like. Once in operative position, device 12 of purifier 10 helps to move the contaminated fluid, such as air, into purifier 10 and into contact with sanitizing device 14. Preferably, before the contaminated air is contacted with sanitizing device 14, it is heated to a temperature of over 300 degrees Celsius by contacting the area near exchange plate 24, which has already been heated by hot air from air heating device.

Once in contact with sanitizing device 14, the contaminants within the air (such as HD, VX, GD, or the like) are oxidized into harmless agents such as water molecules and carbon dioxide, as well as other non-toxic compounds. The oxidation of the contaminants takes place almost immediately upon contact, or even upon close proximity to the surface of sanitizing device 14. The transformation is accomplished through catalyzed oxidation reactions, aided by the chemical materials located in and on sanitizing device 14. Alternatively, sanitizing device 14 can comprise a ceramic oxygen generator, which itself produces pure oxygen. Through its operation the pure oxygen is produced, which then oxidizes the compounds in contaminated air. After oxidizing nearly all the contaminants in the contaminated fluid stream, that stream is removed from the system and released into the environment. Simultaneously, as sanitizing device 14 operates, catalytic material 16 is continuously regenerating itself through electiochemical reactions. Thus, not only is sanitizing device 14 capable of cleaning the air, but will continue to provide its advantageous cleaning capabilities for an extended period of time, without the need for frequent replacement of the device or its components.

In one particularly interesting embodiment, sanitizing device 14 could comprise a portable sanitizing device. Such a device need not be coupled with conventional ventilation systems in buildings, cars, or other environments, but can be placed independently on a stand or table in a room environment, where its exposure to the surrounding atmosphere will provide sanitizing effects in a more localized area

The foregoing description merely explains and illustrates the invention and the invention is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications without departing from the scope of the invention.

Claims

WHAT WE CLAIM IS:

1. An air sanitizer-purifier comprising: a substrate material having a surface area; and

- a catalyst material associated with at least a portion of the substrate material; - wherein the catalyst materials include A (1-X) B (X) C (1-Y) D (Y), where A and

B comprise chemicals selected from the group consisting of La, Sr, Ca, Mg, Ba, Y, and Yb, and C and D comprise chemicals selected from the group consisting of Mn, Fe, Co, Ni, Cu, Ga, Ce, Pt, Bi, Sm, Gd, Y, Yb, and Zr.

2. An air sanitizer-purifier comprising: - a substrate material having a surface area; and

- a catalyst material associated with at least a portion of the substrate material;

- wherein the catalyst materials include A (1-X) B (X) C (1-Y) D (Y), where A, B, C and D comprise alloys of or pure chemicals selected from the group consisting of Ti, V, Ni, Cu, Co, Cr, Zn, Fe, Mn, Mo, Re, Ru, Rh, Pd, Ag, Cd, Sn, W, Ta, Ir, Pt, Au, andPb.

3. The device according to claim 1, wherein the catalyst materials comprise an oxide material capable of at least one of transporting oxygen ions, transporting oxygen molecules, adsorbing oxygen and absorbing oxygen.

4. The device according to claim 1, wherein the substrate material comprises at least one of a metal and a ceramic material.

5. The device according to claim 4, wherein the substrate material comprises a alloyed metal material selected from at least two metals from the group consisting of Fe, Ni, Cr, Mn, Co, Ti, Ta, Al, Ru, Rh, Pd, Ag, Cd, Sn, Ta, W, Re, Ir, Pt, Au, Pb, Zr, Mo, and Mg.

6. The device according to claim 4, wherein the substrate material comprises a ceramic material comprising an oxide material including at least one material selected from the group consisting of Ce, Zr, Mn, Mg, Ti, V, Fe, Co, Ni, Cu, Zn, Ga, Si, Al, and W.

7. The device according to claim 6, wherein the oxide material is a doped material.

8. The device according to claim 6, wherein the oxide material is an undoped material.

9. The device according to claim 4, wherein the substrate material comprises a ceramic material comprising at least one of a carbide and a nitride selected from the group consisting of Si, Al, W, Ti, Ca, and Mg.

10. The device according to claim 1, wherein the substrate material comprises a material having an electronic conductivity.

11. The device according to claim 1, additionally comprising a conductive material associated with the catalyst material.

12. The device according to claim 11, wherein the conductive material comprises a coating of conductive material associated with the catalyst material.

13. The device according to claim 11, wherein the conductive material is intermixed with the catalyst material.

14. The device according to claim 1, wherein the purifier additionally comprises a voltage coupling, wherein the voltage coupling allows for a voltage drop to be placed across the purifier.

15. The device according to claim 14, additionally comprising a D.C. current source associated with the voltage coupling.

16. the device according to claim 14, additionally comprising an A.C. current source associated with the voltage coupling.

17. The device according to claim 14, additionally comprising an oscillating electric charge source associated with the voltage coupling.

18. The device according to claim 1, wherein the substrate material is in the form of a honeycomb.

19. The device according to claim 1, wherein the substrate material comprises a flat sheet in the form of one of the group consisting of a planar sheet, a corrugated sheet, and a mountainous sheet.

20. An air sanitizer-purifier comprising:

- a substrate material having a surface area; and

- wherein the catalyst material comprises a ceramic oxygen generator.

21. A system for the sanitizing/purification of air, comprising:

- an air moving device capable of directing air from a surrounding environment, into and through the system;

- an air heating device;

- a heat exchanger placing the directed air and the system air into thermal contact; - a substrate material having a surface area, wherein the substrate material is positioned so as to contact the directed air; and

- wherein the catalyst materials include A (1-X) B (X) C (1-Y) D 00, where A and B comprise chemicals selected from the group consisting of La, Sr, Ca, Mg, Ba, Y, and Yb, and C and D comprise chemicals selected from the group consisting of Mn, Fe, Co, Ni, Cu, Ga, Ce, Pt, Bi, Sm, Gd, Y, Yb, and Zr.

22. A method for sanitizing/purifying air, comprising the steps of:

- contacting contaminated air with an air purification/sanitation device, wherein the device comprises: - a substrate material having a surface area; and - a catalyst material associated with at least a portion of the substrate material;

- wherein the catalyst materials include A (1-X) B (X) C (1-Y) D (Y), where A and B comprise chemicals selected from the group consisting of La, Sr, Ca, Mg, Ba, Y, and Yb, and C and D comprise chemicals selected from the group consisting of Mn, Fe, Co, Ni, Cu, Ga, Ce, Pt, Bi, Sm, Gd, Y, Yb, and Zr; and

- sanitizing the contaminated air upon placement of that air within a proximate distance to the catalyst material.

23. The method according to claim 22, additionally including the step of heating the contaminated air before the step of contacting.

24. The method according to claim 23, wherein the step of heating the contaminated air additionally comprising the step of heating the catalyst material.

25. The method according to claim 22, wherein the air is heated several hundred degrees Celsius above its initial temperature.

26. The method according to claim 25, wherein the air is heated above 300 degrees Celsius.

27. The method according to claim 24, wherein both the air and the catalyst material are heated several hundred degrees Celsius above its initial temperature.

28. The method according to claim 27, wherein both the air and the catalyst material are heated above 300 degrees Celsius.

29. The method according to claim 22, wherein the step of sanitizing comprises the step of oxidizing at least a portion of a contaminated material contained in the contaminated air, purifying it.