WO2016074217A1

WO2016074217A1 - Adjustable voc/formaldehyde co-absorbing usable mask cartirdge and canister

Info

Publication number: WO2016074217A1
Application number: PCT/CN2014/091109
Authority: WO
Inventors: Li Wang; Hailin LIU; Weifeng Shen; Yuzheng LU
Original assignee: Honeywell International Inc.
Priority date: 2014-11-14
Filing date: 2014-11-14
Publication date: 2016-05-19
Also published as: CN107073301A

Abstract

Improved filter cartridges (102) and methods of forming filter cartridges (102) operable to filter both polar and nonpolar chemicals are provided. The filter cartridge (102) may comprise a combination of at least two activated carbon filtration materials (210), wherein a first carbon material (211) is operable to effectively absorb nonpolar chemicals and a second carbon material (212) is operable to effectively absorb polar chemicals. The chemical materials may be combined and may form a layer of the filter cartridge (102). The filter cartridge (102) may also be operable to filter particulate matter.

Description

ADJUSTABLE VOC/FORMALDEHYDE CO-ABSORBING USABLE MASK CARTIRDGE AND CANISTER

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

BACKGROUND

Respirators often use filter cartridges to protect a user from breathing potentially hazardous vapors. When the respirator is in place on the user (typically attached to the face or head in a way to form a seal) , air is drawn into the respirator through the filter cartridge whenever the user breathes (and air can typically only enter the respirator through the cartridge, so that the air may be filtered by the cartridge to ensure that air breathed in by the user while wearing the respirator is clean and safe) . Such filter cartridges typically contain filtering material that can lock up one or more potentially hazardous vapors. As the filtering material is exposed to the vapor, it typically absorbs the vapor molecules through the pore structure of the material.

SUMMARY

Aspects of the disclosure may include embodiments of a method for forming a filter cartridge comprising combining a first carbon material and a second carbon material, wherein the first carbon material is operable to effectively absorb nonpolar chemicals and the second carbon material is operable to effectively absorb polar chemicals； spreading the combined carbon materials within a hollow shell of the filter cartridge； sealing the shell of the filter cartridge containing the carbon materials； and attaching a cover onto the hollow shell to seal the shell.

In some embodiments, the first carbon material may be operable to effectively absorb volatile organic compounds (VOCs) and the second carbon material may be operable to effectively absorb formaldehyde. In some embodiments, the combined carbon materials may comprise between about 100 grams and about 200 grams. In some embodiments, combining the carbon materials may comprise mixing with a high frequency vibrating equipment to provide homogenous mixing of the carbon materials. In some embodiments, the ratio of the first carbon material to the second carbon material may be approximately 1 to 1 (e.g. 50％of the first carbon material to 50％of the second carbon material) . In some embodiments, the method may further comprise selecting the ratio of the first and second carbon materials based on the expected conditions and environment. In some embodiments, the method may further comprise assembling additional filter material inside the shell of the filter cartridge operable to filter particulate matter. In some embodiments, the disposable mask may be operable to filter particulate matter of 0.3 micrometers or larger. In some embodiments, attaching the cover onto the hollow shell to seal the shell may comprise ultrasonic melting of at least a portion of the cover onto the shell.

Additional aspects of the disclosure may include embodiments of a filter cartridge for use with a respirator mask, the cartridge comprising a first carbon material operable to effectively absorb nonpolar chemicals； a second carbon material operable to effectively absorb polar chemicals, wherein the first carbon material and second carbon material are mixed together approximately homogenously； and a shell operable to contain the carbon filter materials and configured for removable attachment to a respirator mask.

In some embodiments, the filter cartridge may further comprise filter material operable to filter particulate matter from the air. In some embodiments, the filter cartridge may further comprise a cover attached to the hollow shell operable to seal the shell. In some embodiments, the shell may comprise an attachment end for removable attachment to the respirator mask, and one or more air inlet. In some embodiments, the first carbon material may be effectively operable to absorb volatile organic compounds (VOCs) and the second carbon material may be effectively operable to absorb formaldehyde. In some embodiments, the combined carbon materials may comprise between 100 grams and 200 grams. In some embodiments, the ratio of the first carbon to the second carbon in the layer of carbon filter material may be approximately 1 to 1.

Other aspects of the disclosure may include embodiments of a method for forming a filter cartridge comprising selecting a ratio of a first carbon material and a second carbon material based on the expected conditions of filter cartridge use, wherein the first carbon material is operable to effectively absorb volatile organic compounds (VOCs) and the second carbon material is operable to effectively absorb formaldehyde； combining the first carbon material and the second carbon material via comprises mixing with a high frequency vibrating equipment to provide homogenous mixing of the carbon materials； spreading the combined carbon materials within a hollow shell of the filter cartridge； sealing the shell of the filter cartridge containing the carbon materials； and attaching a cover onto the hollow shell to seal the shell.

In some embodiments, the ratio of the first carbon material to the second carbon material may be approximately 1 to 1 (e.g. 50％of the first carbon material to 50％of the second carbon material) . In some embodiments, the method may further comprise assembling additional filter material inside the shell of the filter cartridge operable to filter particulate matter. In some embodiments, the disposable mask may be operable to filter particulate matter of 0.3 micrometers or larger.

These and other features will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

FIG. 1 illustrates an exemplary filter cartridge install on a respirator mask；

FIG. 2A illustrates an exemplary filter cartridge； and

FIG. 2B illustrates a cross section of the mask of FIG. 2A.

DETAILED DESCRIPTION

It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.

The following brief definition of terms shall apply throughout the application:

The term “comprising” means including but not limited to, and should be interpreted in the manner it is typically used in the patent context；

The phrases “in one embodiment, ” “according to one embodiment, ” and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention (importantly, such phrases do not necessarily refer to the same embodiment) ；

If the specification describes something as “exemplary” or an “example, ” it should be understood that refers to a non-exclusive example；

The terms “about” or approximately” or the like, when used with a number, may mean that specific number, or alternatively, a range in proximity to the specific number, as understood by persons of skill in the art field； and

If the specification states a component or feature “may, ” “can, ” “could, ” “should, ” “would, ” “preferably, ” “possibly, ” “typically, ” “optionally, ” “for example, ” “often, ” or “might” (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or to have the characteristic. Such component or feature may be optionally included in some embodiments, or it may be excluded.

Embodiments relate generally to improved filter cartridges and methods of forming filter cartridges operable to filter (absorb) both polar and nonpolar chemicals. The filter cartridge may comprise a combination of at least two activated carbon filtration materials (or media) , wherein a first carbon material is operable to effectively absorb nonpolar chemicals (such as VOCs, for example) and a second carbon material is operable to effectively absorb polar chemicals (such as formaldehyde, for example) . The chemical materials may be combined and may form a layer of the filter cartridge. The filter cartridge may also be operable to filter particulate matter.

FIG. 1 illustrates an embodiment of a respirator mask 100, comprising one or more filter cartridge 102, an air outlet 104, and one or more straps 106 operable to hold the mask 100 against the face of a wearer. In the embodiment shown, air may flow into the mask 100 through the filter cartridge (s) 102 and out of the mask 100 via the air outlet 104, wherein the filter cartridge (s) 102 may filter the air breathed by a user.

FIG. 2A illustrates a filter cartridge 102, wherein the filter cartridge 102 may comprise an air inlet 208 and an attachment point 206 for removable attachment to the respirator mask 100 (of FIG. 1) . Additionally, the cartridge 102 may comprise a shell 204 and a cover (or cap) 202. In some embodiments, the cover 202 may be attached to the shell 204 by melting via ultrasonic welding. In some embodiments, air may flow through the air inlet 208 of the filter cartridge 102 into the respirator mask 100 (of FIG. 1) .

FIG. 2B illustrates a cross-section of the filter cartridge 102 of FIG. 2A. In some embodiments, the filter cartridge 102 may comprise carbon filter media (or material) 210, wherein the carbon filter material may be operable to filter (or absorb) chemicals from the air. Additionally, in some embodiments, the filter cartridge 102 may comprise a particulate filter material 214 operable to filter particulate matter from the air. In some embodiments, the carbon filter material 210 may comprise granular material that is spread within a portion of the hollow shell 204 of the filter cartridge 102. Additionally, the cover 202 may seal to the shell 204 to contain the carbon filter material 210 as well as any other filter materials, such as the particulate filter materials 214. In some embodiments, the filter cartridge 102 may be operable to filter particulate matter of approximately 0.3 micrometers or larger. In some embodiments, the cartridge 102 may comprise other filter layers 216, such as additional carbon filtration material, additional particulate filtration material, among other filtration options. In some embodiments, the particulate filtration layer 214 may be located above the carbon filtration layer 210, wherein particulates may be filtered from the air entering the cartridge 102 through the air inlet 208 before the chemicals are filtered from the air by the carbon filter material 210. However, in other embodiments, the filter materials may be in any order within the cartridge 102.

In some embodiments, the carbon filter media 210 may comprise at least two different carbon materials. For example, a first carbon material 211 (indicated by a plus symbol) may be operable to effectively absorb nonpolar chemicals, while a second carbon material 212 (indicated by a circle) may be operable to effectively absorb polar chemicals, wherein the two carbon materials may be mixed to form the carbon filter media 210 of the filter cartridge 102. In some embodiments, the first carbon material 211 may be specifically configured to filter (absorb) VOCs. In some embodiments, the second carbon material 212 may be specifically configured to filter (absorb) formaldehyde. In some embodiments, the two (or more) carbon materials 210 may be approximately homogenously mixed, such as by mixing with a high frequency vibrating equipment. Mixing the carbon materials 210 homogenously may allow for homogenous filtration ability across the filter cartridge 102. In some embodiments, the mixture of the two carbon materials 210 may be used in a filter cartridge 102 wherein air flow through the filter cartridge 102 (and therefore the carbon materials) is provided by the breathing of a user wearing a respirator mask and not by fan operation. In some embodiments, the mixture of the two carbon materials 210 may be used to filter chemicals from the air and not to filter chemicals from water, such as in a water filtration system.

In some embodiments the first carbon material 211, operable to filter nonpolar chemicals such as VOCs, may comprise Calgon Carbon WSC370. In some embodiments, the second carbon material 212, operable to filter polar chemicals such as formaldehyde (HCHO) , may comprise DeXuan-A-HCHO. However, other brand or types of carbon materials may be used to accomplish the same purpose of filtering (absorbing) both nonpolar and polar chemicals. In some embodiments, the second carbon material 212 may be treated with a catalyst of manganese, cerium, or a combination thereof. In some embodiments, the combination of the two carbon materials may be operable to absorb at an absorption speed of approximately 590 grams per minute per gram of carbon material or higher. In some embodiments, the combination of the two carbon materials may be operable to absorb nonpolar chemicals, such as VOCs, at an absorption speed of approximately 650 grams per minute per gram of carbon material or higher. In some embodiments, the combination of the two carbon materials may be operable to absorb polar chemicals, such as formaldehyde, at an absorption speed of approximately 1400 grams per minute per gram of carbon material or higher. In some embodiments, the combination of the two carbon materials may be operable to absorb at an absorption capacity of approximately 0.7 grams of chemical per gram of carbon or higher._In some embodiments, the combination of the two carbon materials may be operable to absorb nonpolar chemicals, such as VOCs, at an absorption capacity of approximately 0.1 grams of chemical per gram of carbon or higher. In some embodiments, the combination of the two carbon materials may be operable to absorb polar chemicals, such as formaldehyde, at an absorption capacity of approximately 0.8 grams of chemical per gram of carbon or higher.

In some embodiments, the ratio of the two carbon materials may be approximately 1 to 1 (e.g. 50％of the first carbon material 211 to 50％of the second carbon material 212) . In other embodiments, however, the ratio of the carbon materials may be chosen (or adjusted) based on the expected conditions and environment in which the filter cartridge 102 will be used. For example, is it is expected that the environment will contain a higher amount of nonpolar chemical than polar chemicals, the amount of the first carbon material 211 may be greater than the amount of the second carbon material 212. In some embodiments, the total amount of the carbon materials 210 may be between about 100 grams and 200 grams. However, the amount of carbon material 210 within the cartridge may vary based on the application of the filter cartridge 102. For example, a higher capacity filter cartridge may be designed to be used in an environment with high quantities of polar and nonpolar chemicals and/or may be designed for a longer service life, and therefore may require higher amounts of carbon material 210 within the filter cartridge 102. Similarly, a lower capacity filter cartridge may be designed for use in an environment with lower quantities of polar and nonpolar chemicals and/or to be a cheaper option for a user, and therefore may require lower amounts of carbon material 210 within the filter cartridge 102.

In some embodiments the carbon filter media 210 may comprise a granular material. For example, the carbon material may comprise a granular material of about 10/16 mesh size to about 16/18 mesh size. In some embodiments, the carbon material may comprise a granular material size between about 10 mesh size and about 20 mesh size. In some embodiments, the BET (Brunauer–Emmett–Teller) specific surface area of the carbon material may be between 500-2000 square meters per gram.

Some embodiments of the disclosure may comprise methods of forming a filter cartridge 102 (as described above) . In some embodiments, a first carbon material and a second carbon material may be combined, wherein the first carbon material may be operable to effectively absorb nonpolar chemicals and the second carbon material may be operable to effectively absorb polar chemicals. Then, the combined carbon material may be spread within a hollow shell of the filter cartridge, and the shell of the filter cartridge may be sealed to contain the carbon materials. Then, a cover may be attached to the hollow shell to seal the shell.

In some embodiments, the first carbon material may be operable to effectively absorb VOCs and the second carbon material may be operable to effectively absorb formaldehyde. In some embodiments, the combined carbon materials may comprise between about 100 grams and about 200 grams. In some embodiments, combining the carbon materials may comprise mixing with a high frequency vibrating equipment to provide homogenous mixing. In some embodiments, the ratio of the first carbon material to the second carbon material is approximately 1 to 1 (e.g. 50％of the first carbon material to 50％of the second carbon material) . In some embodiments, the ratio of the first and second carbon materials may be selected based on the expended conditions and environment in which the mask will be used. For example, if it is expected (or determined) that the amount of nonpolar chemicals is the air is larger than the amount of polar chemicals in the air, the amount of the first carbon material may be larger than the amount of the second carbon material in the mixture of the carbon materials.

In some embodiments, additional filter material may be assembled inside the shell of the filter cartridges, wherein the additional filter material is operable to filter particulate matter from the air. In some embodiments, the disposable mask may be operable to filter particulate matter of 0.3 micrometers or larger. In some embodiments, combining the first carbon and the second carbon comprises approximate homogenous mixing. In some embodiments, attaching the cover onto the hollow shell to seal the shell comprising ultrasonic melting of at least a portion of the cover onto the shell.

While various embodiments in accordance with the principles disclosed herein have been shown and described above, modifications thereof may be made by one skilled in the art without departing from the spirit and the teachings of the disclosure. The embodiments described herein are representative only and are not intended to be limiting. Many variations, combinations, and modifications are possible and are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment (s) are also within the scope of the disclosure. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment (s) of the present invention (s) . Furthermore, any advantages and features described above may relate to specific embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages or having any or all of the above features.

Additionally, the section headings used herein are provided for consistency with the suggestions under 37 C.F.R. 1.77 or to otherwise provide organizational cues. These headings shall not limit or characterize the invention (s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings might refer to a “Field, ” the claims should not be limited by the language chosen under this heading to describe the so-called field. Further, a description of a technology in the “Background” is not to be construed as an admission that certain technology is prior art to any invention (s) in this disclosure. Neither is the “Summary” to be considered as a limiting characterization of the invention (s) set forth in issued claims. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention (s) , and their equivalents, that are protected thereby. In all instances, the scope of the claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein.

Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of. Use of the term “optionally, ” “may, ” “might, ” “possibly, ” and the like with respect to any element of an embodiment means that the element is not required, or alternatively, the element is required, both alternatives being within the scope of the embodiment (s) . Also, references to examples are merely provided for illustrative purposes, and are not intended to be exclusive.

While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented.

Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.

Claims

A method for forming a filter cartridge (102) comprising:

combining a first carbon material (211) and a second carbon material (212) , wherein the first carbon material (211) is operable to effectively absorb nonpolar chemicals and the second carbon material (212) is operable to effectively absorb polar chemicals；

spreading the combined carbon materials (210) within a hollow shell (204) of the filter cartridge (102) ；

sealing the shell (204) of the filter cartridge containing the carbon materials (210) ； and

attaching a cover (202) onto the hollow shell (204) to seal the shell (204) .
The method of claim 1, wherein the first carbon material (211) is operable to effectively absorb volatile organic compounds (VOCs) and the second carbon material (212) is operable to effectively absorb formaldehyde.
The method of claim 1, wherein the combined carbon materials (210) comprise between about 100 grams and about 200 grams.
The method of claim 1, wherein the ratio of the first carbon material (211) to the second carbon material (212) is approximately 1 to 1 (e.g. 50％of the first carbon material to 50％of the second carbon material) .
The method of claim 1 further comprising assembling additional filter material (214) inside the shell (204) of the filter cartridge (102) operable to filter particulate matter.
A filter cartridge (102) for use with a respirator mask (100) , the cartridge (102) comprising:

a first carbon material (211) operable to effectively absorb nonpolar chemicals；

a second carbon material (212) operable to effectively absorb polar chemicals, wherein the first carbon material (211) and second carbon material (212) are mixed together approximately homogenously； and

a shell (204) operable to contain the carbon filter materials (210) and configured for removable attachment to a respirator mask (100) .
The filter cartridge of claim 6, wherein the shell (204) comprises:

an attachment end (206) for removable attachment to the respirator mask (100) ； and

one or more air inlet (208) .
The filter cartridge of claim 6, wherein the first carbon material (211) is effectively operable to absorb volatile organic compounds (VOCs) and the second carbon material (212) is effectively operable to absorb formaldehyde.
The filter cartridge of claim 6, wherein the combined carbon materials (210) comprise between 100 grams and 200 grams.
The filter cartridge of claim 6, wherein the ratio of the first carbon material (211) to the second carbon material (212) is approximately 1 to 1.