WO2017114687A1 - Composant pour filtre à air - Google Patents
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- WO2017114687A1 WO2017114687A1 PCT/EP2016/081843 EP2016081843W WO2017114687A1 WO 2017114687 A1 WO2017114687 A1 WO 2017114687A1 EP 2016081843 W EP2016081843 W EP 2016081843W WO 2017114687 A1 WO2017114687 A1 WO 2017114687A1
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- air
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
- B01D53/86—Catalytic processes
- B01D53/8668—Removing organic compounds not provided for in B01D53/8603 - B01D53/8665
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/10—Noble metals or compounds thereof
- B01D2255/102—Platinum group metals
- B01D2255/1021—Platinum
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/10—Noble metals or compounds thereof
- B01D2255/102—Platinum group metals
- B01D2255/1023—Palladium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/10—Noble metals or compounds thereof
- B01D2255/102—Platinum group metals
- B01D2255/1026—Ruthenium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/10—Noble metals or compounds thereof
- B01D2255/104—Silver
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/10—Noble metals or compounds thereof
- B01D2255/106—Gold
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/20—Metals or compounds thereof
- B01D2255/206—Rare earth metals
- B01D2255/2065—Cerium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/20—Metals or compounds thereof
- B01D2255/207—Transition metals
- B01D2255/20707—Titanium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/20—Metals or compounds thereof
- B01D2255/207—Transition metals
- B01D2255/20715—Zirconium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/20—Metals or compounds thereof
- B01D2255/207—Transition metals
- B01D2255/2073—Manganese
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/90—Physical characteristics of catalysts
- B01D2255/902—Multilayered catalyst
- B01D2255/9022—Two layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2257/00—Components to be removed
- B01D2257/70—Organic compounds not provided for in groups B01D2257/00 - B01D2257/602
- B01D2257/708—Volatile organic compounds V.O.C.'s
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2258/00—Sources of waste gases
- B01D2258/06—Polluted air
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2259/00—Type of treatment
- B01D2259/45—Gas separation or purification devices adapted for specific applications
- B01D2259/4508—Gas separation or purification devices adapted for specific applications for cleaning air in buildings
Definitions
- the invention relates to the field of air treatment, and in particular, to decomposition of atmospheric formaldehyde.
- US2010/310441 describes catalysts that are capable of use at low temperatures ( ⁇ 80 °C) to remove volatile organic compounds (VOCs) in an enclosed space.
- the catalyst is combined with an adsorbent to form a catalytic article.
- Methods of manufacturing catalytic articles are described in which the catalyst is mixed with discrete particles of adsorbent or supported directly on the adsorbent.
- US2014/255283 describes a device for reducing a volatile organic compound (VOC) content of a gas comprising a manganese oxide (MnO x ) catalyst.
- the manganese oxide (MnO x ) catalyst is capable of catalyzing formaldehyde at room temperature, with complete conversion, to C0 2 and water vapor.
- the manganese oxide (MnO x ) catalyst itself is not consumed by the reaction of formaldehyde into C0 2 and water vapor.
- US2014/255283 also describes a device for reducing or removing a particle, a VOC and/or ozone from a gas comprising an activated carbon filter (ACF) on a media that is capable of being periodically regenerated.
- ACF activated carbon filter
- JPS61235623 describes removing an irritating odor by controlling acceleration in corrosion of a metallic material, by a method wherein a filter is provided to an air intake part of which wetness has been given, and formaldehyde is removed even in air containing humidity.
- a cooler is provided and a cooling medium is made to circulate through a radiating part by compressing the same and air from an air intake part is cooled by making the air expand at this part.
- the air intake part is provided with a dust filter provided on the inside of a cover and a wet filter provided on the inside of the dust filter.
- wetness is given to the same by treating a filter material with an agent whose moisture absorption is high such as lithium chloride or magnesium chloride or calcium chloride or glycerin.
- an agent whose moisture absorption is high such as lithium chloride or magnesium chloride or calcium chloride or glycerin.
- US4892719 describes that indoor pollutants such as formaldehyde or acidic gases, such as SO2, SO3, NO x and H 2 S can be removed from a house by a reactive method consisting of a coating on a furnace filter in a forced air heating system.
- the coating is a polymeric substance with specific functional groups which react with the pollutant and which in the case of formaldehyde or other aldehydes such as acrolein or acetaldehyde would be polymeric hydrazine or polymeric amine such as polyethylenimine, polyallylamine, or polyvinylamine.
- the coating is plasticized with a low volatile liquid such as glycerol in order to extend the useful life of the coating.
- US5206204 describes adsorbents for lower aldehydes which comprises a saturated cyclic secondary amine and a porous carrier therefor.
- the adsorbent can eliminate lower aldehydes efficiently at ordinary temperature over a long period and, furthermore, is inexpensive.
- the adsorbents, wherein a halogenide of alkali metal or alkaline earth metal is further supported on the porous carrier have an excellent heat resistance.
- Formaldehyde (HCHO) is a critical indoor pollutant. Formaldehyde is toxic, allergenic, and carcinogenic. At concentrations above 0.1 ppm in air, formaldehyde can irritate the eyes and mucous membranes, resulting in watery eyes. Inhaled formaldehyde at and above this concentration may cause headaches, a burning sensation in the throat, difficulty with breathing, and can trigger or aggravate asthma symptoms.
- thermal catalytic oxidation is considered as a promising strategy for the removal of formaldehyde due to its environmental- friendly reaction conditions and energy-saving possibilities, especially under room temperature conditions.
- TCO involves the use of a solid catalyst, which provides an alternative reaction pathway between reactants and products by lowering the activation energy of the reaction.
- Room temperature TCO can enable the complete catalytic oxidation of formaldehyde into carbon dioxide and water at room temperature, without other energy input. It overcomes the disadvantages of the relatively short lifetime of adsorbents and additional instrumentation and operating costs required for high-temperature catalytic and photocatalytic oxidation. For instance, PCO needs light, and high temperature catalytic oxidation requires additional heating.
- a number of supported noble metals can be used in the room-temperature catalytic oxidation of formaldehyde, such as platinum (Pt), palladium (Pd), and gold (Au).
- platinum Pt
- palladium Pd
- gold Au
- transition metal oxides especially manganese oxide (MnOx) without noble metal dope, have been reported as having high conversion rates of formaldehyde removal in laboratory tests.
- room-temperature catalytic oxidation is known to be adversely effected by moisture in the air to be treated, the presence of which is unavoidable in domestic situations.
- Fig. 5 demonstrates the negative impact of moisture on the performance of transition metal catalysts (such as manganese-cerium oxide: MnOx-CeOx).
- the data in Fig. 5 were generated from a full sized filter (i.e. a filter which is capable of insertion into a commercial air purifier) which included a ceramic component comprising MnOx-CeOx.
- the filter was installed in an air purifier (Philips AC4076) and tested in a 30 m 3 chamber according to experimental procedure of Chinese national standard GB T 18801-2008. Briefly, the air purifier with the filter was placed at the centre of chamber.
- a formaldehyde meter (formaldemeter htv-m; PPM Technology Co.), which was calibrated using a chemisorption method, was located at a distance of 0.8m from the air purifier, and at a distance of 1.5m from the ground in order to measure formaldehyde.
- the formaldehyde source was injected into the chamber and mixed via use of a ceiling fan for 10 minutes. Following cessation of the ceiling fan, the air purifier was switched on. After one hour, the air purifier was turned off and the chamber was ventilated. Temperature and relative humidity in the chamber were kept stable during each test. Tests were carried out at different humidity levels, and clean air delivery rate (CADR) values were obtained by calculating the decline of formaldyde concentration under different humidities.
- CMR clean air delivery rate
- water can affect the decomposition of formaldehyde in different ways, depending upon the type of catalyst used.
- HCHO decomposition using catalysts comprising noble metals such as platinum/titanium oxide (Pt/Ti0 2 ); platinum/iron oxide (Pt/Fe 2 0 3 ); gold/cerium oxide (Au/Ce0 2 ); silver/manganese oxide/cerium oxide (Ag-MnO x -Ce0 2 ) is increased by adding water to the reactant stream (see C. Zhang, H. He, Catal. Today 2007, 126, 345).
- noble metals such as platinum/titanium oxide (Pt/Ti0 2 ); platinum/iron oxide (Pt/Fe 2 0 3 ); gold/cerium oxide (Au/Ce0 2 ); silver/manganese oxide/cerium oxide (Ag-MnO x -Ce0 2 ) is increased by adding water to the reactant stream (see C. Zhang, H. He, Catal. Today 2007, 126, 345).
- catalysts such as manganese oxide/cerium oxide (MnO x -CeO x ); palladium/aluminium oxide (Pd/A ⁇ C ); iron oxide/ manganese oxide (Fe 2 0 3 -Mn0 2 ); copper oxide/manganese oxide (CuO-Mn0 2 ); and manganese oxide (MnO x ) have been reported to show a decrease in catalytic activity as humidity increases (Yu Wang, Xiaobing Zhu, Mark Crocker, Bingbing Chen, ChuanShi; Applied Catalysis B: Environmental 160—
- the moisture present in indoor air is one of the major causes of the dramatic loss of catalytic activity that occurs when using favourable catalysts for formaldehyde decomposition, as a result of strong adsorption of the moisture on catalytic active sites, especially at ambient temperature.
- Such decomposition can significantly reduce the lifetime of such catalysts in practical applications.
- component for an air filter
- the component comprises a first active layer, a second active layer, and optionally a third layer comprising a water absorb/release layer
- the first active layer comprises a first material (which can also be indicated as first active material) for removing formaldehyde from air
- the second layer comprises a second material (which can also be indicated as second active material) for removing formaldehyde from air
- the first active layer, the second active layer and the optional third layer differ from each other, especially wherein the compositions (i.e. especially the chemical composition) of the first active layer, the second active layer and the optional third layer differ from each other, wherein each of the layers is in contact with at least one of the other layers, wherein:
- the first active layer comprises one or more first materials selected from the group consisting of MnOx-CeOx, CuO-Fe 2 0 3 , CuO-Al 2 0 3 , Pd/Al 2 0 3 , Ce/Al 2 0 3 , Ag/MnOx, and Fe 2 0 3 /Mn0 2 ;
- the second active layer comprises one or more second materials selected from the group consisting of amines, especially selected from the group consisting of primary amines and secondary amines.
- the component is especially a single unit, that may e.g. be configured in an air filter. Especially, the component is configured to allow air flowing through the component.
- the component may comprise one or more channels through which air can flow, while being exposed one or more of the layers.
- a channel like structure e.g. a monolithic channel structure may comprise the layers as coating material, thereby providing the component.
- the first active layer comprises one or more first materials selected from the group consisting of MnOx-CeOx, CuO-Fe 2 0 3 , CuO-Al 2 0 3 , Pd/Al 2 0 3 , Ce/Al 2 0 3 , Ag/MnOx, and Fe 2 0 3 /Mn0 2 .
- the materials may herein also be indicated as catalyst. Such material may be used to decompose formaldehyde.
- the first active layer comprises MnOx-CeOx.
- the first active layer comprises CuO-Fe 2 0 3 .
- the first active layer comprises CuO-Al 2 03.
- the first active layer comprises Pd/Al 2 0 3 .
- the first active layer comprises Ce/Al 2 0 3 .
- the first active layer comprises Ag/MnOx.
- the first active layer comprises Fe 2 0 3 /Mn0 2 .
- Pd/Al 2 0 3 , Ce/ A1 2 0 3 , or Ag/MnO x refer to metal doped oxides.
- the amount of metal (Pd, Ce, Ag, respectively) are in the range of about 0.05-5 wt.%, especially about 0.1-2 wt.%.
- the second active layer comprises one or more second materials selected from the group consisting of primary amines and secondary amines.
- this second active layer may comprise one or more primary amines and/or one or more secondary amines.
- Such second materials may also be indicated as "absorbent".
- the first active layer and the second active layer will be in contact with each other.
- the first material and the second material may in contact with each other.
- the first mateiral and the seocnd material are not in contact with each other.
- the third layer may in embodiments essentiality consist of the absorb/release layer.
- an absorb/release layer are e.g. a layer of hygroscopic material.
- the first active layer may be in contact with one or more of the second active layer and the third layer
- the second active layer may be in contact with one or more of the first active layer and the third layer
- the third layer may be in contact with one or more of the first active layer and the second active layer.
- the first material and the second material may in contact with each other.
- the first mateiral and the seocnd material are not in contact with each other.
- the phrase "for removing formaldehyde from air” may e.g. refer to decomposition of the formaldehyde and/or desorption of the formaldehyde. In this way formaldehyde may be removed from air. Further, the invention is not limited to formaldehyde comprising air but may also apply for other gasses (also) comprising formaldehyde. Further, the phrase “removing formaldehyde from air” especially indicates that the content of formaldenyde in air with the component can be reduced. As indicated above, especially the compositions of the first active layer, the second active layer and the optional third layer differ from each other. In this way, these layers may have different functionalities. A layer may have a plurality of functionalities.
- two or more layers may also comprise identical materials, e.g. identical supports or identical absorbents, etc., but the layers at least differ in composition.
- the first active layer has a higher capacity for removing formaldehyde from air than the second active layer air
- the second active layer has a higher capacity for removing formaldehyde from air than the first active layer.
- the capacity may e.g. be evaluated in terms of one-pass efficiency.
- the difference in capacity may be at least 10%, such as at least 20%, like at least 50%.
- the first active layer has a higher capacity, such as of at least 10%, such as at least 20%, like at least 50% higher than the capacity of the second active layer, for removing formaldehyde from air.
- the second active layer has a higher capacity, such as of at least 10%, such as at least 20%, like at least 50% higher than the capacity of the first active layer for removing formaldehyde from air.
- one or more of the first active layer, the second active layer and the optional third layer comprise a third material selected from the group consisting of an inorganic salt, a glycol, silica gel, activated alumina, a hygroscopic agent, and water absorption polymer, wherein the third material differs in composition from the first material and the second material.
- the second active layer comprises one or more absorbents.
- the absorbent comprises one or more of tris(hydroxymethyl)aminomethane, methylamine, branched po ly (ethy leneimine) , and po ly(ally lamine) .
- one or more of the first active layer, the second active layer and the optional third layer comprise a substrate.
- one or more of the first active layer, the second active layer and the optional third layer comprise one or more of activated carbon fibre, silica, zeolite, ceramic, porous polymer or paper, even more especially one or more of ceramic and porous polymer.
- the substrate comprises a ceramic, especially a ceramic having a porous structure (such as a monolithic element having channels).
- the substrate comprises a polymer, especially a polymer having a porous structure (such as a monolithic element having channels).
- at least the second active layer further comprises said substrate.
- the second active layer comprises one or more of platinum, gold, ruthenium, silver or palladium doped transitional metal oxide, one or more rare earth oxides, one or more forms of mangenese oxide (MnO x ), or one or more transitional oxides, wherein the transitional metal oxide is one or more of titanium dioxide, manganese oxide, iron oxide, cerium oxide, vanadium oxide, copper oxide, zirconium oxide, molybdenum oxide or tungsten oxide.
- the first active layer and the second active layer comprise catalysts
- the catalysts are different.
- different especially refer to different chemical compositions, even more especially, refers to chemicals that include at least one element not in common, especially at least one metal element.
- the first actie layer may comprise palladium and/or cerium and the second active layer may comprise of platinum and/or gold.
- the second active layer may comprise platinum (doped transitional metal oxide), gold (doped transitional metal oxide), ruthenium (doped transitional metal oxide), silver (doped transitional metal oxide) or palladium doped transitional metal oxide, or one or more other catalysts.
- the second active layer is absorbent.
- the component comprises said third layer.
- the third layer may essentially consist of the water absorb/release layer.
- the first active layer is not directly in contact with the water absorb/release layer.
- the component comprises said third layer
- the second active layer is in contact with the water absorb/release layer.
- the second active layer absorbs water associated with the water absorb/release layer.
- the water absorb/release layer comprises one or more inorganic salts, glycols, silica gel, activated alumina, hygroscopic agents and water absorption polymers.
- a filter for an air purifier and/or dehumidification comprising a component as defined herein.
- the invention provides a method for the removal, such as decomposition, of atmospheric formaldehyde comprising passing air through a component as defined herein.
- a component for an air filter comprising a first active layer, a second active layer, and a water absorb/release layer, wherein the first active layer comprises one or more catalysts which optimally decompose formaldehyde at a relative humidity level of less than 40%; and wherein the second active layer comprises one or more reagents which optimally decompose formaldehyde at a relative humidity level of more than 65%.
- the catalyst(s) of the first active layer (“first catalysts") comprise one or more metals and/or metal oxides. In some embodiments the first catalysts comprise one or more transition metals, and/or transition metal oxides. In some embodiments, the first catalysts comprise one or more mixed metals, metal oxides, transition metals or transition metal oxides. In some embodiments the first catalysts are one or more of cerium oxide based manganese oxide (MnOx-CeOx); copper oxide/iron oxide (CuO-Fe 2 0 3 ); copper oxide/aluminium oxide (CuO-Al 2 0 3 ); palladium or cerium/aluminium oxide (Pd/Al 2 0 3 ;
- the reagents of the second active layer are one or more absorbents.
- the absorbents are one or more primary or secondary amines.
- the absorbents are a solution of one or more primary or secondary amines, for example tris(hydroxymethyl)aminomethane (tris) solution, methylamine solution, branched poly(ethyleneimine) solution, or poly(allylamine) solution.
- the second active layer may further comprise a substrate onto which the adsorbent may be loaded or located.
- the substrate is porous.
- the substrate is activated carbon fibre, silica, zeolite, ceramic, porous polymer or paper.
- the reagents of the second active layer may be one or more catalysts.
- the reagents of the second active layer may be one or more of platinum, gold, ruthenium, silver or palladium doped transitional metal oxide, one or more rare earth oxides, one or more forms of MnOx, or one or more transitional oxides.
- the transitional metal oxides may be one or more of titanium dioxide, manganese oxide, iron oxide, cerium oxide, vanadium oxide, copper oxide, zirconium oxide, molybdenum oxide and tungsten oxide.
- the component further comprises a substrate, which may have a mesh or net or honeycomb and the corrugated configuration.
- the first active layer is not directly in contact with the water absorb/release layer. This helps to avoid contact of the catalyst(s) located on the first active layer with moisture retained by the water absorb/release layer.
- the second active layer which may be absorbent, is in contact with the water absorb/release layer. This helps to allow water to migrate from the water absorb/release layer to the second active layer, wherein it is absorbed or otherwise captured.
- the water absorb/release layer comprises one or more inorganic salts, glycols, silica gel, activated alumina, hygroscopic agents and water absorption polymers.
- the water absorb/release layer comprises a substrate, to which a liquid is applied and then the substrate dried.
- a method for the decomposition of atmospheric formaldehyde comprising passing air through a component comprising a first active layer, a second active layer, and a water absorb/release layer, wherein the first active layer comprises one or more catalysts which optimally decompose formaldehyde at a relative humidity level of less than 40%; and wherein the second active layer comprises one or more reagents which optimally decompose formaldehyde at a relative humidity level of more than 65%.
- the first active layer may thus in embodiments comprise one or more active chemicals which have high capability of (indoor) formaldehyde removal at a relative humidity level of less than 40% (under room temperature).
- the second active layer may thus in embodiments comprise one or more active chemicals which have high capability of (indoor) formaldehyde removal at a relative humidity level of more than 65% (under room temperature).
- a high capability (or capacity) of indoor formaldehyde removal may especially mean that removal one-pass efficiency should be higher than 40%.
- the substrate comprises a corrugated paper structure carrying the adsorbent, wherein the paper comprises a substantially non-porous, organic fiber paper and in that the activated carbon is provided as a coating on the paper surface, such as described in WO99/46029, which is herein incorporated by reference.
- the corrugated paper structure comprises a honeycomb structure having air channels approximately 1 mm in diameter.
- the corrugated paper is of an E-flute construction having a cell height between substantially 1.2 to 1.4 mm and a pitch of substantially 3 mm.
- other embodiments may also be possible.
- the substrate may be porous or non-porous.
- the substrate may include macroscopic channels, like channels having channel diameters of 0.5 mm or larger.
- the substrate may also include microscopic channels, like zeolites or active carbon, with channels having channel diameters (substantially) smaller than 0.5 nm.
- the term “diameter” may also refer to "equivalent diameter”.
- the substrate may be a shaped body, like a channel like substrate.
- the substrate may be a monolithic substrate with channels (especially with diameters of 0.5 mm or larger). However, the substrate may also be planar. The substrate may also be curved, like a tube.
- the substrate may include a fibrous material, like paper, or corrugated paper, or cellulose filter paper.
- the substrate may also include fibrous material like glass
- microfibers or quartz microfibers, etc. etc..
- the component may be used as such.
- the component may be used in an environment or device wherein air is not transported with mechanical means.
- the component may be configured in a stationary device, like an air refresher (here, an air refresher without a gas displacement system is meant).
- the component may e.g. be configured in an air conditioner, a climate control system, an air distribution system, such as a ventilation system, a hood, etc..
- the component may be used indoor, such as in a house, an office, a hospitality area, etc..
- the component may also be used in mobile interiors, such as in cars, busses, coaches, cabins, trucks, trains, etc. etc..
- the component may also be comprised in a filter device comprising a gas displacement system.
- a filter device comprising a gas displacement system.
- Such filter device may be used to remove formaldehyde (and optionally other undesired species) from air.
- the component may be configured in a device or system including a gas displacement system.
- the invention also provides a filter device
- the filter device (especially useful for filtering air) comprising a housing having a gas inlet and a gas outlet, the component as described herein, and optionally a gas displacement system configured for retrieving a gas from the gas inlet, contacting the gas with the component, and further transporting the gas to the outlet.
- the filter device may also be indicated as "filtration device”.
- the filter device may comprise a channel, with the gas inlet at one side of the channel and the gas outlet at the other side of the channel.
- the gas displacement system such as a pump, such as a ventilator, displaces the gas (during operation of the filter device) from the inlet in the direction of the outlet (through the channel). The gas displacement system sucks gas into the inlet, and after purification, emits the gas from the outlet.
- gas especially refers to air.
- channel may also refer to a plurality of channels (like a channel system with functionally connected gas channels).
- the component may be configured within such channel. Gas may flow along the component. However, in other embodiments gas may also flow through the component, such as through micro channels or macro channels (see also above).
- a plurality of components may be used which may be configured as filter unit. Such filter unit may especially comprise one or more macro channels.
- the filter device comprises a filter unit comprising a plurality of components, wherein the filter unit is configured as through filter.
- a filter unit comprising a plurality of components, wherein the filter unit is configured as through filter.
- An example thereof is the structure as described in WO99/46029, which is herein incorporated by reference.
- Embodiment 1 A component for an air filter, wherein the component comprises a first active layer, a second active layer, and a water absorb/release layer, wherein the first active layer comprises one or more catalysts which optimally decompose
- the second active layer comprises one or more reagents which optimally decompose formaldehyde at a relative humidity level of more than 65%.
- Embodiment 2 A component as described (claimed) in embodiment 1, wherein the catalysts of the first active layer comprise one or more metals, metal oxides, transition metal or transition metal oxides.
- Embodiment 3 A component as described (claimed) in embodiment 1 or 2, wherein the catalysts of the first active layer are one or more of MnOx-CeOx, CuO-Fe 2 0 3 , CuO-Al 2 0 3 , Pd/Al 2 0 3 , Ce/Al 2 0 3 , Ag/MnOx, and Fe 2 0 3 /Mn0 2 .
- Embodiment 4 A component as described (claimed) in any of embodiments 1-
- the reagents of the second active layer are one or more absorbents.
- Embodiment 5 A component as described (claimed) in embodiment 4, wherein the absorbents are one or more primary or secondary amines.
- Embodiment 6 A component as described (claimed) in embodiment 5, wherein the absorbents are one or more of tris(hydroxymethyl)amino methane solution, methylamine solution, branched poly(ethyleneimine) solution, or poly(allylamine) solution.
- Embodiment 7 A component as described (claimed) in any of embodiments 1-6, wherein the second active layer further comprises a substrate.
- Embodiment 8 A component as described (claimed) in embodiment 7, wherein the substrate is one or more of activated carbon fibre, silica, zeolite, ceramic, porous polymer or paper.
- Embodiment 9 A component as described (claimed) in any of embodiments 1-3, wherein the reagents of the second active layer are one or more of platinum, gold, ruthenium, silver or palladium doped transitional metal oxide, one or more rare earth oxides, one or more forms of MnOx, or one or more transitional oxides, wherein the transitional metal oxide is one or more of titanium dioxide, manganese oxide, iron oxide, cerium oxide, vanadium oxide, copper oxide, zirconium oxide, molybdenum oxide or tungsten oxide.
- the transitional metal oxide is one or more of titanium dioxide, manganese oxide, iron oxide, cerium oxide, vanadium oxide, copper oxide, zirconium oxide, molybdenum oxide or tungsten oxide.
- Embodiment 10 A component as described (claimed) in any of embodiments
- Embodiment 11 A component as described (claimed) in any of embodiments 1-10, wherein the first active layer is not directly in contact with the water absorb/release layer and/or wherein the second active layer is in contact with the water absorb/release layer.
- Embodiment 12 A component as described (claimed) in any of embodiments
- Embodiment 13 A component as described (claimed) in any of embodiments 1-12, wherein the water absorb/release layer comprises one or more inorganic salts, glycols, silica gel, activated alumina, hygroscopic agents and water absorption polymers.
- Embodiment 14 A filter for an air purifier and/or dehumidification comprising a component according to any of embodiments 1-13.
- Embodiment 15 A method for the decomposition of atmospheric formaldehyde comprising passing air through a component comprising a first active layer, a second active layer, and a water absorb/release layer, wherein the first active layer comprises one or more catalysts which optimally decompose formaldehyde at a relative humidity level of less than 40%; and wherein the second active layer comprises one or more reagents which optimally decompose formaldehyde at a relative humidity level of more than 65%.
- Fig. 1 shows a schematic view of one embodiment of a component according to the invention
- Fig. 2 shows a schematic view of one embodiment of a component according to the invention
- Fig. 3 shows a graph demonstrating formaldehyde removal performance for a filter comprising a component according to the invention compared to a filter comprising a single catalyst layer;
- Fig. 4 shows a graph demonstrating the one-pass efficiency for a filter comprising a component according to the invention compared to a filter comprising a single catalyst layer.
- Fig. 5 shows the clean air delivery rate (CADR) of thermo catalytic oxidation material under conditions of increasing humidity DETAILED DESCRIPTION OF THE EMBODIMENTS
- the present invention comprises an air filter component for the decomposition of atmospheric formaldehyde.
- the component of the present invention comprises at least two active layers, which are both capable of the decomposition of formaldehyde, but which perform differently under the same conditions of relative humidity; and at least one water absorb/release layer.
- the term 'layer' as used herein indicates an arrangement of the material of the layer in question in a substantially planar fashion. The components of the layer do not need to be arranged continuously.
- the term 'layer' can thus mean a number of spheres or other shaped pieces of the material in question, arranged in substantially the same plane.
- the first active layer comprises one or more catalysts (referred to herein as one or more catalysts).
- first catalysts which optimally decompose formaldehyde under conditions of low humidity.
- low humidity' means a relative humidity of less than
- the first catalysts comprise one or more metals or metal oxides. In some embodiments the first catalysts comprise one or more transition metals, and/or transition metal oxides. In some embodiments, the first catalysts comprise one or more mixed metals, metal oxides, transition metals or transition metal oxides.
- cerium oxide based manganese oxide MnOx-CeOx
- copper oxide/iron oxide CuO-Fe 2 0 3
- copper oxide/aluminium oxide CuO-Al 2 0 3
- palladium or cerium/aluminium oxide Pd/Al 2 0 3 ; Ce/Al 2 0 3
- silver/manganese oxide Ag/MnOx
- the second active layer comprises one or more reagents which optimally decompose formaldehyde under conditions of high humidity.
- 'high humidity' as used herein means a relative humidity of more than 65%.
- the second active layer is able to capture water, for example by absorption or adsorption. In some embodiments the second active layer is able to capture and release water. In some embodiments the second active layer is able to capture water associated with the water absorb/release layer. In some embodiments the second active layer is able to capture excess water that is associated with the component as a result of saturation of the water absorb/release layer. In some embodiments, the formaldehyde decomposition performance of the second active layer is improved as a result of water located on or within or associated with the water absorb/release layer.
- the reagents themselves substantially constitute the second active layer.
- the second active layer further comprises a substrate with which the reagents may be associated, or upon which the reagents may be loaded or located.
- the reagents of the second active layer comprise one or more absorbents loaded on a substrate.
- the absorbents are one or more primary or secondary amines.
- the absorbents are a solution of one or more primary or secondary amines, such as
- the absorbent may be of a concentration of about 50%>, about 40%>, about 30%>, about 25%, about 20%, about 15% or about 10%. In some embodiments the absorbent is tris solution. In some embodiments the absorbent is tris solution having a concentration of about 20%.
- the substrate is porous. In some embodiments the substrate is one or more of activated carbon fibre, silica, zeolite, ceramic, porous polymer or paper. In some embodiments the substrate is activated carbon fibre.
- the reagents of the second active layer comprise one or more catalysts which optimally decompose formaldehyde under conditions of high humidity (referred to herein as "second catalysts").
- the second active layer comprises platinum, gold, ruthenium, silver or palladium doped transitional metal oxide.
- Transitional metal oxides include titanium dioxide, manganese oxide, iron oxide, cerium oxide, vanadium oxide, copper oxide, zirconium oxide, molybdenum oxide and tungsten oxide.
- the reagents of the second active layer comprise one or more rare earth oxides, or one or more forms of MnOx, or a mixture of transitional oxides (for example Mno.75Co2.25O4), the activity of which is increased under conditions of high humidity.
- the water absorb/release layer is capable of capturing, retaining and releasing water.
- the water absorb/release layer comprises one or more absorbents, which are capable of capturing water from the air, and a substrate, which is capable of absorbing and retaining water.
- the substrate comprises one or more of silica gel, activated alumina, water absorption polymers, or inorganic salts. In some embodiments, the substrate comprises one or both of anhydrous or hemihydrate calcium sulphate.
- the absorbents comprise one or more hygroscopic agents, glycols, water absorption polymers or inorganic salts. In some embodiments, the absorbents comprise one or both of potassium formite and potassium bicarbonate.
- the absorbents are applied to the substrate in liquid form. In some embodiments the absorbents are applied to the substrate by spraying, coating or impregnation. The substrate may then be dried. For example, a mixture of water
- absorption polymer and hydroscopic agent may be prepared as a solution, and then coated or sprayed onto a pre-prepared porous substrate. The substrate may then be dried.
- a solution of potassium formite and potassium bicarbonate may be prepared and applied to anhydrous or hemihydrate calcium sulphate.
- a solution comprising 8% potassium formite and 8% potassium bicarbonate may be sprayed on the surface of 40% prepared anhydrous calcium sulphate.
- the substrate is made by moulding a mixture of inorganic salt or water absorption polymers and one or more hygroscopic agents.
- the component of the present invention may further comprise a substrate, which may be used to support one or more of the layers.
- the substrate may comprise any substance suitable for supporting the layer(s) with which it is in contact, and which is also suitable for use in an air purification and/or dehumidification system.
- the substrate is of a mesh or net configuration, with 'holes' in which to locate elements of one or more of the layers.
- the substrate is made of ceramic, metal or polymer, for example, a metal net, or a polymer having a honeycomb structure.
- the layers may be arranged in any configuration.
- the layers are arranged so that the first active layer is not directly in contact with the water absorb/release layer. This helps to avoid contact of the catalyst(s) located on the first active layer with moisture retained by the water absorb/release layer.
- the layers are arranged so that the second active layer is in contact with the water absorb/release layer. This helps to allow water to migrate from the water absorb/release layer to the second active layer, wherein it is absorbed or otherwise captured.
- each of the layers of a component according to the present invention may be determined by the method of manufacture. In some embodiments, the thickness of the layers is not consistent between layers. In some embodiments, one or more of the layers has a thickness of about 3000 ⁇ , 2000 ⁇ , 1000 ⁇ , 500 ⁇ , 200 ⁇ , 150 ⁇ , 100 ⁇ , 90 ⁇ or 50 ⁇ . In some embodiments, the first and/or second active layer of the component has a thickness of about 2000 ⁇ , 1000 ⁇ , 500 ⁇ , 200 ⁇ , 150 ⁇ , 100 ⁇ , 90 ⁇ or 50 ⁇ .
- a component according to the present invention may be included in the filter of an air purification and/or dehumidification system, such as an air purifier and/or air dehumidifier.
- the dimensions of a component according to the present invention are such that it can be located within the filter system of an air purifier and/or dehumidifier.
- the length of a component according to the present invention may be less than about 370mm; the width of a component according to the present invention may be less than about 280mm, and the depth of a component according to the present invention may be less than about 30mm.
- An air purifier and/or dehumidifier containing a component according to the present invention may comprise a housing which comprises means for activating and deactivating the purifier and/or dehumidifier, and/or a user interface, to allow selection of the desired function (air purification and humidification; air purification only; air humidification only, or selection of function as dependent upon ambient relative humidity values).
- operation of the air purifier and/or dehumidifier is controlled by means of a humidity sensor, which uses the set-point ambient relative humidity level RH max and RH m i n .
- a measured RH > RH max switches the air purifier and/or dehumidifier on; and a measured RH ⁇ RH m i n switches the air purifier and/or dehumidifier off.
- the air purifier and/or dehumidifier further comprises a user reminder mechanism, such as the illumination of a light or the activation of a sound, in order to indicate to the user when to change the component or filter.
- a user reminder mechanism such as the illumination of a light or the activation of a sound, in order to indicate to the user when to change the component or filter. In some embodiments this may be effected via a sensor and an algorithm, as provided, for example, by a suitably programmed computer.
- Atmospheric moisture is captured by the water absorb/release layer. Atmospheric
- formaldehyde is decomposed by the catalysts of the first active layer and/or the reagents of the second active layer.
- the level of formaldehyde decomposition achieved by the respective layers depends upon the humidity of the air drawn across the component:
- the air drawn across the component is relatively dry.
- the water absorb/release layer absorbs moisture present in the air. Accordingly, decomposition of formaldehyde is principally effected by the moisture-sensitive catalyst(s) located on the first active layer.
- decomposition of formaldehyde may be effected by the catalyst(s) located on the first active layer.
- Decomposition may also be effected by the reagents located on the second active layer, which can decompose formaldehyde at levels of higher humidity in comparison to the catalyst(s) of the first active layer.
- the water absorb/release layer absorbs moisture present in the air, thereby reducing the amount of moisture contacting the first active layer.
- the second active layer may also absorb moisture present in the air. Decomposition of formaldehyde is principally effected by the reagents of the second active layer.
- the water absorb/release layer may saturate.
- Excess water from the water absorb/release layer may be captured and utilised by the second active layer, thereby maintaining or enhancing its formaldehyde-decomposing ability.
- the water absorb/release layer is capable of releasing water it has retained, thereby regenerating.
- the released water may maintain or enhance the formaldehyde-decomposition ability of the reagents located on the second active layer.
- the air filter component of the present invention thus gives rise to several benefits:
- the component can decompose formaldehyde under a wide range of humidity levels. This is achieved as a result of the provision of active layers which have different formaldehyde decomposition abilities under the same conditions of humidity; and the provision of a water absorb/release layer which controls the amount of moisture to which each of the layers is exposed.
- the water absorb/release layer maintains the first active layer, which comprises moisture-sensitive catalysts, in a dry or relatively dry condition, whilst supplying the second active layer, which comprises reagents which decompose formaldehyde under higher levels of humidity, with moisture that has been captured from the air passing through the component.
- the component thus achieves improved and consistent decomposition of atmospheric formaldehyde under varying levels of humidity, such as those typically found in domestic situations.
- the component of the present invention has an improved lifetime: firstly, the first catalyst(s), which are typically expensive materials, are protected from degradation as a result of exposure to moisture. The lifetime of the catalyst is thereby extended. Secondly, the water absorb/release layer regenerates in response to varying conditions of humidity, such as those typically encountered in domestic situations.
- Fig. 1 shows a schematic view of one embodiment of a component according to the invention.
- the component comprises a first active layer (1), which comprises one or more first catalysts, which optimally decompose formaldehyde at low levels of humidity; a second active layer (2), which comprises one or more reagents which optimally decompose formaldehyde at high levels of humidity; a water absorb/release layer (3); and a substrate (4).
- Fig. 2 shows a schematic view of an alternative embodiment of a component according to the invention.
- the component comprises a first active layer (1), which comprises one or more first catalysts, which optimally decompose formaldehyde at low levels of humidity; a second active layer (2), which comprises one or more reagents which optimally decompose formaldehyde at high levels of humidity; and a water absorb/release layer (3).
- first active layer (1) which comprises one or more first catalysts, which optimally decompose formaldehyde at low levels of humidity
- a second active layer (2) which comprises one or more reagents which optimally decompose formaldehyde at high levels of humidity
- a water absorb/release layer (3) In Fig. 1 the small circles are absorb layer 3 whereas in Fig. 2 the small circles are active layer 2.
- the materials are in a layout like Fig. 1.
- the substrate is ceramic which is used to support functional layers;
- the water absorb/release layer is made of inorganic salt with mixture of potassium formite, potassium bicarbonate and hemihydrate calcium sulfate;
- the second active layer is prepared by loading chemical absorbents (20% Tris solution) on activated carbon fibre;
- the first active layer is made of catalyst which is cerium oxide based manganese oxide (MnOx-CeOx).
- Cerium oxide based manganese oxide MnOx-CeOx
- Such materials may also be used for the layout of Fig. 2.
- Figs. 3 and 4 demonstrate a comparison of formaldehyde removal performance, under different conditions of humidity, by a filter comprising a single catalyst layer composed of cerium oxide based manganese oxide; and a component in accordance with Fig. 2 of the present application. Data were generated in a 30 m 3 air tight chamber in both cases. Clean Air Delivery Rate (CADR) values (Fig. 3) were measured using the protocol in
- the one-pass efficiency (OPE) values were obtained by dividing the CADR values by the flow rate generated by the air purifier.
- CADR is a measure of the volume of atmospheric pollutants that can be removed by the filter in one hour.
- One-pass efficiency measures the percentage of atmospheric pollutants captured in single pass of air through the filter.
- Figs. 3 and 4 demonstrate that the filter comprising a single catalyst layer removes formaldehyde effectively under 50% and 36%> relative humidity, but CADR value declines as the humidity increases.
- the formaldehyde removal performance of the filter comprising a single catalyst layer decreases as humidity increases.
- the component according to the present invention removes formaldehyde effectively both under low humidity and high humidity, with little decrease of CADR (and therefore loss of formaldehyde removal performance) under high humidity (68% relative humidity) in comparison to lower levels (51% relative humidity).
- substantially herein, such as in “substantially consists”, will be understood by the person skilled in the art.
- the term “substantially” may also include embodiments with “entirely”, “completely”, “all”, etc. Hence, in embodiments the adjective substantially may also be removed.
- the term “substantially” may also relate to 90%> or higher, such as 95% or higher, especially 99% or higher, even more especially 99.5% or higher, including 100%.
- the term “comprise” includes also
- the invention further applies to a device comprising one or more of the characterizing features described in the description and/or shown in the attached drawings.
- the invention further pertains to a method or process comprising one or more of the characterizing features described in the description and/or shown in the attached drawings.
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Abstract
La présente invention concerne un composant de filtre à air pour la décomposition du formaldéhyde atmosphérique par l'intermédiaire de, au moins en partie, une oxydation catalytique, et un procédé associé pour la décomposition du formaldéhyde atmosphérique par l'intermédiaire de, au moins en partie, une oxydation catalytique. Le composant comprend au moins une première couche active, au moins une deuxième couche active, et au moins une couche d'absorption/libération d'eau, la première couche active comprenant un ou plusieurs catalyseurs qui décomposent de façon optimale le formaldéhyde à un taux d'humidité relative inférieur à 40 % ; et la deuxième couche active comprenant un ou plusieurs réactifs qui décomposent de façon optimale le formaldéhyde à un taux d'humidité relative supérieur à 65 %. Le composant peut décomposer le formaldéhyde dans une large plage de taux d'humidité. Le composant protège en outre un ou plusieurs catalyseur(s) situé(s) sur la première couche active contre l'exposition à l'humidité, de manière à prolonger la durée de vie du catalyseur et, par conséquent, du composant.
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CN2015099888 | 2015-12-30 | ||
CNPCT/CN2015/099888 | 2015-12-30 | ||
EP16152664 | 2016-01-26 | ||
EP16152664.5 | 2016-01-26 |
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PCT/EP2016/081843 WO2017114687A1 (fr) | 2015-12-30 | 2016-12-20 | Composant pour filtre à air |
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CN108031279A (zh) * | 2017-12-12 | 2018-05-15 | 成都育芽科技有限公司 | 一种环保甲醛净化剂及其制备方法 |
CN109012647A (zh) * | 2018-07-03 | 2018-12-18 | 厦门大学 | 一种柴油机尾气碳烟脱除金属复合氧化物催化剂及其制备方法 |
CN109289916A (zh) * | 2018-10-24 | 2019-02-01 | 山西新华化工有限责任公司 | 高压水热负载法制备甲醛净化材料方法 |
CN110559844A (zh) * | 2018-06-06 | 2019-12-13 | 中国石油化工股份有限公司 | 一种含有苯乙烯组分有机废气的化学预处理方法 |
CN110559845A (zh) * | 2018-06-06 | 2019-12-13 | 中国石油化工股份有限公司 | 一种含有丁二烯组分有机废气的化学处理方法 |
EP3590591A1 (fr) | 2018-07-05 | 2020-01-08 | Taurus Research and Development S.L.U. | Filtre à air pour éliminer des composés organiques volatile analogues à l'aldéhyde de l'air intérieur |
WO2020086525A1 (fr) * | 2018-10-23 | 2020-04-30 | Basf Corporation | Filtre adsorbant de catalyseur pour la purification de l'air |
CN111921375A (zh) * | 2020-09-03 | 2020-11-13 | 珠海格力电器股份有限公司 | Ag-MnO2/AC复合除醛材料、其制备方法、除醛模块和空气净化设备 |
EP3842120A1 (fr) | 2019-12-23 | 2021-06-30 | Taurus Research and Development S.L.U. | Filtre et procédé d'élimination de cov similaires à de l'aldéhyde à partir de l'air intérieur |
CN114392736A (zh) * | 2022-02-17 | 2022-04-26 | 苏州道一至诚纳米材料技术有限公司 | 常温净化甲醛的催化膜及其制备方法与用途 |
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CN110559845A (zh) * | 2018-06-06 | 2019-12-13 | 中国石油化工股份有限公司 | 一种含有丁二烯组分有机废气的化学处理方法 |
CN109012647A (zh) * | 2018-07-03 | 2018-12-18 | 厦门大学 | 一种柴油机尾气碳烟脱除金属复合氧化物催化剂及其制备方法 |
EP3590591A1 (fr) | 2018-07-05 | 2020-01-08 | Taurus Research and Development S.L.U. | Filtre à air pour éliminer des composés organiques volatile analogues à l'aldéhyde de l'air intérieur |
WO2020008041A1 (fr) | 2018-07-05 | 2020-01-09 | Taurus Research And Development, Slu | Filtre à air pour éliminer les covs de type-aldéhyde à partir d'air intérieur |
US11883774B2 (en) | 2018-07-05 | 2024-01-30 | Air Tech Group, Slu | Air filter for removing aldehyde-like VOCs from indoor air |
WO2020086525A1 (fr) * | 2018-10-23 | 2020-04-30 | Basf Corporation | Filtre adsorbant de catalyseur pour la purification de l'air |
CN109289916A (zh) * | 2018-10-24 | 2019-02-01 | 山西新华化工有限责任公司 | 高压水热负载法制备甲醛净化材料方法 |
WO2021129985A1 (fr) | 2019-12-23 | 2021-07-01 | Taurus Research And Development, Slu | Filter et method pour éliminer les cov de type aldéhyde de l'air intérieur |
EP3842120A1 (fr) | 2019-12-23 | 2021-06-30 | Taurus Research and Development S.L.U. | Filtre et procédé d'élimination de cov similaires à de l'aldéhyde à partir de l'air intérieur |
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CN114392736A (zh) * | 2022-02-17 | 2022-04-26 | 苏州道一至诚纳米材料技术有限公司 | 常温净化甲醛的催化膜及其制备方法与用途 |
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