Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEM AND METHOD FOR AIR TREATMENT
CROSS REFERENCE TO RELATED APPLICATIONS
U.S. Patent Application Serial No. 15/878,598, filed 24 January 2018, U.S.
Patent Application, Serial No. 15/461,433, filed 16 March 2017, and U.S.
Provisional Patent
Application Serial No. 62/626,548, filed on 05 February 2018, are hereby
incorporated by
reference herein in their entirety and are made a part hereof, including but
not limited to those
portions which specifically appear hereinafter.
BACKGROUND OF THE INVENTION
Field of the Invention
The subject matter described herein relates generally to cleaning air, and
more
specifically to built-in air cleaning systems that treat air by removing one
or more impurities
from the air and are controlled with inputs from the operation of components
and systems in
the built-in environment.
In one aspect, the subject matter disclosed herein relates to a system of
modular
and interchangeable methods and assemblies for treating an atmosphere to
remove impurities.
Such impurity removal may involve one or more of a treatment to sanitize,
filter,
decontaminate, deodorize, purify, condition, heat, humidify, and/or dry the
atmosphere, for
example. Such methods and assemblies may employ a particulate filter to remove
aerosols and
particulate matter, germicidal UV light at wavelengths between 200 and 300 nm
to inactivate
micro-organisms, ozone generation to oxidize chemical contaminants, the ozone
in conjunction
with UV light to more rapidly oxidize impurities in the air, an oxidizing
catalyst to convert
chemical compounds in the air into less harmful constituents, a catalytic
decomposer to destroy
ozone, UV light to promote more complete mineralization of VOCs across a low
temperature
oxidizing catalyst, ozone to promote more complete mineralization of VOCs
across the low
temperature catalyst, and a fan or other air mover to draw air through the
system. In one
aspect of the invention, the materials, apparatuses and assemblies are
integrated into an air
cleaning product that is built into a residential kitchen and/or is connected
electronically to a
range and a ventilation hood in order to better manage the grease and odors
that are created
from the cooking process. In another aspect of the invention, the air cleaning
product is
integrated into and/or within an automobile where it is connected
electronically to the remote
starter, automobile cabin temperature sensor, and/or air conditioning system
to remove VOCs
that evolve from the cabin materials. In another aspect of the invention, the
air cleaning product
is built into a refrigerator and/or connected electronically to a door switch,
an internal
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temperature sensor, and/or an evaporator fan to remove odors and VOCs from the
food storage
compartment.
Discussion of Related Art
Residential, commercial, industrial, and/or automotive spaces can have
atmospheres that are contaminated with odors, gases, volatile organic
compounds, volatile
inorganic compounds, microbes, particulate matter and/or allergens that cause
discomfort or
health hazards to people occupying those spaces. Conventional air cleaning
technologies filter
the air with materials that trap or otherwise adsorb or absorb gases, odors,
microbes and/or
allergens. These trapped or otherwise held contaminants are always present in
the filters and
can be re-emitted into the atmosphere. Activated carbon is typically used to
capture odors
and/or volatile compounds from the air. It is well known that activated carbon
captures more
contaminants when the contaminant concentration in the environment is high.
When the
contaminant concentration falls, the gases begin to desorb from the activated
carbon and
exhaust or flow back into the air. While this is not useful to completely
remove the
contaminants from the air, it is a way to make flow of contaminants into an
improved air
treatment system more stable when the concentration in the environment is
rapidly changing.
One preferred air cleaning approach would be to convert the odors, gases
and/or volatile
organic compounds into harmless compounds that are not noticed by or cause
harm to
occupants in the room. It is also preferable for an air purifier to inactivate
microbes and/or
alter allergens in a way that renders them harmless rather than to capture the
particles without
altering their properties. It is also desirable to have an air purifier that
offers a self-clean cycle
that deodorizes, oxidizes or otherwise cleans its internal components of or
from captured
pollutants that cause odors, or can reproduce and grow over time (such as
microbes) or that
could decrease the performance of the components that are removing the
pollutants from the
air. That way, there is less need to replace filters that are filled with
particulates and other
contaminants that can be re-emitted into the atmosphere.
There is a need for an alternative approach to air cleaning that would convert
or
inactivate rather than capture gaseous contaminants in the atmosphere. There
is also a need to
ensure that the contaminants that are converted by the system are fully
oxidized and do not
produce significant secondary contaminants. There is also a need for an
alternative approach
to air cleaning that incorporates a self-clean function to deodorize and
sanitize the filters that
capture aerosols. There is a need for a catalyst containing air cleaning
system to periodically
refresh the catalyst so that its performance is maintained over time. There is
a need for the
various components of an air cleaning system to be modular so that the
manufacturer has a
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cost-effective way of creating a suite of products that preferentially clean
one type of pollutant
or another, or that are offered to the market at different price points with
different air cleaning
capabilities.
There is a need for an air cleaning system that cleans cooking odors from a
room
.. such as a kitchen or combined kitchen and/or dining room. This cooking odor
removal system
could beneficially be configured as a built-in appliance that has a set
operating cycle tied to the
operation of the cooktop and the ventilation hood. With a built-in system, the
air cleaner could
be connected electronically to the cooktop and the ventilation hood such that
the ventilation
hood operates when the cooktop is powered or energized. When cooking is over
or complete
and the cooktop power is shut off, the ventilation hood fan could be shut down
and the air
cleaner could be turned on. The air cleaner could then begin an air cleaning
cycle that removes
residual odors and aerosols of grease or oils, for example, in the air in the
kitchen. This air
cleaning cycle could be customized based on the size of the kitchen, for
example.
There is a need for an air cleaning system that could be built into an
automobile
and operated in conjunction with other automobile systems or characteristics,
such as the
internal temperature or the operation of the air conditioning system. An air
cleaner built into
an automobile could be activated by the remote starting fob, and/or mobile
telephone, for
example, so that the air begins to be cleaned before the occupant enters the
car. An air cleaning
system built into a car could be activated when the temperature in the car
exceeds a threshold
that could lead to excessive generation of VOCs from the materials in the
cabin. This
automobile air cleaning system could be activated or deactivated as
appropriate when the air
conditioning and ventilation system of the car are operating.
There is a need for an air cleaning system to be built into a refrigerator so
that
it cleans the air in the refrigerator in response to certain conditions of the
refrigerator, such as
turning off when the door is opened, or turning on after the door has been
subsequently closed,
for example, after new foods have been added to the refrigerator. The air
cleaning device could
be operated preferentially during certain cooling cycles or conditions, such
as when the internal
evaporator fan is operating and/or when the compressor is not operating.
SUMMARY OF THE INVENTION
It is an object of the subject matter disclosed herein to provide an improved
method and/or apparatus for treating an atmosphere containing pollutants such
as chemical
contaminants, volatile organic compounds, odors, aerosols, particulate matter,
allergens,
pollen, volatile inorganic compounds and/or other airborne compounds that are
unhealthy,
unwanted or unpleasant.
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Also provided are a method and device to generate, use, and ultimately at
least
partially destroy the generated ozone for decontamination, deodorization,
and/or conditioning
of the air and/or the materials. The air cleaning unit can be positioned
inside a space of various
suitable configurations or designs. Air that requires treatment is drawn from
the space into the
.. cleaning unit, passes across an ozone generator, such as a UV bulb that
emits light rays in the
UV wavelength that generates ozone, or a corona discharge unit that creates
ozone from a
voltage difference across a gap. In one embodiment it has been found that the
combination of
ozone and UV light serve to rapidly destroy contaminants within the cleaning
unit. The clean
air is then drawn across a catalyst to dissociate ozone to molecular oxygen.
Clean, ozone-free
air is then reintroduced to the chamber or surrounding space.
Also provided are a method and device to oxidize volatile gaseous compounds,
odors, and molecular contaminants in three steps. In the first step, certain
molecules are
partially broken down by ozone in the presence of UV light. These products of
the reaction
between the contaminants and ozone in the presence of UV light may be smaller
hydrocarbons
or other molecules that have been transformed in some way from their original
chemical
structure. The products of the reaction may be partially or fully oxidized
compounds. In a
second step, these transformed molecules are then passed through an oxidizing
catalyst that
can further oxidize or completely mineralize the transformed chemicals. In
this method, air
that requires treatment is drawn from the chamber into the cleaning unit, and
passes across an
ozone generator, such as a UV bulb that emits light rays in the UV wavelength
that generates
ozone, or a corona discharge unit.
The invention provides an apparatus for treating air that includes a housing
with
an air inlet and an air outlet. The housing encloses an air treatment zone and
an ozone removal
zone, wherein the ozone removal zone is positioned downstream of the air
treatment zone with
respect to a flow direction of the air being treated. A first catalyst layer
extends across the air
treatment zone and includes a first catalyst material. A second catalyst layer
extends across
the ozone removal zone and is spaced apart from the first catalyst layer. The
second catalyst
layer includes a second catalyst material that is different from the first
catalyst material,
wherein the first catalyst material oxidizes organic and/or inorganic
compounds, and the second
catalyst material removes ozone Embodiments of this invention include an ozone
generator
and/or an ultraviolet source disposed upstream of, downstream of, or within
the first catalyst
layer.
As an example, a first ozone generator and/or an ultraviolet source is
downstream of the first catalyst layer, and is configured to promote oxidation
of chemical
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contaminants via a first catalyst material and/or to clean the first catalyst
layer. A second ozone
generator and/or ultraviolet source can be disposed upstream of the first
catalyst layer. The
first ozone generator and/or ultraviolet source can also be downstream of the
second catalyst
layer and a further catalyst layer can be downstream of the first ozone
generator and/or an
ultraviolet source, wherein the further catalyst layer comprises the first
catalyst material or the
second catalyst material.
The invention further includes an apparatus for treating air with an ozone
generator within the air treatment zone, a plurality of first catalyst layers
each spaced apart
from each other and extending across the air treatment zone, and each
including a first catalyst
material, and a plurality of second catalyst layers extending across the ozone
removal zone,
each spaced apart from each other and the first catalyst layers. The second
catalyst layers each
include a second catalyst material that is different from the first catalyst
material, wherein each
of the first and second catalyst materials comprises manganese. An ozone
and/or ultraviolet
source is disposed within an air flow space between the first and second
catalyst layers or
between the second catalyst layers and a downstream further catalyst layer,
wherein the further
catalyst layer comprises the first catalyst material or the second catalyst
material.
The invention further includes a method for treating air including: partially
oxidizing chemical contaminants via application of ozone and/or ultraviolet
light; oxidizing the
chemical contaminants via a first catalyst material downstream of the
application of ozone
and/or ultraviolet light; and removing ozone via a second catalyst material
downstream of the
first catalyst material. The method can further include applying further ozone
and/or ultraviolet
light downstream of or within (e.g., downstream of the first catalyst inlet or
sheet) the first
catalyst material, and/or downstream of or within the second catalyst
material. The
downstream application can assist in increasing an oxidation rate of the
chemical contaminants
throughout a layer of the first catalyst material. The method can further
include altering a rate
at which the chemical contaminants enter a layer of the first catalyst
material via a layer of
adsorbent material upstream of the layer of the first catalyst material.
Embodiments of this invention further include a method for treating air
including the steps of: providing or foiming an air treatment zone in a
housing downstream of
a housing inlet; partially oxidizing chemical contaminants via a first
application of ozone
and/or ultraviolet light within the air treatment zone; further oxidizing the
chemical
contaminants through a first catalyst layer including a first catalyst
material, downstream of
the application of ozone and/or ultraviolet light; removing ozone through a
second catalyst
layer including a second catalyst material downstream of the first catalyst
layer; and applying
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further ozone and/or ultraviolet light downstream of the first and/or second
catalyst material
layer. The further ultraviolet light can additionally or alternatively be
adapted to clean the first
catalyst layer and/or the second catalyst layer.
In embodiments of this invention, it has been found that the combination of
ozone and UV light serves to rapidly oxidize contaminants within the cleaning
unit. The UV
light can be generated by the UV bulb that generates the ozone (wavelengths
less than 200 nm),
or by a second UV bulb generating light at wavelengths in the UVC spectrum
(wavelength 200
¨ 300 nm) or by light emitting diodes (LEDs) that emit at UV wavelengths that
are 250 nm and
longer. The UV light could also be generated by an array of LED sources that
individually
emit at various wavelengths in the UVA, UVB and UVC spectra. The partially
oxidized
contaminants are then drawn through a catalyst designed to further oxidize
these partially
oxidized contaminants.
The ozone and/or UV sources can be used to provide a different self-cleaning
mode. The invention further includes steps and configurations for cleaning the
first catalyst
material by exposing the first catalyst material to ozone at a flow rate lower
than used in an air
cleaning mode and an ozone concentration higher than used in the air cleaning
mode, wherein
the cleaning removes chemicals that have been adsorbed on the first catalyst
material. The
invention includes steps of establishing a predetermined operating cycle
including an air
cleaning mode and a self-cleaning mode, wherein the operating cycle comprises
a first air
cleaning time at a first flow rate and a second self-clean time at a reduced
flow rate; and
operating the further downstream ozone and/or ultraviolet light during the
self-cleaning mode.
Catalysts useful in the invention may be specifically formulated to oxidize
contaminants at room temperature. A room temperature or relatively low
temperature catalyst
is one that is formulated to perform at temperatures between 00 and 40 C.
Alternatively, a
heater in the system could be used in conjunction with a catalyst formulated
to operate at
elevated temperatures. A catalyst system in the air purifier could contain two
catalyst
foimulations: one catalyst designed to oxidize contaminants such as
hydrocarbons, aldehydes,
amines, alcohols or other compounds; and the second catalyst designed to
dissociate ozone to
molecular oxygen. In the third step, the ozone containing air is drawn over
the ozone reduction
catalyst to remove ozone from the air. A second UV lamp could be used after
either catalyst
layer to achieve more complete oxidation of the VOCs. Clean, ozone-free air is
then emitted
from the device and reintroduced to the room.
In some embodiments, in the apparatus for treating air, the device includes a
first catalyst section hosting the catalyst, a second catalyst section hosting
the different catalyst,
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and a spacer positioned between the first and the second catalyst sections. In
some
embodiments of the section holding the catalysts, each catalyst section is
comprised of a set of
catalyst sheets separated by spacers. These sheets of catalysts may be in the
geometry of an
expanded metal, a honeycomb, a corrugated sheet, a porous foam and/or other
volume with a
relatively high surface area that allows air to flow through it. The spacers
allow mixing of the
air between the catalyst sheets, decreasing the chance that some contaminants
in the air travel
through the catalyst section untreated. The spacers also can create a region
of turbulence at the
entrance section of each catalyst layer that enhances reaction rates in the
channels of the
catalyst.
In some embodiments, the catalysts may be comprised of active materials that
oxidize chemical compounds at room temperature. This catalyst may be made of
manganese
oxides, for example. In some embodiments of this invention, the catalyst
comprises manganese
dioxide wherein manganese dioxide is a general term and is intended to refer
to and include
different forms of manganese oxides, including but not limited to
cryptomelane, Nsutite,
pyrolusite, ramsdellite which is also referred to as alpha-Mn02, beta-Mn02 or
R-Mn02 or
oxides of manganese with a molar ratio of oxygen to manganese of 1 to 3, for
example.
The catalyst may be enhanced by including other elements, such as sodium,
cerium, copper, or precious metals to provide higher conversion or more
specific conversion
of individual impurities, such as volatile organic compounds.
The catalyst material itself may be prepared at different temperatures or
using
different processes in order to achieve specific performance characteristics.
The calcining
temperature of the material can impact the surface area of and the number of
active sites on the
material. The surface area and active sites can impact the relative rates of
adsorption and
desorption from the catalyst. The differences in rates of adsorption and
desorption can impact
the relative conversion efficiencies of VOCs and ozone. These differences can
also impact the
sensitivity of the catalyst to moisture. In this way, two catalysts made of
the same chemical
materials can have widely different performance levels and different uses. For
example, a
manganese oxide catalyst prepared in one way can be an excellent low
temperature oxidation
catalyst. A manganese oxide catalyst prepared in a different way can be an
excellent ozone
removal catalyst.
The catalyst may be applied to a variety of substrates that provide a useful
geometry for the system. The substrate may be a metal honeycomb structure, a
metal
corrugated structure, a ceramic corrugated structure, an extruded ceramic
structure and/or an
expanded metal structure.
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In some embodiments, the catalyst is designed to resist the adsorption of
water
into the active sites of the catalyst. The adsorption of water can decrease
the effectiveness with
which catalysts convert ozone to oxygen. Hydrophobic compounds such as
siloxanes are added
to catalysts to resist the adsorption of water molecules. Alternatively, the
pore structure can be
altered to allow water to be desorbed from the catalyst material.
The cell density of the support structures can be between 100 and 1000 cells
per
square inch, with preferable performance of cell densities of the support
structures between
350 and 900 cells per square inch. The catalytic activity of the manganese
catalyst can be
enhanced by positioning UV light to shine into the honeycomb structure. The
enhancement of
the reaction rate may result from increasing the energy level of an adsorbed
gas molecules or
from creating various reactive species that cause additional oxidation of the
adsorbed VOCs.
The catalytic activity of the manganese catalyst may be refreshed by adding
ozone between the
layers of the oxidizing catalyst in order to maintain an active oxidizing
atmosphere throughout
the catalyst layers.
It is another object of the subject matter disclosed herein to trap and treat
particulate matter or aerosols on or in a filter. This filter may be a high
efficiency particle
arresting (HEPA) filter or other particle capturing material that restricts
the passage of particles
or aerosols through the material. It is desirable to treat the particles on
the filter so that the
contaminants themselves do not degrade the performance of the filter. It is
also desirable to
treat the particles so that they are rendered inert and cannot cause harm if
the particles come
off the filter either in standard use or when replacing the filter. It is
desirable to treat the
particles on the filter so that they do not emit odors or toxic gases into the
atmosphere while
attached to and concentrated on the filter. It is desirable to treat any
microbial particles so that
the microbes cannot reproduce on the filter and sporulate or otherwise
regenerate from the filter
itself.
It is another object of the subject matter disclosed herein to trap and treat
aerosols of grease or oil on a cleanable grease filter that is made of metal
screen, expanded
metal, and/or other water washable filter. This grease filter could be
configured so that a direct
exposure to UV light and ozone oxidize the grease off of the filter. The
grease filter could also
be configured to allow large amounts of grease to flow off the filter into one
or more channels
specifically designed to contain and direct the grease into a cleanable
storage container.
One method of treating the particulate matter on the filter is to expose the
filter
to ozone in a manner that ensures that the ozone does not exit or discharge
the air cleaner and
become introduced into the storage chamber or enclosed room or space. One
method to clean
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the filter with ozone is to flow air through the unit and turn on or start an
ozone generating
device such as a UV bulb that operates below 200 nm wavelength, or by turning
on or starting
a corona discharge unit. It may be preferable to adjust the air flow to a
level that allows the
ozone concentration to rise above a threshold level, such as between 300 ppb
and 10 ppm.
Preferably this concentration may be between 500 ppb and 2 ppm. It may also be
preferable
to adjust the flow rate so that a catalyst in the system removes the ozone on
the downstream
side of the filter and operates at a reasonable space velocity, such as less
than 200,000 hr-1 or
more preferably less than 100,000 hr-1. By adjusting the air flow rate during
the self-clean
cycle with ozone generation, the particle treatment can be maximized and the
system cost can
be minimized. This operational limitation will reduce the amount of ozone
reduction catalyst
needed while producing high enough concentrations of ozone to fully clean the
filter of odors
and organic materials.
To ensure that the products of oxidation are as fully mineralized as possible,
it
may be preferable to operate the system at catalyst space velocities that are
even lower, such
as at 10,000 hr-1. It is another object of the subject matter disclosed herein
to provide a self-
cleaning function for the internal components of the air purifier, for
example, by exposing a
filter to UV light while passing or flowing air through the filter at a low, a
medium, a high or
no flow rate to deodorize and sanitize as well as oxidize material captured on
or attached to the
filter.
It is another object of the subject matter disclosed herein to provide a self-
cleaning function that combines exposure of a particulate filter (e.g., a
particle matter filter) to
UV light with air flow through the particulate filter to deodorize, sanitize
and/or oxidize
material captured on a filter or a filter material, preferably but not
necessarily in combination
with a control cycle that reduces the air flow rate to a low level while
exposing the particulate
filter to ozone gas and reducing a space velocity of the ozone-containing air
through a catalyst
downstream of the particulate filter to a level less than 100,000 hr-1, for
example.
It is another object of the subject matter disclosed herein to provide a self-
cleaning function that cleans the catalyst of adsorbed contaminants that have
not been fully
reacted and desorbed from the catalyst. This catalyst self-cleaning function
is in some
embodiments is provided by creating an air flow through the unit and operating
the ozone
generator to establish an ozone concentration throughout the catalyst that
will remove at least
a portion of the contaminants on the catalyst that occupy active sites and
would otherwise
decrease the catalytic performance of the catalyst. When the catalyst is
exposed to ozone at a
preferable concentration at a preferable space velocity, the ozone will react
with the adsorbed
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chemicals and allow them to be desorbed from the catalyst. Space velocities
for this function
could be as low as 10,000 hr-1 for example.
In another aspect of this invention, it may be preferable to operate a heater
upstream of the catalyst during the self-cleaning mode in order to increase
the reaction rate of
the ozone with the molecules adsorbed in the surfaces of the catalyst. The
higher temperatures
increase the reaction rate of the molecules with the ozone and provide a more
complete
oxidation of the molecule. The higher catalyst temperatures also can increase
the desorption
rate of the oxidized chemicals off of the surface of the catalyst. The heating
of the catalyst can
also serve to drive any adsorbed water out of the catalyst, thus increasing
its ozone conversion
performance. In another aspect of the invention, the heater may surround the
exterior of the
catalyst to provide heating of the catalytic material with limited or no air
flow through the
catalyst.
In another aspect of this invention, it may be preferable to operate a UV bulb
at a layer downstream of the inlet to the catalyst, shining UV light through
the honeycomb to
increase the rate of complete oxidation of molecules on active sites on the
catalyst. This outlet
UV light could be positioned at the outlet of the oxidizing catalyst layers or
the ozone removal
catalyst layers.
There is also provided a method for at least one of sanitizing,
decontaminating,
filtering, deodorizing, conditioning and drying an atmosphere exposed to a
material within an
enclosed space. In accordance with one embodiment, such method involves
circulating the
atmosphere through an atmosphere treating unit in a primary flow direction.
Ozone is
generated within the atmosphere treating unit. The generated ozone mixes with
the atmosphere
in the atmosphere treating unit. The mixture of atmosphere and ozone is
exposed to UV light
in the atmosphere treating unit to remove at least a portion of the
contaminants in the
atmosphere. The ozone is removed from the UV light-exposed mixture of
atmosphere and
ozone to form an ozone-depleted containing an amount of ozone below a
preselected threshold
amount. The ozone-depleted mixture can then be appropriately exhausted into
the enclosed
space. In some embodiments of the subject matter disclosed herein, a control
system is
employed to reverse the flow of the blower or air mover, thereby passing or
flowing air
containing ozone out of the air treating unit and into the enclosed space.
This reversed air flow
can be timed or controlled with a sensor in a way to provide a defined dosage
of ozone into the
enclosed space. Once the dose or dosage is delivered, the flow direction can
be reversed again
to the primary flow direction so that both the contaminants in the air and the
ozone in the air
can be removed.
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The system of the subject matter disclosed herein, which includes the
apparatus
and/or the method, can produce ozone to oxidize contaminants and then complete
the oxidation
of the contaminants across a first oxidizing catalyst and then dissociate the
excess ozone back
to oxygen across a second ozone removal catalyst in order to maintain
appropriate levels of
ozone within the enclosed space or storage container. The system of the
subject matter
disclosed herein provides a number of significant benefits compared to
existing technology.
Circulation of air and ozone in the presence of UV light through a well-
designed
unit can be more efficient at cleaning the air as compared to injecting
gaseous ozone, at non-
hazardous levels, into still or calm air or other ambient conditions. It
appears that at low
concentrations of ozone, random encounters with contaminants results in too
slow of a process
of contaminant removal. The reaction of ozone with ethylene or other organic
gases is greatly
enhanced in the presence of UV light. However, there can be significant
benefits to combining
both of these methods to maximize benefits obtained from the use of ozone.
The subject matter disclosed herein provides two opportunities to oxidize the
odors and the microorganisms, one in an air cleaning unit, and the second,
such as at a lower
ozone concentration, in the ambient air of the storage container or room. This
dual approach
can better remove impurities from the air in the enclosed space and from
surfaces of the
materials. Ozone concentrations are relatively high in the air cleaning unit
and the mixing rates
between the ozone and the air is relatively high, and thus the oxidation rates
of the impurities
is relatively high. The air in the enclosed space or room can be quickly
deodorized and
sanitized. By establishing the desired control sequence of flow direction
through the air
treating unit, the concentration of ozone in the enclosed space can be
precisely established. A
very low concentration of ozone can be established in the enclosed space or
room in order to
sanitize surfaces of the materials. This dual approach can minimize negative
effects of ozone
concentrations in the air handling system or the surface of the materials in
the room or
container.
It is another object of the subject matter disclosed herein to clean the air
in a
space such as a room in a residential, commercial, or industrial building. The
subject matter
disclosed herein cleans the air by inactivating, altering and/or converting
these contaminants
into harmless gases and/or particles. The subject matter disclosed herein is
an alternative to
filtering or capturing contaminants in a way that requires frequent
replacement of filters and
allows for the re-emission of these unaltered contaminants back into the
atmosphere.
It is another object of the subject matter disclosed herein to provide a self-
cleaning function, for example, by exposing a filter to ozone and ultra-violet
wavelength light
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to deodorize and sanitize as well as oxidize material captured on the filter
and/or by exposing
the catalyst to ozone, UV light, and/or heat to clean/refresh the catalyst
from adsorption of
organic compounds.
It is another object of the subject matter disclosed herein to clean the air,
such
as in or within an automobile. The assembly and method can be used to treat
air in an
automobile, where contaminants may be generated from the interior cabin
materials of the car,
i.e., VOC emissions from the plastics and glues and stabilizers and leather.
Contaminants in
the air of an automobile cabin may also come through the ventilation system or
through the
windows from outside the car where pollution levels may be high. Pollutants
outside a car may
include particulate matter, ozone, carbon monoxide, soot, VOCs, and other
chemicals.
In accordance with the disclosed subject matter, apparatuses, systems, and
methods are described for treating impurities in air and materials.
Disclosed subject matter includes, in one aspect, an apparatus for treating
air,
which includes a housing with an air inlet and an air outlet, the housing
enclosing an air
treatment zone comprised of multiple elements that can be used in various
combinations
depending on the contaminants being cleaned from the air. The elements are
designed in a way
to be included or excluded from a product assembly, making a modular air
cleaning device that
can be configured by the manufacturer to address one or more contaminants in a
cost effective
manner. The modular sections include an air inlet section with a baffle to
prevent light of any
type, including ultraviolet light, from exiting the unit through the air inlet
area. The modular
sections may also include a volume that contains an ultraviolet light. The
ultraviolet light can
be of a germicidal wavelength, an ozone generating wavelength, and/or a
wavelength that
breaks down specific materials and contaminants.
The ultraviolet light may be produced by a mercury vapor lamp that emits a UV
wavelength below 200nm, with most of the emission at 185nm, or between 200 and
280 nm
with most of the emission at wavelength of 254nm. The UV light could be
generated by light
emitting diodes (LEDs) that emit light at specific wavelengths between 260 and
500 nm. This
includes emissions in the spectra referred to as UVA, UVB or UVC. An array of
LEDs may be
used to generate UV light at various wavelengths to achieve different
objectives, such as
enhancing the reaction rates of different molecules with ozone, or breaking
down specific
molecules, or breaking down DNA or proteins in microbes. Ozone may be
generated from UV
lamps that emit at wavelengths of 170 to 190 nm, and preferably at 185nm.
Ozone may also
be generated from corona discharge units. The modular sections may also
include a filter that
removes particulate matter. The filter section may be preferably positioned so
that the
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ultraviolet light could shine on the side of the filter that traps particles.
Another modular
section could be a catalyst section that oxidizes a variety of chemicals. This
catalyst section
could be configured with sheets of catalyst that are separated by spacers.
Another modular section could be a catalyst that is specifically configured to
remove ozone from the air. This catalyst sections also could be configured
with sheets of
catalyst that are separated by spacers. Another modular section could be an
adsorbent material
that at least temporarily removes VOCs from the air at one rate and releases
the VOCs at a
second rate that may allow more complete conversion of these VOCs by the
catalytic system.
Another modular section could be a heater that could increase the temperature
of the air to add
warmth to the room. Heating the air would reduce the chill that an air
purifier can cause by
operating at relatively high air flow rates in a cold room. The heater could
also heat the air to
be treated so that the reaction rates across the catalyst are increased.
Another modular section
could be a UV light that shines or emits UV light in the catalyst layers,
either at the catalyst
exit or between the catalyst layers. Another modular section of the air
treatment unit could be
a heat exchanger to remove the heat from the treated air before returning the
air to the room.
Another module of the air treatment unit could be a fan to induce flow through
the modular
sections of the air treatment unit.
The modular units can be oriented such that the louvers allow the air to enter
the unit, the ozone generating section is downstream of the inlet air louvers.
In some
embodiments of this invention, UV light section is downstream of the inlet
louvers, the filter
is down stream of the UV light sections, the first catalyst section is
downstream of the filter,
the second catalyst section is down stream of the first catalyst section, and
an air mover is
positioned near the air outlet configured to draw the air through the air
inlet into the air
treatment zone from outside the housing, moving the air through the entire or
all of the air
treatment zone and then emitting the air through the air outlet out of the
apparatus. An
adsorbent layer can be located between the inlet louvers and the air mover.
In some embodiments, the apparatus for treating air further includes a
proximity
sensor attached to the housing, wherein the proximity sensor detects the
presence of a cover
outside the housing.
In some embodiments, in the apparatus for treating air, the proximity sensor
is
a magnetic proximity sensor.
In some embodiments, in the apparatus for treating air, the UV light source is
turned on only if the proximity sensor detects the presence of the cover on
the apparatus.
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In some embodiments, the apparatus for treating air further includes a power
connector that connects to a power source.
In some embodiments, in the apparatus for treating air, an interior surface of
the
housing in the air treatment zone is made of a metal or at least partially
coated with a reflector
layer.
In some embodiments, in the apparatus for treating air, the interior surface
of
the housing in the air treatment zone is made of or at least partially coated
with aluminum.
In some embodiments, a catalyst used comprises manganese dioxide.
In some embodiments, a catalyst used is supported on a material such as a
metallic honeycomb, a metallic corrugated support, a ceramic corrugated
support, a ceramic
extruded support, expanded metal and/or porous foam.
In some embodiments the support structures for the catalyst have openings in
the range of 100 to 1000 cells per square inch.
In some embodiments the air treatment system includes a controller that can
independently operate the multiple ozone generators, the multiple UV light
emitters, the heater,
and/or the fan speed in order to create various modes of air cleaning that
target specific
contaminants or provide the self-cleaning function for the device.
In some embodiments, the apparatus for treating air further includes a ballast
configured to convert power received from the vehicle to higher frequency and
higher voltage
suitable for the apparatus.
In some embodiments, in the apparatus for treating air, the ozone generator
includes an ultraviolet light source.
In some embodiments, in the apparatus for treating air, the contaminant
removal
zone includes a catalyst that oxidizes contaminants or partially oxidizes
contaminants.
In some embodiments, in the apparatus for treating air, the ozone remover
includes catalyst that decomposes ozone.
In some embodiments, in the apparatus for treating air, the ozone generator
comprises an ultraviolet (UV) light source, and the UV light from the UV light
source treats
the air in the air treatment zone and the particulate filter.
In some embodiments, in the apparatus for treating air, the ozone generator
comprises a corona discharge unit.
In some embodiments, in the apparatus for treating air, the particulate filter
comprises a High Efficiency Particulate Arresting (HEPA) filter.
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In some embodiments in the apparatus for treating air, the aerosol filter
comprises a metal mesh and/or a metal screen filter.
In some embodiments in the apparatus for treating air, the particulate filter
comprises materials that can tolerate exposure to UV light and ozone, such as
a filter made of
glass fibers, or a filter coated with a resistant material such as a
fluorocarbon, such as a Teflon
material.
In some embodiments, the particulate filter comprises a layered material where
one layer can serve to protect the second layer from UV light. These layers
can be combined
of glass fibers, carbon fibers, and/or fibers of other spun plastic that are
compatible with ozone
and UV light. =
In some embodiments, in the apparatus for treating air, the UV light source
comprises a first UV lamp generating UV light in the wavelength of about 185
nm.
In some embodiments, in the apparatus for treating air, the UV light source
further comprises a second UV lamp generating UV light in the wavelength of
about 200 -
300nm.
In some embodiments, in the apparatus for treating the air the UV light source
further comprises a UV source generating UV light at a wavelength in a
spectrum between 200
and 500 nanometers in wavelength.
In some embodiments in the apparatus for treating the air the UV light sources
is an LED operating at a specific wavelength between 200 and 500 nanometers in
wavelength.
In some embodiments, in the apparatus for treating the air the UV light source
is an array of LEDs operating at a number of wavelengths between 200 and 500
nm.
In some embodiments, the apparatus for treating air further includes a second
UV lamp generating UV light positioned downstream of the inlet and/or the
catalyst layers.
In some embodiments, in the apparatus for treating air, the particulate filter
allows the ozone generated by the ozone generator to penetrate the particulate
filter to treat
both upstream and downstream sides of the particulate filter.
In some embodiments, in the apparatus for treating air, the particulate filter
allows the ozone generated by the ozone generator to penetrate the particulate
filter to treat an
inlet of the ozone removal zone.
In some embodiments, the apparatus for treating air further comprises a pre-
filter positioned upstream of the particulate filter and downstream of the air
treatment zone.
In some embodiments, in the apparatus for treating air, the pre-filter
comprises
a loose weave filter.
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In some embodiments, in the apparatus for treating air, the pre-filter is
positioned upstream of the air treatment zone.
In some embodiments, the apparatus for treating air further includes a pre-
filter
positioned upstream of the particulate filter and downstream of the air
treatment zone, wherein
the pre-filter allows the UV light from the UV light source to penetrate the
pre-filter to treat
the particulate filter.
In some embodiments, in the apparatus for treating air, the air mover
comprises
a volute and a fan, with the volute being connected to an upstream of the fan.
In some embodiments, the apparatus for treating air further includes a
material
that can adsorb gases, at least temporarily. While adsorbing materials such as
activated carbon
and/or potassium permanganate, may not permanently hold the contaminants, they
may adsorb
and then desorb the gases at different rates, allowing the adsorber to change
the rate at which
the contaminants are released into the rest or remainder of the air treatment
system. A layer of
adsorbing material, such as activated carbon could be located upstream of the
prefilter,
downstream of the prefilter, upstream of the aerosol filter or downstream of
the air filter,
upstream of the catalyst bed or downstream of the first layer of catalyst in
the catalyst bed.
In some embodiments, the apparatus for treating air further includes a user
interface module configured to receive user input and present information to
the user, and an
electronic control module configured to set the apparatus to operate in one of
a plurality of
operation modes, wherein the plurality of operation modes include a regular
operation mode,
where the ozone generator is on and the air mover operates at a first speed.
In some embodiments, in the apparatus for treating air, the electronic control
module is configured to set the apparatus to operate in one of a plurality of
operation modes
automatically based on at least one of output of at least one sensor and time.
In some embodiments, in the apparatus for treating air, the electronic control
module is configured to set the apparatus to operate in one of a plurality of
operation modes
automatically based on at least one of an output of at least one other
appliance and time. In
some embodiments, in the apparatus for treating air, the at least one sensors
is placed near the
air inlet, near the air outlet, or both.
In some embodiments, in the apparatus for treating air, the at least one
sensor
detects occupancy of an ambient environment where the apparatus is positioned
or situated.
In some embodiments, in the apparatus for treating air, the at least one
sensor
detects a contaminant content and level of an ambient environment where the
apparatus is
positioned or situated.
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In some embodiments, in the apparatus for treating air, the electronic control
module is configured to set the apparatus to operate in one of a plurality of
operation modes
based on the user input.
In some embodiments, in the apparatus for treating air, the plurality of
operation
modes further include a self-cleaning mode, where the ozone generator is on,
the ozone
generated by the ozone generator treats and cleans interior components of the
apparatus, and
the air mover operates in a second speed lower than the first speed.
In some embodiments, in the apparatus for treating air, the plurality of
operation
modes further include a self-cleaning mode, where the ozone generator is on,
the ozone
generated by the ozone generator treats and cleans interior components of the
apparatus, and
the air mover operates in a second speed lower than the first speed, with the
second speed set
to reduce the space velocity through the catalyst to less than 100,000 hr-1.
In some embodiments, the apparatus for treating air further includes a user
interface module configured to receive user input and present information to
the user, and an
electronic control module configured to set the apparatus to operate in one of
a plurality of
operation modes, wherein the plurality of operation modes include a regular
operation mode,
where the ozone generator is on and the air mover operates at a first speed.
In some embodiments, in the apparatus for treating air, the plurality of
operation
modes further include a self-cleaning mode, where the UV light source is on,
the UV light from
the UV light source and the ozone generated by the UV light source treat and
clean interior
components of the apparatus, and the air mover operates in a second speed
lower than the first
speed.
In some embodiments, in the apparatus for treating air, the UV light source
comprises a first UV lamp generating UV light in the wavelength of about 185
nm and a second
UV lamp generating UV light in the wavelength of about 254 nm, and the
plurality of operation
modes further include an ozone removal mode, where the first UV lamp is off
and the second
UV lamp is on.
In some embodiments, in the apparatus for treating air, the plurality of
operation
modes further include a particle removal only mode, where the ozone generator
is off.
In some embodiments, the apparatus for treating air further includes a
wireless
communication module configured to communicate with a central management
system.
In some embodiments, in the apparatus for treating air, the electronic control
module sets the apparatus to operate in one of the plurality of operation
modes based on
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instructions received from the central management system via the wireless
communication
module.
In some embodiments, in the apparatus for treating air, the instruction is at
least
partially based on information received from another appliance.
In some embodiments, in the apparatus for treating air, the instruction is at
least
partially based on information received from the system that the appliance is
built into.
In some embodiments, the apparatus for treating air can be built into the
kitchen
cabinets and connected electronically to the range and the ventilation hood.
The electronic
control of the apparatus could be configured to operate a set operating cycle
that includes a
schedule of operating modes including cleaning air from the room, self-
cleaning, and
deodorizing the unit itself. The duration and elements of the cycle could be
customized by the
home owner by providing the controller information about the size of the
kitchen, for example.
The timing of the cycle could be defined by the timing of the operation of the
range, or other
cooking appliance that could create food odors in the kitchen, and the
operation of the
ventilation hood, which generally operates when the range or cooktop is in
operation. The air
treatment apparatus could be configured to operate after the range has been
used and the
ventilation hood has been turned off. Residual odors in the room would then be
removed in a
set cleaning cycle. An example of an operating cycle is as follows: the air
treatment system
operates at high flow, for example 100 to 200 cfm with no ozone bulb operating
in order to
rapidly collect aerosols of grease or smoke from the room. Subsequent to this
aerosol cleaning
period, the air flow could reduce to 50 to 150 cfm with both the ozone
generating bulb and a
germicidal bulb operating upstream of the grease filter. In this mode a UV
bulb operating
downstream of the initial catalyst layer can also be operating. After a
cleaning cycle of
approximately 1 ¨3 hours, corresponding to 1 to 15 air exchanges of the room,
the air treatment
system could reduce its flow rate to 10 to 30 cfm in order to deodorize and
oxidize the material
collected on the grease filter and catalyst. During this self-clean cycle
either UV only or ozone
bulbs downstream of the first catalyst layer could be operated independently
or together. This
self-clean cycle could be maintained for 0.5 -3 hours. These cycle elements
could be operated
in any sequence depending on the nature of the air in the kitchen.
In some embodiments, the apparatus for treating the air can be built into or
installed in an automobile. VOCs can be emitted by the interior plastics and
fabrics in a new
car. This emission rate can be significantly increased when the car interior
is heated, such as
by the sun. Such VOC emissions can be controlled using a built in air
treatment system that
converts rather than captures these VOCs.
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Such an air cleaner can be built into the automobile and can be equipped with
a
variable speed fan to allow for the adjustment of air flow and hence the
treatment rate of the
air in the car cabin. In addition, UV and/or ozone generating devices can be
switched on or off.
In one embodiment, control of the air cleaner can be initiated via a mobile
phone
application. For example, if the car interior temperature exceeds a certain
value, the air cleaner
can be automatically operated. Furthermore, operating modes can be selected
depending on the
presence or absence of vehicle occupants. For example, high airflow provides
higher treatment
rates, but can be too noisy for certain vehicle occupants.
In one embodiment, a driver anticipates using the car at a certain time and
via
an app, starts the air cleaner some time (e.g., 5 ¨ 30 minutes) before
entering the car. The air
cleaner can remove the VOCs from the interior and then shut off when the
driver enters the
vehicle. In another use case, a person smokes cigarettes during a drive. The
user than activates
the air cleaner on exiting the vehicle and the air cleaner runs for a
specified cycle to remove
the odor of cigarettes from the interior of the car.
In some embodiments the apparatus for cleaning air can be built into a reach-
in
refrigerator. The electronic control of the apparatus could be configured to
operate in response
to various outputs from the refrigerator such as the door switch, the
evaporator fan operation,
and the compressor operation. In one embodiment, the air cleaning apparatus
turns off when the
door is opened. In another embodiment, the air cleaning apparatus turns on for
a set interval
after the door has been closed or shut. In one embodiment the air cleaning
apparatus turns on
only if the evaporator fan is operating. In another embodiment the air
cleaning apparatus turns
on or off if the compressor has not been operating for a set period of time.
The details of one or more variations of the subject matter described herein
are
set forth in the accompanying drawings and the description below. Other
features and
advantages of the subject matter described herein will be apparent from the
description and
drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 shows a schematic view of an apparatus for treating air, according to
one
embodiment of this invention.
FIG. 2 shows a schematic view of an apparatus for treating air, according to
one
embodiment of this invention.
FIG. 3 shows a perspective, sectional view of an apparatus for treating air,
according to one embodiment of this invention.
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FIG. 4 shows a front view of an apparatus for treating air, according to one
embodiment of this invention
FIG. 5 shows a cross section of a front view of an apparatus for treating air,
according to one embodiment of this invention.
FIG. 6 shows a schematic view of an air treatment system built into the
cabinetry
of a kitchen.
FIG. 7 shows a schematic view of an air treatment system built into the cabin
of an automobile.
FIG. 8 shows an exploded perspective view of an air treatment system for a
refrigerator.
FIG. 9 shows an air treatment system built into a refrigerator.
FIG. 10A shows a graph of a control comparison for FIG. 10B.
FIG. 10B shows a graph detailing the performance benefit of using ozone to
clean a catalyst during a formaldehyde removal cycle.
FIG. 11A shows a table that lists different configurations of an air purifier
that
can be achieved by including or excluding the modular components illustrated
in FIG. 1.
FIG. 11B shows a table that lists additional configurations of an air purifier
that
can be achieved by including or excluding the modular components illustrated
in FIG. 1.
FIG 12A and 12B each shows a dual replaceable bulb cartridge that is part of
the apparatus for treating air, as shown in FIG 3.
FIG. 13 representatively shows a bulb socket configured to receive the dual
replaceable bulb shown in FIG. 12.
FIG. 14 shows the ozone reduction performance of several catalyst formulations
on different substrate geometries at a range of space velocities.
Throughout this specification and in the claims, like reference symbols in the
various drawings indicate like elements.
DETAILED DESCRIPTION OF THE INVENTION
Throughout this specification and in the claims, the terms air cleaning unit
and
atmosphere treating unit are intended to relate to an apparatus for
sanitizing, filtering,
decontaminating, deodorizing, purifying, conditioning, heating, humidifying,
drying and/or
otherwise treating, cleaning, modifying and/or improving an atmosphere within
a space.
FIG. 1 is a schematic view of a modular air treatment system 100 of components
that can be combined in various ways to achieve some objectives of the air
treatment system
of this invention. The schematic shows an air inlet section 110 to receive an
air flow illustrated
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by arrows. The air inlet section 112 has baffles 112 to contain light
generated inside the air
treatment system. The schematic also shows a prefilter 114 that can remove
large material
from entering the treatment areas of the air treatment system 100. Downstream
of the prefilter
114 is one or more of an ozone generator 120 and/or a UV light source 122. The
ozone
generator 120 may be a UV bulb emitting at frequencies less than 200 nm, or it
may be a corona
discharge unit. The UV light source may be a mercury lamp emitting at
wavelengths above
200 nm or it may be one or an array of light emitting diodes that emit at a
wavelength inside
the UV spectrum from 200 to 500 nm. Downstream of the UV lights 122 is a
particulate filter
130 that is exposed to some combination of ozone and UV light. This filter 130
can be, for
example, made of fiberglass to collect particulate matter or can be made of
metal mesh to
collect aerosols of grease and smoke.
Downstream of the filter 130 are catalyst layers, such as formed of a
plurality
of catalyst sheets, which may be one or more formulations and structures,
depending on the
desired performance of the air treatment unit. A first set of catalyst layers
140 may be oxidizing
catalysts that break down chemical contaminants, and extend across an air
treatment zone. A
second catalyst layer 150 may be ozone removal catalysts and extend across an
ozone removal
zone. In embodiments of this invention, each catalyst layer is spaced apart
from an adjacent
catalyst layer, such as by spacer elements 142. The resulting air space 144
between adjacent
catalyst layers desirably acts to allow or create a more mixed or turbulent
air flow through the
catalyst layers. This prevents or disrupts a linear air flow through the
catalyst material, such
as when the catalyst layers have a matching honeycomb passageway
configuration. A further
catalyst layer 155 is downstream of the second catalyst layer 150. The further
catalyst layer
155 can include the first catalyst material, the second catalyst material, or
a third catalyst
material. In FIG. 1, the further catalyst layer 155 includes the second
catalyst material.
A heater 160 may be positioned upstream of the catalysts 140. A fan 162 is
positioned downstream of the catalyst layers 140 and 150.
In FIG. 1, additional UV bulb 124, either ozone generating or not ozone
generating, is positioned between the catalyst layers 140. The additional UV
bulb 124 is
downstream of one of the first catalyst layer 140, and can be alternatively be
disposed between
the first catalyst layers 140 and the second catalyst layer 150, or between
the second catalyst
layer 140 and the further layer 155, depending on need. In addition, multiple
additional UV
sources can be placed between the spaced apart catalyst layers, depending on
need.
FIG. 2 is a schematic of a modular system of components similar to FIG. 1, but
illustrating an alternative configuration. In FIG. 2 the particle and/or
grease removal filter 130
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has a cylindrical geometry. An adsorbent layer 132 has been added to this
modular system of
air cleaning components. The adsorbent layer is illustrated on an outside
surface of the
cylindrical filter 130 (desirably away from UV source 122), and can
additionally or
alternatively be on an inlet side of the prefilter 114 and/or the inlet side
of the most upstream
first catalyst layer 140.
FIG. 3 is an illustration of an air treatment apparatus 200 configured to be
built
into kitchen cabinetry (See FIG. 6). The apparatus 200 includes a housing 202
enclosing a
module construction, with functional components formed as modular attachments
that are
attachable to the housing 202. For example, a first attachable module 204
includes an ozone
generator, a second attachable module 206 includes the first and/or second
catalyst layers, and
at least one further attachable module includes an air inlet baffle 210, a
particle material filter
230, or an air mover assembly 262. The modules can be attached by any suitable
means, such
as by fastening on a module attachment element 205 of the housing 202.
In FIG. 3, the air inlet baffle 212 and air outlet 264 are located on the same
lateral side of the apparatus 200, allowing the air to be drawn into the air
treatment apparatus
from the room and exhausted back into the room (See FIG. 6). The three other
vertical sides of
the air treatment apparatus 200 can be between cabinets or a wall. The air
enters the apparatus
from the bottom of the unit, turns about 90 degrees and flows around a curved
baffle 218
designed to contain the UV light 222 in the apparatus 200 without adding
significant pressure
drop to the system. The UV lamps 222, including one or both that generate
ozone, are
positioned upstream of the grease filter 230. After passing through the grease
filter 230, where
aerosols of grease and smoke are removed from the air, the air passes through
a plurality of
spaced apart low temperature oxidizing catalyst layers 240. The air
subsequently passes
through spaced apart ozone reduction catalyst layers 250. Between or within
the plurality of
ozone reduction catalyst sheets/layers 250 is another set of UV bulbs 224 that
may or may not
generate additional ozone. The UV light and/or ozone can be used to for
further oxidation
and/or to clean the catalyst layers 250.
In embodiments of this invention, the ozone and UV light together create
active
species that support continued oxidation of chemical bound to the active sites
in the catalysts.
These active species also serve to help the oxidized chemicals desorb from the
catalyst. There
may be multiple layers of both catalyst types in the apparatus. The air flow
is drawn through a
fan 262 and exits through a set of baffles 264 designed to allow free flow of
clean air while
preventing any backflow or penetration back into the fan area. The outlet
grill 264 distributes
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the air flow so that it exhausts slowly and evenly and does not blow
noticeably on a person
standing close to the apparatus.
FIG. 4 shows a front view of the apparatus 200. The dual bulb cartridges 222
and 224 are configured to be easily removable by pulling firmly on the
cassette handle 225.
The bulb connects to a socket with multiple connector points (See FIG. 12A),
allowing the
apparatus to sense whether the bulb is properly positioned or in place.
FIG. 5 shows a cross section of the apparatus 200 and illustrates the shape of
the concave UV baffle 218 and bulb reflector 226. The matching curved surfaces
of the bulb
reflector 226 and the air inlet baffle 218 contain the UV light and prevent
the light from exiting
the bottom of the apparatus without creating significant pressure drop for the
air to flow into
the body of the apparatus. The second set of UV lamps is located between the
catalyst layers,
downstream of the first layers 240 and upstream of the fan 262. The curved
surface of the bulb
reflector 228 has an increase in the curvature at each edge 229 of the
reflector to ensure
containment of the UV light.
FIG. 6 shows the built-in air treatment system 200 installed in cabinetry in a
kitchen in electronic communication with a cooking appliance and a ventilation
hood. The
built-in air treatment system could be installed under the counter at any
location in the kitchen.
The apparatus is controlled by outputs from the surrounding environment,
selected from
environment sensors and/or operation of fans, motors, or appliances, separate
and independent
.. from the apparatus. Referring to FIG. 6, the air treatment system 200 has a
control device (with
necessary hardware, data processers, and encoded software instructions) that
can communicate
with a range, a cooktop and/or the ventilation hood via wired or wireless
connections. The
wireless communication could be a local area network, Bluetooth connection, Wi-
Fi, infrared
or other means of allowing the air treatment system 200 to operate based on
the modes or states
of the cooking appliance and ventilation hood.
FIG. 7 shows an air cleaning apparatus 300 built into an automobile cabin,
located or positioned either in the dashboard (300) or the center console
(300') according to
some embodiments of the subject matter disclosed herein. The apparatus for
treating air 300
can be mounted on a dashboard inside the automobile. The power connector of
the apparatus
200 can be connected to a power source inside the automobile, such as an
automobile battery.
In some embodiments, the apparatus for treating air 300 can also contain a
ballast, which can
regulate voltage, current, and/or frequency of the power. The power connector
can be
connected to the ballast, which can be connected to a power source inside the
automobile. In
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some embodiments, the ballast can be part of the automobile itself. The
apparatus 300 can be
covered by a decorative and/or protective cover 320.
In some embodiments, the apparatus for treating air 300 can be mounted inside
the automobile HVAC system next or close to the air conditioning evaporator.
In operation,
the air is drawn from the cabin of the automobile 310 into the apparatus for
treating air 300.
After treatment, the air is emitted from the apparatus 300 into the car cabin
or into the HVAC
system of the automobile. The air can flow back into the cabin of the
automobile through the
existing HVAC ducting of the automobile. In some embodiments, the apparatus
300 itself can
include no active air mover component. Instead, the apparatus 300, when
mounted near or next
to HVAC system of the car, can leverage the fan of the ventilation system to
function as an air
mover. Alternatively, the apparatus 300 can be self-contained with its own fan
that draws air
from the cabin 310 into the apparatus 300 and back into the cabin 310. In some
embodiments
a second air mover could be used to mix the exhaust air from apparatus 300
into the cabin 310
and mix the cabin air.
FIG. 8 illustrates an exploded view of an apparatus for treating air 4200
according to some embodiments of the subject matter disclosed herein. The
apparatus for
treating air 4200 can include a light cover 4210, a cover gasket 4212, a
proximity sensor (e.g.,
magnetic proximity sensor) 4214, an unit cover 4215, an air inlet 4216, a
gasket enclosure to
evaporator cover 4218, a UV light bulb 4220, a UV light bulb socket 4222, a UV
light bulb
holding bracket 4224, an air treatment zone 4226, an enclosure of the air
treatment zone 4227,
power and sensor wires 4228, an ozone removal zone 4231, a catalyst housing
4230, a first
catalyst section 4236, a catalyst spacer 4234, a second catalyst section 4232,
an air mover (e.g.,
a fan) 4240, a housing for the air mover 4238, and an air outlet 4242.
The apparatus for treating air 4200 can include a housing with an air inlet
(e.g.,
4216) and an air outlet (e.g., 4242). In some embodiments, the enclosure for
the air treatment
zone 4227, the catalyst housing 4230, and the housing for the air mover 4238
can form a multi-
section or unibody housing for the apparatus for treating air 4200. The
apparatus for treating
air 4200 can include an air treatment zone (e.g., 4226) and an ozone removal
zone (e.g., 4231).
As illustrated in FIG. 8, the ozone removal zone 4231 is positioned downstream
of the air
treatment zone 4226 with respect to a flow direction of the air being treated.
The apparatus for treating air 4200 can include an UV light source (e.g.,
4220)
in the air treatment zone 4226 configured to generate ozone from the air. The
UV light from
the UV light source and the ozone generated by the UV light source can treat
(e.g., clean,
sanitize, or deodorize) the air in the air treatment zone 4226.
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The apparatus for treating air 4200 can include catalyst in the ozone removal
zone 4231 that removes at least a portion of the ozone generated by the UV
light source (e.g.,
4220). As illustrated in FIG. 8, the ozone removal zone 4231 can include the
first catalyst
section 4236 and the second catalyst section 4232, separated by the spacer
4234. The
configuration of two separate catalyst sections with a spacer in between can
improve the flow
of air through the ozone removal zone 4231. For example, the spacer 4234 can
allow the air
coming out of the first catalyst section 4236 to redistribute before entering
into the second
catalyst section 4232. The redistribution of air flow can improve the
performance of the ozone
removal zone 4231. The first catalyst section 4236 and the second catalyst
section 4232 could
contain the same or different catalyst compositions.
The apparatus for treating air 4200 can include an air mover (e.g., 4230)
positioned near the air outlet (e.g., 4242) that can draw the air through the
air inlet (e.g., 4216)
into the air treatment zone (e.g., 4226) from outside the housing, moving the
air through the air
treatment zone (e.g., 4226) and the ozone removal zone (e.g., 4231), and then
emitting the air
through the air outlet (e.g., 4242) out of the apparatus 4200.
The apparatus for treating air 4200 can include a proximity sensor (e.g.,
4214).
The proximity sensor can be attached to the housing. The proximity sensor can
detect the
presence of a cover outside the housing of the apparatus 4200. The cover can
be protective
(e.g., to provide additional shield of the UV light) or decorative. The
apparatus 4200 can turn
off the UV light source if a cover is not detected. In some examples, the
proximity sensor can
be magnetic.
The apparatus for treating air 4200 can include a power connector (e.g.,
4228).
The power connector can be connected to a power source inside a container
(e.g., a refrigerator)
to provide power to the apparatus 4200. In some embodiments, the apparatus for
treating air
4200 can also include one or more sensors to detect the condition of the
ambient environment
(e.g., temperature, air quality, contaminant content and/or level, etc.).
In some embodiments, the interior surface of the housing of the apparatus 4200
(e.g., in the air treatment zone 4226) can be at least partially coated with a
reflector layer (e.g.,
metal layer such as aluminum). The components of the apparatus can be made in
various
materials, such as metal or plastics. Certain structural materials (e.g.,
plastics) can reduce the
weight and/or cost of the apparatus 4200, but can deteriorate over time,
especially in the
presence of UV light. Coating the interior surface of the housing with a
reflector layer can
shield the structural materials from UV light and extend its usage life; it
can also reduce the
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absorption of UV by the interior surface of the apparatus and enhance the UV
light intensity
inside the air treatment zone, thus improving the performance of the air
treatment zone.
FIG. 9 shows an air cleaning apparatus 4200 located in the back panel 4310 of
a reach-in type refrigerator 4300. The air cleaning apparatus has a decorative
front plate 4320
that is configured to protect and allow air flow into the apparatus. The
operation of air cleaning
apparatus 4200 can be defined by the position of the door switch, the
operation of the
evaporator fan, and/or the operation of the compressor.
FIG. 10B is a graph that illustrates the value of ozone in maintaining the
formaldehyde removal performance of a low temperature oxidizing catalyst.
Without ozone
use (FIG. 10A) the performance of the catalyst decays over time. With ozone
use, the
performance of the catalyst in oxidizing foimaldehyde is maintained. This
catalyst self-
cleaning cycle with ozone provides benefit to the performance of the system.
FIGS. 11A and 11B illustrate the combinations of the modular components
described herein that can be combined in different configurations to achieve
different
performance characteristics of an air cleaning apparatus.
FIGS. 12A and 12B shows the configuration of a dual bulb replacement cassette
422. The cassette has electrical contacts 425 on one side and a mechanical
detent 426 on the
underside. The electrical contacts 425 line up with contacts in a
corresponding bulb socket. In
this configuration, four of the electrical contacts 425 match to contacts in
the socket to close
and allow power to flow from the ballasts to the bulb and light the bulb. One
additional contact
is used to close a circuit to the controller to indicate that the bulb has
been installed. If the bulb
is removed, the check circuit is open and the controller sends an error
message to a display
indicating that the bulb is not in place.
FIG. 13 shows an exemplary bulb circuit diagram that illustrates the
connections
between the bulb cassette and the ballasts that power the bulbs. The contacts
that are part of
the bulb detect circuit are distinct from the contacts that power the bulbs.
In embodiments of
this invention, the bulb has an internal circuit between its contacts that
closes a circuit to the
controller to indicate that the bulb has been installed. If the bulb is
removed, the check circuit
is open indicating the bulb is not installed.
FIG. 14 is a graph that shows the possible and preferred operating region of
the
catalysts for ozone operation. High ozone removal efficiencies are achieved
with space
velocities below 200,000 hr-1 and preferably below 100,000 hr-1. The ozone
removal
efficiencies are uniformly above 98% at space velocities below 30,000 hr-1.
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It is to be understood that the disclosed subject matter is not limited in its
application to the details of construction and to the arrangements of the
components set forth
in the description or illustrated in the drawings. The disclosed subject
matter is capable of
other embodiments and of being practiced and carried out in various ways.
Also, it is to be
understood that the phraseology and terminology employed herein are for the
purpose of
illustration and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon
which
this disclosure is based, may readily be utilized as a basis for the designing
of other structures,
methods, and systems for carrying out the several purposes of the disclosed
subject matter. It
is important, therefore, that the claims be regarded as including such
equivalent constructions
insofar as they do not depart from the spirit and scope of the disclosed
subject matter.
For example, the term "air" is used in general in this document and it can be
interpreted to include both natural air and/or any gaseous or vaporous matter.
With the method and apparatus according to different embodiments of this
invention, the modularity of the system can be arranged so that a manufacturer
can add or
remove elements into a common platform to achieve different products.
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