Advanced antimicrobial and chemical filters for gas and water systems

Abstract

The present invention relates to functionalized filter materials with specific antibacterial, phase transfer and catalytic properties, consisting of carbon and ceramic substrates, which are coated with various types of inorganic and polymeric impregnants for specific applications such as air and water pollution control, catalysis, etc. The substrates are activated by special processes and the impregnants can be reacted with specific redox systems to enhance their effectiveness.

Description

[Technical Field]

[0001] The present invention relates to the field of functionalization of filter materials.

[0002] More particularly, the present invention relates to functionalized, metallized, polymerized filter materials, such as ceramic substrates containing activated carbon and zeolites, that have unique antibacterial, phase transfer, and catalytic properties, and methods for their preparation. [Background technology]

[0003] Activated carbon is used to purify liquids and gases in a variety of applications, including municipal drinking water, food and beverage processing, odor removal, and industrial pollution control. One gram of activated carbon has a surface area of ​​3,000 m 2 (32,000 sq ft). The adsorption capacity of activated carbon is largely determined by pore structure characteristics such as surface area, pore volume, and pore size distribution.

[0004] Furthermore, due to its antibacterial and antiseptic properties, antibacterial-loaded activated carbon can be used as an adsorbent for water purification. For example, natural spring water can be converted into drinking water by treating it with a mixture of treated activated carbon and alumina beads. This has several applications, including but not limited to: methane and hydrogen storage, air / water purification—absorbing volatile chemicals at the molecular level, caffeine removal, sewage treatment, and air filters. Activated carbon is also used to treat oral poisoning and overdose. Activated carbon tablets and capsules are available over-the-counter in many countries as a treatment for diarrhea, indigestion, and flatulence. See the following references:

[0005] The research paper "Application of Metal-Impregnated Carbon as an Adsorbent for the Removal of Sulfur Compounds Using Fixed-Bed Column Technology" by Martins AV et al. discusses the efficiency of using activated carbon (AC) in the adsorption of sulfur compounds, especially when its surface is modified with metals. Comparing the adsorption capacities of sulfur compounds from actual gasoline, AC-Pd materials were more selective than other materials and exhibited rapid saturation behavior, which may be explained by the presence of other components competing for adsorption sites, reducing the effectiveness of sulfur compound removal. Both pure AC and Pd-AC exhibited good regeneration. The regenerated Pd-AC adsorbent could recover approximately 85% of its desulfurization capacity.

[0006] US2020290014A1 describes a method for preparing a nano-enabled activated carbon block, a nano-enabled activated carbon block produced by the method, a home water purifier including the nano-enabled activated carbon block, and a method for filtering tap water using the home water purifier. The method includes contacting activated carbon particles with a solution containing a metal(s) precursor (e.g., a titanium compound and / or an iron compound and / or a zirconium compound) so as to fill the pores of the activated carbon particles. The method further includes precipitating a metal (hydr)oxide (e.g., titanium dioxide and / or zirconium dioxide and / or iron oxide) from the solution, thereby depositing metal oxide nanoparticles within the pores of the activated carbon particles. The method also includes preparing a nano-effective activated carbon block from the activated carbon particles having the metal oxide nanoparticles precipitated within the pores.

[0007] JP20072273122A relates to a method for producing a calcined activated carbon block filter having numerous small pores advantageous for capturing bacteria while maintaining voids, and having high capture and adsorption capabilities. The method for producing a calcined activated carbon block filter of the present invention includes kneading composite powdered activated carbon, kneading composite powdered activated carbon consisting of a mixture of powdered activated carbon as a base material and ultrafine powdered activated carbon with a particle size of 20 μm or less, an inorganic binder, and water, granulating the raw material, adjusting the content of the inorganic binder to 50 wt% or more and the content of the composite powdered activated carbon to 50 wt% or less, relative to 100 wt% of the total of the inorganic powdered activated carbon and the composite powdered activated carbon in the raw material, press-molding the raw material, and firing the molded product to obtain a calcined activated carbon block filter having numerous pores with fine pore diameters and improved capture and adsorption capabilities.

[0008] Despite the widespread use of carbon block filters for water and gas filtration, there is a clear need for improved filter materials. In this invention, porous surfaces with high surface areas, such as activated carbon, including graphene, ceramics, and zeolites, including natural and synthetic zeolites, act as absorbents and are coated with different types of organic and inorganic impregnating agents, such as iodine, silver, copper, Al, Mn, Zn, Fe, Li, Ca, and conductive polymers, for specific applications in air and water pollution control and catalysis. Specific materials, such as strong oxidizing agents and reagents, are impregnated and coated onto these absorbents, such as zeolites and alumina beads.

[0009] The information disclosed in the Background section is intended to enhance understanding of the general background of the present invention and should not be construed as an admission or in any way suggesting that this information forms prior art already known to those skilled in the art.

[0010] A primary object of the present invention is to provide compositions and methods for preparing metallized and polymerized filter materials with unique antimicrobial, vapor phase transport, and catalytic properties.

[0011] Another object of the present invention is to provide a composition for higher absorption of organic pollutants that can be used to improve the shelf life of food products by absorbing gases that cause spoilage. Summary of the Invention

[0012] The present invention seeks to overcome the problems encountered in the prior art and discloses compositions and methods for preparing metallized and polymerized filter materials with unique antimicrobial, gas phase transport, and catalytic properties.

[0013] According to an embodiment of the present invention, the present invention relates to a process for manufacturing an activated molecular filter, which comprises the steps of taking a measured amount of substrate in a reaction vessel, activating it, and then mixing it with a measured amount of at least one impregnating agent to functionalize the substrate and form a molecular filter media. Furthermore, depending on the desired application and activity of the molecular filter, reducing and oxidizing agents may be added during the functionalization step, and a binder may be added to immobilize soluble ions within the molecular filter media.

[0014] According to an embodiment of the present invention, the present invention discloses a process for manufacturing an active molecular filter, wherein the substrate is made of a porous surface with a high surface area selected from the group consisting of carbon, including graphene, ceramic, zeolites, both natural and synthetic zeolites, silica molecular sieves, microporous phosphoric oxides, as well as organic-inorganic hybrid materials such as metal organic frameworks (MOFs), and combinations thereof.

[0015] According to an embodiment of the present invention, the substrate is fired in a furnace to 1200° C. to increase the surface area of ​​the substrate, but is not melted and is activated.

[0016] In accordance with an embodiment of the present invention, the present invention discloses a process wherein the impregnating agent is selected from the group consisting of elements or salts of silver, zinc, copper, aluminum, manganese, iron, calcium, palladium, iodine, and both conductive and water-soluble polymers such as polyvinylpyrrolidone, polyvinyl alcohol, polyaniline, polypyrrole, and combinations thereof.

[0017] According to an embodiment of the present invention, the reducing agent is selected from the group consisting of formaldehyde, hypophosphite, ascorbic acid, borate, metabisulfite, and combinations thereof.

[0018] According to embodiments of the present invention, the impregnating agent and substrate are mixed with a solvent in a reaction vessel, often a rotary mixer, to form a "coating" or impregnating agent on the substrate. The key is to gently penetrate the substrate without mechanically damaging it, which is made possible by the tumbling action of the mixer.

[0019] In accordance with an embodiment of the present invention, the present invention discloses a process in which the functionalization of a substrate is carried out by any of the techniques such as, but not limited to, electrolysis, electroless deposition by redox reaction, extrusion techniques and combinations, depending on the surface of the substrate and the activity required.

[0020] According to an embodiment of the present invention, the present invention discloses a process of "reducing" or "oxidizing" impregnation on the surface of a porous material using reducing and oxidizing agents to create metal or polymer systems in molecular filters. In another embodiment, electrons can also be used in the present invention instead of reagents.

[0021] According to embodiments of the present invention, in the extrusion process, materials are "extruded" into various shapes to increase surface area and improve interaction with reagents for air and water pollutant purification. The functionalized process results in highly porous materials for applications in pollutant removal and catalytic conversion. To maximize the stoichiometric reaction of pollutants, the active agent can be directly extruded with minimal substrate and binder. For example, in the reaction of sodium metabolites with oxygen, the extruded material can contain a very large, predominant proportion of the reagent itself.

[0022] According to an embodiment of the present invention, there is provided an active molecule filtration composition comprising at least a porous substrate and at least an impregnating agent, wherein the impregnating agent is a metallic, organic, or inorganic impregnating agent for functionalizing the porous substrate.

[0023] According to an embodiment of the present invention, the molecular filter is in the form of a filter block, a porous media, or a coating on a fabric, or packed within a perforated casing, or a combination thereof.

[0024] According to an embodiment of the present invention, molecular filter "blocks" are fabricated using molding techniques with a binder and resin, followed by firing to burn out the binder and leave a high surface area porous filter block. In another embodiment, the binder has a melt flow rate of 2-5 g / 10 min, and the molecular filter media and binder mixture is heated to a temperature in the range of 150-950°C for the desired shape and porosity of the molecular filter block.

[0025] The foregoing summary is illustrative and is not intended to be in any way limiting. In addition to the exemplary aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description. DETAILED DESCRIPTION OF THE INVENTION

[0026] While embodiments of the present disclosure are amenable to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and described below. It is to be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is intended to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure. Moreover, the phraseology and terminology employed herein is for the purpose of description only and not of limitation.

[0027] As used in this disclosure, the terms "comprises," "comprising," or other variations thereof are intended to cover a non-exclusive inclusion, and an apparatus, device, system, assembly, or method consisting of a list of components or a sequence of steps does not include only those components or steps, but may include other components or steps not expressly listed or inherent in such apparatus, assembly, or device. In other words, one or more elements or steps in a system or apparatus or process preceded by "comprises...a" or "comprising...a" does not, without more constraints, exclude the presence of other elements or additional elements or additional steps in the system or apparatus or process, as the case may be.

[0028] The primary object of the present invention is to provide compositions and methods for preparing metallized and polymerized filter materials with unique antimicrobial, gas phase transport, and catalytic properties.

[0029] In accordance with an embodiment of the present invention, the present invention relates to a process for manufacturing an activated molecular filter, comprising the steps of: (a) taking a measured amount of substrate in a reaction vessel and activating it; (b) functionalizing the substrate by mixing it with a measured amount of at least one impregnating agent to form a molecular filter medium; wherein, depending on the desired application and activity of the molecular filter, a reducing agent or an oxidizing agent may be added in the functionalization step, and a binder may also be added to immobilize soluble ions within the molecular filter medium.

[0030] In one embodiment of the present invention, the present invention discloses a process for manufacturing an active molecular filter, wherein the substrate is comprised of a porous surface with a high surface area selected from the group consisting of carbon, including graphene, ceramic, zeolites, both natural and synthetic zeolites, silica molecular sieves, microporous phosphoric oxides, as well as organic-inorganic hybrid materials such as metal organic frameworks (MOFs), and combinations thereof.

[0031] In another embodiment of the invention, the substrate is fired in a furnace to 1200° C. to increase the surface area of ​​the substrate, but does not melt.

[0032] In another embodiment of the present invention, the present invention discloses a process wherein the impregnating agent is selected from the group consisting of elements or salts of silver, zinc, copper, aluminum, manganese, iron, calcium, palladium, iodine, and both conductive and water soluble polymers such as polyvinylpyrrolidone, polyvinyl alcohol, polyaniline, polypyrrole, and combinations thereof.

[0033] In yet another embodiment of the present invention, the reducing agent is selected from the group consisting of formaldehyde, hypophosphorous acid, ascorbic acid, borate, metabisulfite, and combinations thereof.

[0034] In another preferred embodiment, the present invention discloses a process in which the impregnating agent and substrate are mixed with a solvent in a reaction vessel, often a rotary mixer, to form a "coating" or impregnating agent on the substrate. The key is to gently penetrate the substrate without mechanically damaging it with the tumbling action of the mixer.

[0035] In one embodiment of the present invention, the present invention discloses a process in which the functionalization of the substrate is carried out by any of the techniques such as, but not limited to, electrolysis, electroless deposition by redox reactions, extrusion techniques and combinations thereof, depending on the surface of the substrate and the activity required.

[0036] In yet another embodiment of the present invention, the present invention discloses a process of "reducing" or "oxidizing" the impregnated material on the surface of the porous material using reducing and oxidizing agents to create metal or polymer systems in molecular filters. In another embodiment, electrons can also be used in the present invention instead of reagents.

[0037] In a preferred embodiment of the present invention, the extrusion process "extrudes" materials into various shapes to improve surface area and interaction with reagents for air and water pollutant purification. The functionalized process results in highly porous materials for applications in pollutant removal and catalytic conversion. To maximize the stoichiometric reaction of pollutants, the active agent can be directly extruded with minimal substrate and binder. For example, in the reaction of sodium metabolites with oxygen, the extruded material can contain a very large, predominant proportion of the reagent itself.

[0038] In an exemplary embodiment, the present invention provides a composition for an active molecular filter material, comprising at least a porous substrate; and at least an impregnating agent, wherein the impregnating agent is a metallic, organic, or inorganic impregnating agent for functionalizing the porous substrate.

[0039] In yet another embodiment of the present invention, the molecular filter is in the form of a coating on a filter block, a porous media, or a fabric, or packed within a perforated casing, or a combination thereof.

[0040] In yet another embodiment of the present invention, molecular filter "blocks" are fabricated using molding techniques using a binder and resin, followed by firing to burn out the binder and leave a high surface area porous filter block. In another embodiment, the binder has a melt flow rate of 2-5 g / 10 min, and the molecular filter media and binder mixture is heated to a temperature in the range of 150-950°C for the desired shape and porosity of the molecular filter block.

[0041] The present invention provides a method for preparing metallized and polymerized filter materials with special antibacterial, gas phase transport, and catalytic properties.

[0042] Porous surfaces, such as graphene-containing activated carbon, zeolites, and ceramics, have large surface areas. Porous materials contain voids (or pores), which can be isolated or interconnected to form complex networks of channels that are filled with fluids (e.g., air, liquid water) under normal atmospheric conditions. Inorganic porous materials include natural and synthetic zeolites (from low- to high-siliceous zeolites), pure silica molecular sieves, microporous phosphate oxides, and even organic-inorganic hybrid materials, such as metal-organic frameworks (MOFs), which are made by mixing finely ground metal powders with carbon as carbon blocks and activating them through heating. Heating the material further increases its surface area, increasing the surface area available for reaction with pollutants.

[0043] Inorganic impregnants, such as iodine, silver, copper, Al, Mn, Zn, Fe, Li, Ca, Pd, and conductive polymers, are deposited on these activated materials as metals for functionalization of carbon, zeolites, and ceramics, functioning by adsorbing and reacting with contaminants. Water-soluble polymers can be selected from polyvinylpyrrolidone, polyvinyl alcohol, and other materials. Furthermore, if the material is soluble, it can also be made insoluble for stable, long-lasting activity. The choice of impregnant and polymer depends on the desired application. Metallization captures / adsorbs analytes onto the surface area, and the metal on the surface immobilizes the analyte, converting it into an inert or less toxic substance. This reduces the activation energy.

[0044] The present invention discloses a process for producing a metal-impregnated block filter, which includes contacting a substrate, such as a ceramic powder, with a salt or element of silver, zinc, and / or copper in the presence of a reducing agent to form an aqueous mixture, and then mixing the mixture with a binder having a melt flow rate of 2-5 g / 10 min to form a binding mixture. The binding mixture is then added to a mold, and the mold with the binding mixture is heated to a temperature in the range of 150-950°C to obtain a block filter within the mold. Failure to raise the filter to a molten stage will result in loss of porosity. Finally, the formed carbon block filter is demolded from the mold.

[0045] Metallization / functionalization can be accomplished by techniques such as, but not limited to, ball or pan mixers, tumble drying, extrusion techniques, and combinations. In mixers, the reactants and substrate are mixed in a mixer with a solvent such as water to form a "coating" on the substrate. The reagents also penetrate and occupy many "sites" on the porous material. Drying temperatures are typically between 100 and 900°C, at which point the reagents are properly "immobilized" on the substrate.

[0046] It is also possible to "extrude" materials during the functionalization process, referred to here simply as the extrusion process. Porous materials for applications in catalysis and filtration can be fabricated by emulsifying ceramic powder suspensions to form ceramic emulsions, which are then sintered at different temperatures and then extruded. The emulsification of the ceramic suspension in paraffin, which has a melting point higher than room temperature, is key to the success of this method, as the freezing of the organic mixture allows for the stability of the matrix during the extrusion process. Reagents can be mixed with the ceramic material, and in some cases the reagents themselves can be extruded.

[0047] Ceramic filter blocks can also be prepared using functionalized materials that can be mixed with binders, such as those derived from monomers with ester or amide functionality, poly(vinylamine), poly(vinylformamide), or copolymers of vinyl alcohol and vinylamine.

[0048] A prepared carbon block was immersed in a metal salt such as copper sulfate, and an electric current was passed through the carbon block, which acted as the cathode. In some cases, the copper block was used as the anode. Metal deposition of copper occurred within and on the carbon block. In the next example, a reducing agent such as "hypophosphite" or formaldehyde was used in conjunction with the copper solution instead of electrons. In this way, copper metal was reduced onto the carbon block. These types of activated carbon possessed very significant antibacterial properties, as explained in the first two examples below. [Example]

[0049] Example 1: Microbiological studies were conducted on activated carbon blocks developed according to the process of the present invention. For this purpose, the time-kill test of E. coli samples was observed using the ASTM E2315 - Suspension Time-Kill Test. The samples demonstrated microbial activity. Culture medium was prepared by streaking a pure culture of E. coli onto a soybean casein digest agar plate and incubating at 37°C for two days. After incubation, the surface of the agar plate was scraped. The growth suspension was adjusted to a concentration of 10 cfu / ml. Equal volumes of the test and control substances were dispensed into sterile test tubes. The test and control substances were separately inoculated onto test microorganisms, mixed, and incubated. The control suspension was immediately plated to represent the initial, i.e., time zero, concentration. At the end of each contact time, an aliquot of the test solution was neutralized. Dilutions of the neutralized test solution were placed on the appropriate agar plates and incubated at the appropriate temperature to determine the surviving microorganisms at each contact time. The percent reduction of microorganisms was calculated by comparing the initial microbial concentration with the surviving microbial concentration. All tests were performed in duplicate and the bacterial counts were averaged (Table 1).

[0050] [Table 1]

[0051] From this, it was inferred that the test sample-impregnated activated carbon according to the first process of the present invention exhibits antibacterial activity against Escherichia coli when exposed for 30 minutes.

[0052] Example 2: According to an exemplary embodiment, copper was impregnated into a carbon block, and upon reaction, the copper-blue electrolyte solution turned colorless. After rinsing, a drop of acid was added, causing the solution to turn blue again, indicating the presence of copper as a blue-colored copper salt and confirming the functionalization of the matrix with the metal. X-ray spectroscopy results indicated the presence of copper. Microbiological results were observed to be positive, with a 6-log reduction of E. coli after 30 minutes of contact time.

[0053] Example 3: In accordance with one embodiment of the present invention, it was observed that a process using an activated carbon block as the cathode of an electrolytic reaction in which controlled metallization of the block can occur results in a bonded carbon block filter with relatively low variability in metal content throughout the block, relatively low deviation from theoretical metal content, and relatively low metal leaching rates from the block during use. Formulations developed according to the process of the present invention were subjected to time-kill testing of E. coli samples using ASTM E2315 - Suspension Time-Kill Test. The test sample was designated the 'antimicrobial activated carbon control (treated)', and the reference sample was designated the 'non-antimicrobial activated carbon control (untreated)'. One sample of each was used (Table 2). Culture preparation and experiments were performed as in the previous examples. Microbial reduction was calculated by comparing the initial microbial concentration with the surviving microbial concentration. All tests were performed in duplicate, and the counts were averaged. Microbiological results following this process demonstrated antibacterial activity. Activated carbon impregnated with copper using this process demonstrated a 99.9999 reduction.

[0054] [Table 2]

[0055] Compared to "activated carbon without antibacterial agents (untreated)," "activated carbon with antibacterial agents (treated)" showed antibacterial activity against E. coli when exposed for 15 minutes.

[0056] Example 4: A laboratory-scale filter system was set up to study the VOC and formaldehyde removal efficiency of a combination of alumina impregnated with oxidizing agents, such as permanganate and cerium ammonium nitrate, and metallized activated carbon. The efficiency of these two filter media was examined, demonstrating complete removal of VOCs and formaldehyde from the air. The process of this invention was confirmed to have significant cost savings due to reduced energy consumption. The filter material of this invention is useful for removing harmful and unpleasant particles, gases, odors, bacteria, and viruses from the environment. Its potential applications include corrosion prevention for equipment and machinery, odor reduction, improved equipment reliability, preservation of museum artifacts, and extended shelf life for food and everyday consumables.

[0057] Example 5: Metallization of activated carbon materials with catalysts such as palladium for carbon monoxide removal is an example of a catalytic reaction in which the catalytic properties of the metal centers, along with the high adsorption surface area of ​​the activated carbon, aid the reaction. It is necessary to develop a catalyst that is resistant to CO attack and activates at low temperatures. The palladium in this process was prepared in colloidal solution using palladium chloride and special complexing agents such as stannic chloride and tartaric acid. The palladium on the surface of the activated carbon was reduced, and the palladium centers assisted in the oxidation of carbon monoxide. Atomic dispersion palladium bonded to oxygen atoms on the carbon surface resisted CO poisoning and achieved high CO oxidation activity at low temperatures. This type of filter could be used in defense and submarine applications.

[0058] Example 6: Radioactivity Removal. A special matrix was prepared by mixing activated carbon with potassium hydroxide and iodide. Another layer was 4% magnesium chloride and diluted sodium hydroxide. A water-soluble polymer, such as polyvinylpyrrolidine, was mixed into this matrix to firmly bind the reagent and high-surface substrate, making it resistant to the dissolution medium. These two materials were introduced as layers into the filter, helping to reduce the radioactive uranium in the sample (Table 3). Results are shown for a uranium-spiked water solution before and after passing through the column. Water was passed through the column at 5 ml / min. Iodide ions are strong reducing agents, readily releasing an electron. Under optimal conditions, they can readily bind with uranium, immobilizing it in the matrix.

[0059] [Table 3]

[0060] Example 7: Heavy Metal Removal. Fine alumina powder was mixed with manganese and other transition metal salts and heated in a furnace to 1200°C. This mixture was excellent for removing lead and other heavy metals from drinking water. When this mixture was mixed with carbon and passed through the above media, the amount of lead was reduced (Table 4). The high surface area media formed allows for exchange reactions between active metal ions and heavy metals. Toxic substances such as lead, cadmium, arsenic, and mercury can be removed using this filter matrix.

[0061] [Table 4]

[0062] Example 8: Composition as an Ethylene Absorber: Fruits are either producers or absorbers of ethylene. Apples, bananas, melons, pears, and peaches are all producers of ethylene. To extend the shelf life of these fruits, ceramic beads containing 6 to 20% oxidizers such as permanganate and ammonium ferric nitrate were prepared. Approximately 6% KMno4 in alumina beads was found to be useful in extending the life of bananas, for example.

[0063] Example 9: Oxygen and Humidity Control Composition: Another gas to be controlled is oxygen. Special ceramic reagent beads were prepared using 10-20% sodium metabisulfite and alumina balls. This "reducing agent" regulated the oxygen content and extended the shelf life of certain fruits, especially tomatoes. Humidity control was also achieved using molecular beads (special ceramic) with very high surface area that were "baked" in a high-temperature oven up to 900°C. This medium aided in the absorption and desorption of humidity, extending the shelf life of the fruit.

[0064] In electrolytic polymer-coated carbon using conductive polymers, porous carbon or absorbent matrices are coated with biocompatible polymers to form a smooth, permeable layer without clogging the pores. This process involves electrolytic deposition of polymers onto a substrate that can be used for hemoperfusion, a therapeutic procedure in which blood is withdrawn from the patient's body and passed through an external adsorbent to remove harmful substances. This type of simulated matrix has also been prepared, demonstrating the removal of toxins with molecular weights up to several thousand daltons that bind to the coated substrate. Binding is by physical adsorption and depends on molecular weight and lipophilicity. Low molecular weight toxins are generally adsorbed.

[0065] In warfare, where multiple personnel are seated in tanks, this type of material can have a significant impact, as it can remove toxic warfare agents in a confined environment. The application of metal-impregnated carbon to gas filters is noteworthy. For example, the ABEK filter absorbs dangerous gases and vapors, allowing users to breathe safely. Furthermore, because the metal is impregnated into the filter, there is no risk of it leaching into solutions or water. Catalysts such as zinc sulfate, copper sulfate, and molybdenum oxide were used to prepare the carbon, which blocks incoming gases and vapors through chemical adsorption.

[0066] It will be further understood that the functions or structures of multiple components or steps may be combined into a single component or step, or that the functions or structures of one step or component may be divided among multiple steps or components. The present invention contemplates all such combinations. Unless otherwise specified, the dimensions and shapes of various structures depicted herein are not intended to limit the present invention, and other dimensions and shapes are possible. Additionally, while features of the present invention may be described in the context of only one of the illustrated embodiments, such features may be combined with one or more other features of other embodiments for any given application. It will also be understood from the above that the creation of the unique structures herein and their operation also constitute methods in accordance with the present invention. The present invention also encompasses intermediate and final products resulting from the practice of the methods herein. The use of "comprising" or "including" also contemplates embodiments that "consist essentially of" or "consist of" the referenced features.

[0067] Although embodiments of the present invention have been described in terms that specify structural features, it should be understood that the invention is not necessarily limited to the particular features described. Rather, the specific features and methods are disclosed as embodiments for the present invention. Numerous modifications and adaptations of the systems / components of the present invention will be apparent to those skilled in the art, and it is therefore intended by the appended claims to cover all such modifications and adaptations that fall within the scope of the present invention.

[0068] advantage: · Porous materials with high surface area provide numerous reactive sites with high reagent content, allowing for maximum capture of contaminants. - Carbon monoxide removal Ethylene removal with ceramic beads coated with manganate and ammonium iron nitrate Oxygen removal by sodium metabisulfite-impregnated beads ·Humidity adjustment Removal of radioactivity Heavy metal removal - Metal is impregnated, and stable coating is achieved without eluting the metal.

Claims

1. A method for manufacturing an active molecular filter, comprising the steps of: a. activating a porous substrate by placing a measured amount of the porous substrate in a reaction vessel; Here, in order to increase the surface area of ​​the porous substrate, the porous substrate is activated by heating it in a furnace to 1200 ° C. without melting it, and calcining it. b. functionalizing said porous substrate to form a molecular filter media by mixing with a measured amount of: i. at least an impregnating agent selected from copper, iron, potassium, palladium, and manganese; and ii. Polyvinylpyrrolidone polymer wherein, depending on the required application and activity of the molecular filter, a reducing or oxidizing agent is added in the functionalization step, and optionally, a binder is added to immobilize the soluble ions within the molecular filter media; the binder is poly(vinylamine), poly(vinylformamide), or a copolymer of vinyl alcohol and vinylamine; the oxidizing agent is potassium permanganate or ceric ammonium nitrate; the binder has a melt flow rate of 2-5 g / 10 min, and the mixture of the molecular filter media and the binder is heated to a temperature in the range of 150-950° C. for the desired shape and porosity of the molecular filter block; The mixture involves electroless deposition of the impregnating agent by a redox reaction.

2. 2. The method for manufacturing an active molecular filter according to claim 1, wherein the porous substrate comprises a porous surface having a high surface area selected from the group consisting of carbon, including graphene, ceramic, zeolites, both natural and synthetic zeolites, silica molecular sieves, microporous phosphoric oxides, organic-inorganic hybrid materials such as metal organic frameworks (MOFs), and combinations thereof.

3. 2. The method of claim 1, wherein the impregnating agent is selected from the group consisting of elements or salts of silver, zinc, copper, aluminum, manganese, iron, calcium, palladium, iodine, and both conductive and water-soluble polymers such as polyvinylpyrrolidone, polyvinyl alcohol, polyaniline, polypyrrole, and combinations thereof.

4. 10. The method of claim 1, wherein the reducing agent is selected from the group consisting of formaldehyde, hypophosphites, ascorbic acid, borates, metabisulfites, and combinations thereof.

5. 2. A method for manufacturing an active molecular filter according to claim 1, wherein in the reaction vessel, the impregnating agent and the porous substrate are mixed with a solvent to form a "coating" or impregnating agent on the porous substrate that gently penetrates the porous substrate without mechanically damaging it.

6. 2. A method for an active molecular filter according to claim 1, wherein the functionalization of the porous substrate is carried out by any of the techniques such as, but not limited to, electrolysis, electroless deposition by redox reaction, extrusion techniques and combinations thereof, depending on the surface of the porous substrate and the activity required, depending on the surface of the substrate and the activity required.

7. A method for manufacturing an active molecular filter according to claim 6, wherein the impregnating agent is "reduced" or "oxidized" on the surface of the porous material using a reducing or oxidizing agent for direct impregnation of metals or polymers into the molecular filter.

8. A method for manufacturing an active molecular filter as described in claim 6, wherein the extrusion process "pushes" the material into various shapes to increase surface area and enhance interaction with reagents that purify air and water pollutants.

9. An active molecular filter, comprising: - at least a porous substrate selected from carbon, alumina and ceramic; at least an impregnating agent selected from iron, potassium and manganese, and - comprising a polyvinylpyrrolidone polymer; The impregnating agent is a metallic, organic, or inorganic molecule for functionalization of the porous substrate.

10. 10. The active molecular filter of claim 9, wherein the molecular filter is in the form of a filter block, a porous media, a coating on a fabric, or packed within a perforated casing, or a combination thereof.

11. 11. A method for producing an active molecular filter as claimed in claim 10, wherein the molecular filter "block" is made by molding techniques using a binder and resin, followed by firing to burn out the resin and leave a high surface area porous filter block.

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