Apparatus, systems, and methods for trapping and destroying pathogens

Abstract

A filtration device which may principally comprise a case housing a sterilization media which may comprise a. laminate, or layering, of at least one filtration media, and one or more heating elements. The filtration device may be provided with one or more electrical contacts which may communicate a current to the one or more heating elements in a manner which may allow the one or more heating elements to be heated to a desired temperature for a desired duration. A method of forming the filtration device and its sterilization media is further disclosed, along with a method of trapping and destroying or incapacitating pathogens or contaminants included in air being circulated by an environmental system comprising the filtration device.

Description

IN THE UNITED STATES PATENT AND TRADEMARK OFFICE APPLICATION FOR UNITED STATES LETTERS PATENT Apparatus, Systems, and Methods for Trapping and Destroying Pathogens By: Monzer A. Hourani 7670 Woodway Dr., Suite 160 Houston, Texas 77063 Citizenship: USAtty Docket No.6400-00702 Apparatus, Systems, and Methods for Trapping and Destroying Pathogens CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] Not applicable. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable. BACKGROUND OF THE INVENTION Field of the Invention

[0003] This invention relates to the field of air purification and more specifically to filtration devices and methods for removing pathogens from air. Background of the Invention

[0004] Pathogens are a serious problem when disposed in air. They can cause the spread of viruses and other health problems. They may especially be a problem in enclosed areas such as hospitals, office buildings, airplanes, and the like.

[0005] There has been a variety of conventional methods and devices for removing pathogens from air. Many of such conventional methods and devices involve removing the pathogens and / or killing the pathogens.

[0006] Conventional methods and devices include filters such as high-efficiency particulate air filters (HEPA filters). Drawbacks to such conventional methods include their inefficiencies in removing and killing viruses.

[0007] Consequently, there is a need for improved devices and methods for removing pathogens from air. BRIEF SUMMARY OF SOME OF THE PREFERRED EMBODIMENTS

[0008] These and other needs in the art are addressed in one embodiment by a filtration device. The filtration device comprises a case providing an internal volume and a sterilization media disposed within the internal volume of the case. The sterilization media comprises at least one filtration media and one or more heating elements. The filtration media and one or more heating elements are formed in a laminate, or layered, configuration. The filtration device also includesAtty Docket No.6400-00702 one or more electrical contacts in electrical communication with at least a portion of the sterilization media. The electrical communication comprises communication of at least a portion of a current to the heating element of the sterilization media, which causes the heating element to heat the filtration media to a desired temperature for a desired duration.

[0009] These and other needs in the art are addressed in another embodiment by an electrical contact for a filtration device. The electrical contact includes a conducting plate comprising a size and a shape. The electrical contact also includes a conducting rod secured to the conducting plate. A secondary plate is secured to the conducting plate. A sterilization media comprising at least one filtration media and one or more heating elements is secured between the conducting plate and the secondary plate. The size and the shape of the conducting plate are selected to substantially evenly distribute a current to at least one of the one or more heating elements.

[0010] These and other needs in the art are also addressed by a method of trapping and destroying or incapacitating pathogens or contaminants. The method includes providing an environmental system which circulates an air including pathogens or contaminants. In addition, the method includes disposing a filtration device within the environmental system. The filtration device includes a case providing an internal volume. The filtration device also includes a sterilization media disposed within the internal volume of the case. The sterilization media comprises at least one filtration media and one or more heating elements. The filtration media and the one or more heating elements are formed in a laminate, or layered, configuration. The filtration device also includes one or more electrical contacts in electrical communication with at least a portion of the sterilization media. The electrical communication comprises communication of at least a portion of a current to the heating element of the sterilization media, which causes the heating element to heat the filtration media to a desired temperature for a desired duration. The method also includes circulating the air including the pathogens or contaminants through the filtration device. In addition, the method includes trapping the pathogens or contaminants in the filtration media of the filtration device. Moreover, the method includes providing a current to the one or more electrical contacts of the filtration device. The method also includes heating the filtration media to a desired temperature for a desired duration, thereby destroying or incapacitating the pathogens or contaminants trapped by the filtration media.Atty Docket No.6400-00702

[0011] In addition, these and other needs in the art are addressed by a method of forming a filtration device which traps and destroys or incapacitates pathogens or contaminants included in air circulated in an environmental system. The method includes forming a laminate, or layering, of at least one filtration media and one or more heating elements. The forming comprises aligning along a length the one or more heating elements to be in surface contact with all or a portion of at least one surface of the at least one filtration media. In addition, the method includes folding the laminate, or layering, along the length so as to form one or more pleats and thereby providing a pleated sterilization media. Moreover, the method includes positioning at least one separator between each of the one or more pleats of the sterilization media. Additionally, the method includes disposing the pleated sterilization media including the at least one separator in a case. Further, the method includes securing one or more electrical contacts to the pleated sterilization media, thereby forming the filtration device.

[0012] Disclosed herein is a filtration device which may principally comprise a case providing an internal volume within which may be housed a sterilization media, wherein the sterilization media may comprise laminate, or layering, of at least one filtration media and one or more heating elements. The filtration device may further comprise one or more electrical contacts which may communicate a current to the one or more heating elements in a manner which may allow the one or more heating elements to be heated to a desired temperature for a desired duration. In an embodiment, the filtration device may be further configured with one or more thermocouples which may be in thermal communication with the sterilization media, thereby allowing the temperature of the sterilization media to be measured. In certain embodiments, the filtration device may comprise a plurality of sterilization media, which may be connected in electrical communication via one or more electrical jumpers.

[0013] Disclosed herein is a method of forming a filtration device, wherein the method may comprise at least in part forming a laminate, or layered, sterilization media comprising at least one filtration media and one or more heating elements, folding the laminate, or layered, sterilization media into a configuration which may comprise one or more pleats, inserting at least one separator between each of the one or more pleats during the folding, and disposing the folded sterilization media within a case which may be formed through techniques known to one of ordinary skill in the art. The method may further comprise providing the filtration device with at least one electrical contact in electrical communication with the one or more heating elements, and may furtherAtty Docket No.6400-00702 comprise configuring the filtration device with at least one thermocouple which may be in thermal communication with the sterilization media. In certain embodiments, the method may further comprise joining each of a plurality of sterilization media with an electrical jumper prior to, or upon, the plurality of media being disposed within the case.

[0014] Disclosed herein is a method of trapping and destroying pathogens which may comprise disposing a filtration device within an environmental system, circulating air including pathogens or contaminants through the environmental system, communicating all or a portion of the air including pathogens or contaminants into or through the filtration device, and trapping the pathogens or contaminants within all or a portion of a filtration media comprising a sterilization media of the filtration device. The method may further comprise heating one or more heating elements which may be in surface contact with the filtration media to a desired temperature, for a desired duration, thereby destroying or incapacitating the pathogens or contaminants.

[0015] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter that form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other embodiments for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent embodiments do not depart from the spirit and scope of the invention as set forth in the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which:

[0017] Figure 1A illustrates a first isometric view of an embodiment of a filtration device according to the present disclosure;

[0018] Figure 1B illustrates a second isometric view of an embodiment of a filtration device according to the present disclosure;

[0019] Figure 2 illustrates an isometric view of an embodiment of a filtration device case according to the present disclosure;Atty Docket No.6400-00702

[0020] Figure 3A illustrates a first view of an embodiment of a sterilization media separator according to the present disclosure;

[0021] Figure 3B illustrates a second view of an embodiment of a sterilization media separator according to the present disclosure;

[0022] Figure 3C illustrates a third view of an embodiment of a sterilization media separator according to the present disclosure;

[0023] Figure 4 illustrates a first view of an embodiment of a sterilization media according to the present disclosure;

[0024] Figure 5 illustrates a second view of an embodiment of a sterilization media according to the present disclosure;

[0025] Figure 6A illustrates a first view of an embodiment of an electrical contact according to the present disclosure;

[0026] Figure 6B illustrates a second view of an embodiment of an electrical contact according to the present disclosure;

[0027] Figure 7A illustrates a first view of an embodiment of an electrical contact disposed in an embodiment of a sterilization media according to the present disclosure;

[0028] Figure 7B illustrates a second view of an embodiment of an electrical contact disposed in an embodiment of a sterilization media according to the present disclosure;

[0029] Figure 8A illustrates a first view of an embodiment of an electrical isolator according to the present disclosure;

[0030] Figure 8B illustrates a second view of an embodiment of an electrical isolator according to the present disclosure;

[0031] Figure 8C illustrates a view of an embodiment of an electrical contact and an electrical isolator disposed in an embodiment of a filtration device case according to the present disclosure;

[0032] Figure 9 illustrates an embodiment of two sterilization media joined by an embodiment of an electrical jumper according to the present disclosure;

[0033] Figure 10A illustrates a first view of an embodiment of an electrical jumper according to the present disclosure;

[0034] Figure 10B illustrates a second view of an embodiment of an electrical jumper according to the present disclosure;Atty Docket No.6400-00702

[0035] Figure 11A illustrates a first view of an embodiment of an electrical jumper joining an embodiment of two sterilization media according to the present disclosure;

[0036] Figure 11B illustrates a second view of an embodiment of an electrical jumper joining an embodiment of two sterilization media according to the present disclosure;

[0037] Figure 12 illustrates an embodiment of a thermocouple disposed in an embodiment of a filtration device according to the present disclosure; and

[0038] Figure 13 illustrates an embodiment of an environmental system including a filtration device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0039] In the disclosure that follows, certain descriptions may include reference to an X-Y-Z coordinate axis system known to one of ordinary skill in the art, comprising three axes commonly used to define spatial relationships in three dimensions, and wherein each of the three axes is oriented perpendicularly to any adjacent axis. As used herein, the X axis generally defines an orientation which may be forward and backward, the Y axis generally defines an orientation which may be leftward or rightward, and the Z axis generally defines an orientation which may be upward or downward. More specifically, in relation to embodiments of the present invention, the forward and backward orientations defined by the X axis are to be understood as aligning to downstream and upstream directions of airflow, respectively, the leftward and rightward orientations defined by the Y axis are to be understood as aligning to leftward and rightward directions relative to the downstream direction, and the upward and downward orientations defined by the Z axis are to be understood as aligning to upward and downward orientations relative to a plane defined by the X and Y axes.

[0040] As disclosed herein, filtration device 200 may be disposed within environmental system 100, and may allow pathogens, such as bacteria, viruses, molds, or other contaminants which may be included in air being circulated by or within environmental system 100 to be removed from the air circulating by or within environmental system 100 by trapping and destroying the pathogens or contaminants within filtration device 200. As will be described in the details that follow, filtration device 200 may contain a filtration media which may trap the pathogens and / or contaminants, and may contain one or more heating elements which may transfer heat to the filtration media, at a desired temperature and for a desired duration, which may destroy the trapped pathogens and / orAtty Docket No.6400-00702 contaminants. Environmental system 100 may comprise any environmental system, such as a heating, ventilating, and air conditioning (HVAC) system, which may be located within or adjacent to an enclosed environment such as a facility, hospital office space, airport terminal, church, or an enclosed craft or vessel, such as an air-, water-, ocean-, or space-based craft or vessel.

[0041] Referring to Figs. 1A and 1B, filtration device 200 may principally comprise case 210, sterilization media 220, and one or more electrical contacts 260. In embodiments, filtration device 200 may further comprise one or more or sealing elements 203, 204, for example a silicone gasket, disposed between one or more surfaces of sterilization media 220 and one or more internal surfaces of case 210, or all or a portion of one or more surfaces of sterilization media 220 may be secured to all or a portion of one or more internal surfaces of case 210, for example with an adhesive such as a silicone adhesive. In certain embodiments, filtration device 200 may be fitted with one or more thermocouples 270 in contact with, or located in proximity to, one or more portions of sterilization media 220, as shown in Fig.12. When disposed in environmental system 100, filtration device 200 may be electrically grounded by providing a grounding connection 311 between one or more features of case 210 and one or more features of environmental system 100.

[0042] In embodiments, filtration device 200 may be formed to provide upstream face 201, downstream face 202, and may be provided with one or more sealing elements 203, 204 disposed about a surface of one or more faces of filtration device 200. In an embodiment, air which may be circulated in environmental system 100 may enter filtration device 200 via upstream face 201, communicate with and through sterilization media 220, and exit filtration device 200 via downstream face 202. In the embodiment shown in Figs.1A and 1B, filtration device 200 has been provided with sealing elements 203a,b,c,d surrounding a perimeter of upstream face 201 and sealing elements 204a,b,c,d surrounding a perimeter of downstream face 202. Each of the one or more sealing elements 203, 204 may be formed from any suitable material, for example silicone, and may be formed to comprise any suitable size, shape, and cross-sectional profile which when disposed about filtration device 200 may reduce the chance of, restrict, or prevent the flow of air circulating in environmental system 100 from deviating to flow around filtration device 200, and instead encourage the flow of air circulating in environmental system 100 to communicate with and through sterilization media 220. In embodiments, each of the one or more sealing elements 203, 204 may be installed about one or more perimeter faces of case 210 through any suitable techniques, for example using adhesive materials, fasteners, and the like.Atty Docket No.6400-00702

[0043] Referring now to Fig.2, case 210 may be formed to have any size and shape suitable for providing an internal volume of sufficient capacity to house a quantity of sterilization media 220 determined to be appropriate for the environmental system 100 into which filtration device 200 may be installed. The size and / or shape of case 210 may also be selected in part to conform to one or more internal surfaces of environmental system 100. For example, in alternate embodiments, case 210 may be formed to have a shape which may be generally that of a cube, a cuboid, a prism, a pyramid, a cylinder, a cone, a sphere, or a hemisphere, or other three-dimensional shape which may be derived from such shapes alone, in part, or in combination. In embodiments, case 210 may comprise a plurality of faces, wherein all or a portion of one or more faces of case 210 may be formed to be at least partially open, which may allow the air being circulated through environmental system 100 to communicate into or through case 210, for example from an upstream external surface of case 210, through the interior volume of case 210, to a downstream external surface of case 210. In this manner, the shape of case 210 and selection of the one or more open surfaces may define plenum 211, within which sterilization media 220 may be disposed. The size of case 210 may be selected based upon a desired quantity or volume of sterilization media 220 to be housed within plenum 211, one or more dimensional aspects of the environmental system 100 into which filtration device 200 may be installed, or combinations thereof.

[0044] Case 210 may be formed using any suitable technique. In the embodiment shown in Fig. 2, case 210 has been formed to have a cuboid shape, providing case 210 with eight vertices, twelve edges, and six faces, with upstream face 212 and downstream face 213 generally open to define plenum 211. In embodiments, case 210 may be formed from one or more pieces of sheet-type material which may be folded, bended, crimped, cut, or otherwise shaped via known means to provide case 210 with a desired shape. For example, in embodiment of case 210 having a cuboid shape as shown in Fig.2, case 210 may be formed from a single piece of sheet material which may be folded in a manner to provide case 210 with eight vertices, twelve edges, and six faces, two of which faces may be at least partially open. In an alternate example embodiment, case 210 having a cuboid shape may be formed from four separate pieces of sheet material, each of which may be partially folded to provide one or more surfaces which may be used to join the four pieces together in a manner which may provide case 210 with eight vertices, twelve edges, and six faces, two of which faces may be at least partially open. In embodiments, one or more edges of case 210, or the individual pieces of sheet material forming case 210, may be joined through any suitable fasteningAtty Docket No.6400-00702 techniques, for example using threaded fasteners, riveting, tabbed joints, self-clinching joints, welding, or other suitable methods of joining sheet-based components. Case 210 may be formed from any material which may be suitable to house sterilization media 220 and suitable for use in environmental system 100. For example, case 210 may be formed from suitable metallic materials such as galvanized steel, aluminum, or stainless steel, suitable non-metallic materials, for example particle board, or combinations of such suitable metallic and non-metallic materials.

[0045] Case 210 may be provided with one or more perimeter faces surrounding the one or more at least partially open faces of case 210. In embodiments, such perimeter faces may be of sufficient size to retain sterilization media 220 within the internal volume formed by case 210, and may provide sufficient surface area for locating one or more apertures and / or receive one or more gaskets. In the embodiment shown in Fig. 2, case 210 has been formed to provide upstream perimeter faces 212a,b,c,d surrounding partially open upstream face 212, and downstream perimeter faces 213a,b,c (not shown) and 213d (shown) surrounding partially open downstream face 213. As can be seen in Fig.2, perimeter faces 212a,c have been provided with apertures 214, while perimeter faces 212b,d have been provided with apertures 215. Similarly, perimeter faces 213a,c have been provided with apertures 214, while perimeter faces 213b,d have been provided with apertures 215. In embodiments, apertures 214 may allow filtration device 200 to be fitted with one or more electrical contacts 260, as can be seen in Fig. 8C, and apertures 215 may allow additional components (not shown) to be coupled to filtration device 200. In embodiments, perimeter faces 212a,b,c,d and 213a,b,c,d may be sized to provide sufficient surface area suitable to locate one or more sealing elements 203, 204, for example sealing elements 203a,b,c,d and sealing elements 204a,b,c,d as illustrated in Figs.1A and 1B. In alternate embodiments, case 210 may be formed having one or more flanges or headers surrounding all or a portion of one of the faces of case 210, for example a single-turn flange, a double-turn flange, a single header, a double header, or combinations thereof, which may be suitably adapted for securely installing filtration device 200 in one or more locations of environmental system 100.

[0046] Filtration device 200 may be configured to house one or more sterilization media 220, each of which may be formed as a laminate, or layering, of at least one filtration media 230 and one or more heating elements 240, which together as the laminate may be formed to receive one or more separators 250 in a manner which will be described.Atty Docket No.6400-00702

[0047] Filtration media 230 may be any known filtration media capable of meeting a desired filtering efficiency for environmental system 100, and capable of withstanding a predetermined amount of heating for a predetermined duration of time, which will be further described below. For example, in embodiments, filtration media 230 may be characterized as meeting filtration standards associated with High-Efficiency Particulate Air (HEPA) filters. As set forth by the United States Environmental Protection Agency, HEPA filters may remove at least 99.7% of any dust, pollen, mold, bacteria, and other airborne particles having a size of 0.3 microns or greater. A variety of HEPA filters are available commercially, which may be further characterized by a Minimum Efficiency Reporting Value, or MERV, commonly having a value between 1 and 16 that may correlate to a filter’s ability to capture particles between 0.3 and 10 microns. In embodiments, filtration media 230 may comprise a sheet-type material providing a desired filtration performance, which may have a length, width, and thickness, and may be formed to include a plurality of pores or other geometric features which may relate in whole or in part to the desired filtration performance.

[0048] In embodiments, the thickness of filtration media 230 may correspond to a desired filtration performance, and may further correspond to one or more characteristics which may correlate – positively, inversely, or otherwise – to the desired filtration performance. For example, a given filtration performance may correspond to a thickness of filtration media 230 which may allow filtration media 230 to accommodate a size and density of pores meeting the filtration performance, and the thickness, and size and density of the pores, may define a range of airflow through filtration media 230 which may be achieved. Continuing the example, a higher filtration performance may correspond to a higher thickness, a decrease in pore size, or an increase in pore density, or combinations thereof, which may correlate to a lower range of airflow through filtration media 230 which may be achieved. In embodiments, filtration media 230 may be selected based upon consideration of one or more of such corresponding or correlating characteristics, thereby providing a gauge of suitability of filtration media 230 for use in filtration device 200 in relation to environmental system 100.

[0049] In embodiments, the length and width of the sheet-type material forming filtration media 230 may be selected based upon one or more geometric and / or dimensional characteristics of plenum 211 formed within case 210. In embodiments, and in relation to a method of forming sterilization media 220 which will be described further below, the length of the sheet-type materialAtty Docket No.6400-00702 forming filtration media 230 may be selected such that filtration media 230 may be folded over on itself one or more times, which may form a pleated arrangement of filtration media 230, with the length of filtration media 230 being sufficient to allow the folded arrangement to conform to the volume of plenum 211.

[0050] Heating element 240 may be any electrically conductive material which may provide filtration device 200 with a method of transferring a desired or predetermined amount of heat to filtration media 230 for a desired or predetermined duration, and may separately allow a desired or predetermined capacity of airflow through environmental system 100 to pass through heating element 240 without exceeding a desired or predetermined degradation in the rate of airflow through environmental system 100. Heating element 240 may transfer the desired or predetermined amount of heat to filtration media 230 in a manner in which the heat may be distributed across one or more surfaces of filtration media 230 within a desired or predetermined measure of temperature distribution, for example through conductive, radiant, or convective methods of transferring heat. In embodiments, heating element 240 may be formed from, or as, an electrically conductive mesh, cloth, fabric, or screen, which may be generally sheet-like in form, may comprise a length, width, and thickness, and may be formed to include a plurality of openings, voids, pores, or other geometric features which may accommodate a desired or predetermined rate of airflow through heating element 240. For example, heating element 240 may comprise a woven wire mesh capable of transforming an electrical current into heat when a voltage is applied to heating element 240. In embodiments, heating element 240 may be formed from any suitable electrically conductive material, for example stainless steel or galvanized steel. In embodiments, heating element 240 may be provided with, or formed to provide, one or more surfaces or apertures suitable for connection to one or more electrical contacts 260 or thermocouples 270, which will be described below.

[0051] In embodiments, the thickness of heating element 240 may correspond to one or more aspects of its construction, for example a thickness of a wire used to form a weave pattern along with any relational dimensional aspects of a pattern of overlapping warp and weft which may be used in forming the weave. In alternate embodiments, the thickness of heating element 240 may correspond to a thickness of a sheet-like material from which heating element 240 may be formed. Heating element 240 may provide, or be provided with, a plurality of openings or geometric voids which may define a rate of airflow through heating element 240 which may be achieved. In embodiments, the openings or voids may be uniform or non-uniform in size, and may beAtty Docket No.6400-00702 distributed across heating element 240 in a manner which may be uniform or non-uniform. In an embodiment, the size and / or density of openings or voids provided by heating element 240 may correlate to an ability of heating element 240 to transfer heat to filtration media 230, or a measure of efficiency in which heating element 240 may transfer heat to filtration media 230.

[0052] In embodiments, the length and width of heating element 240 may be selected based upon one or more geometric and / or dimensional characteristics of plenum 211 formed within case 210, and may be also selected, at least in part, based on one or more dimensional considerations which may allow heating element 240 to remain electrically isolated from case 210. In embodiments, and in relation to a method of forming sterilization media 220 which will be described further below, the length of heating element 240 may be selected such that heating element 240 may be folded over on itself one or more times, which may form a pleated arrangement of heating element 240, with the length of heating element 240 being sufficient to allow the folded arrangement to correspond to the length of filtration media 230 as well as conform to the volume of plenum 211. In embodiments, the width of heating element 240 may be less than the width of filtration media 230, such that when a laminate, or layering, of at least one filtration media 230 and one or more heating elements 240 is formed, the laminate, or layering, may offer an exposed portion of filtration media 230 along the length of at least one side of filtration media 230. In this manner, the resulting sterilization media 220 may be provided with electrically inert portions along one or more perimeter edges, which may allow sterilization media 220 to be disposed within plenum 211 in a manner which electrically isolates the one or more heating elements 240 from case 210.

[0053] In embodiments, heating element 240 may be defined by an effective, average, or mean cross sectional area which may correlate to one or more dimensional aspects, and / or method(s) of forming or construction, of heating element 240, which, in combination with the material from which heating element 240 may be formed, may provide heating element 240 with a measure of electrical resistivity. For example, the effective cross-sectional area of heating element 240 may be derived based upon a weaved pattern of construction, wherein the warp and weft wires may comprise known diameters, and the weave pattern may comprise a known density of openings, in relation to a known width across which the weaved pattern may be formed. In this manner, the electrical resistivity of heating element 240 may be measured in units of resistivity per unit of length, for example Ohms per meter, Ohms per foot, etc. In embodiments, the measure ofAtty Docket No.6400-00702 electrical resistivity of heating element 240 may in turn correspond to an efficiency at which heating element 240 may be heated to a desired or predetermined temperature when a voltage is applied across heating element 240, which may in turn pass a current through heating element 240. Accordingly, the method of construction and dimensional aspects, including length, of heating element 240 may be selected such that heating element 240 may be suitable for use in filtration device 200 in relation to one or more dimensional aspects of filtration device 200, as well as in relation to a voltage or current which may be provided to filtration device 200.

[0054] Figs. 3A, 3B, and 3C illustrate an embodiment of separator 250. When disposed in sterilization media 220, separator 250 may provide sterilization media 220 with an electrically inert and structurally sufficient separation between each of one or more pleats which may be formed when a laminate, or layering, of at least one filtration media 230 and one or more heating elements 240 may be folder over itself. In addition to providing such structural stability and / or separation, separator 250 may bias all or a portion of one or more surfaces of the one or more heating elements 240 against all or a portion of one or more surfaces of the at least one filtration media 230 of sterilization media 220. In this manner, separator 250 may serve to increase an amount of surface contact between a surface of heating element 240 and filtration media 230, thereby increasing an efficiency at which heating element 240 may transfer heat to a surface of filtration media 230.

[0055] Separator 250 may be formed from any suitable electrically inert non-metallic material, or from any suitable electrically conductive material, such as a metal, which may be coated in any suitable electrically inert non-metallic material. For example, in an embodiment separator 250 may be formed from an aluminum sheet coated with a non-conductive synthetic material, such as Polytetrafluoroethylene (PTFE) or another electrically inert material, suitable for use in environments exhibiting sustained levels of heat or in applications comprising contact with heated surfaces. In embodiments, the material(s) from which separator 250 are formed may be selected based on an ability to resist degradation or failure when exposed to a desired temperature for a desired duration. Generally, materials which may form harmful chemical byproducts when heated or exposed to heat may be considered unsuitable for use in forming separator 250.

[0056] Separator 250 may be formed from, or as, a sheet-type material which may have a length, a width, and a thickness. In an embodiment, the length of the sheet-type material comprising separator 250 may correlate to one or more dimensions of case 210, plenum 211, or sterilization media 220, such that the sheet type-material may be folded or corrugated along its length, therebyAtty Docket No.6400-00702 providing separator 250 with a length SZ which may correspond to an internal dimension of plenum 211 in the Z direction. The width of the sheet-type material from which separator 250 may be formed may correspond to an internal dimension of plenum 211 in the X direction, less any amount desired to provide spacing between separator 250, sterilization media 220, and an internal surface of case 210, for example spacing DX shown in Fig. 4, such that separator 250 is provided with depth SXas shown in Fig. 3C. Upon being folded or corrugated in the manner just described, separator 250 may be formed to have width SY, which may be selected based upon a desired spacing between each of one or more pleats formed by the laminate of filtration media 230 and heating element 240 being folded over itself one or more times in the manner which will be described. The folding or corrugating may provide separator 250 with a plurality of alternating peaks and valleys in the Z direction, which may impart a biasing aspect in the Y direction, such that one or more such peaks being in contact with a proximal portion of heating element 240 may serve to bias the proximal portion of heating element 240 against filtration media 230, thereby improving an ability of heating element 240 to transfer heat to filtration media 230. Separator 250, being formed in this manner, may also be provided with a desired structural integrity capable of separating the one or more pleats of laminate while offering a desired or minimal surface contact with heating element 240, and further offering a desired or minimal airflow obstruction in the X direction when separator 250 is disposed within the one or more pleats comprising sterilization media 220.

[0057] In embodiments, sterilization media 220 may be formed through a method whereby a laminate, or layering, of one or more lengths of heating elements 240 may be placed into surface contact with the at least one length of filtration media 230, thereby forming a length of sterilization media 220 in a sheet-type arrangement. The sheet-type length of sterilization media 220 may then be folded or otherwise configured to form an arrangement of one or more pleats, with one or more lengths of separator 250 disposed between each pleat, as shown in Fig. 4. In embodiments, the arrangement of the one or more pleats of the folded sterilization media 220 may be aligned along an axis at a right angle to the orientation of the one or more lengths of separator 250 disposed between each of the one or more pleats of the folded sterilization media 220, as shown in Fig. 5. Thus, separator 250 may encourage all or a portion of an adjacent heating element 240 to be in surface contact against all or a portion of a surface of filtration media 230 adjacent to the heating element 230. In an embodiment of an assembled filtration device 200, the folded sterilizationAtty Docket No.6400-00702 media 220 may be configured such that the original widths of filtration media 230 and heating element 240 align vertically with the Z axis, or may alternately be aligned horizontally with the X axis, the Y axis, or some other arbitrary axis, relative to the assembled filtration device 200.

[0058] In the example embodiment illustrated in Figs.4 and 5, one length of filtration media 230 may be disposed between two lengths of heating element 240 such that each of the lengths of heating elements 240a,b is brought into surface contact with opposing surfaces of filtration media 230, thereby providing a sheet-type arrangement of sterilization media 220. As can be seen in Figs. 4 and 5, the length of the sheet-type sterilization media 220 may then be formed into an alternating pleated arrangement traversing along the Y axis, such that the length of the sheet-type sterilization media 220 may extend along the X axis in the downstream direction, traverse along the Y axis in the right direction a distance PY (from a centerline of a first fold to a centerline of an adjacent fold), extend along the X axis in the upstream direction, continue to traverse along the Y axis in the right direction a distance PY, extend in along the X axis in the downstream direction, and so on. In such an embodiment, the width between each of the pleats so formed would be sufficient to accommodate the width SY of each separator 250 disposed with in the pleat, and the width PY of each pleat may be selected such that all or a portion of the one or more peaks of separator 250 may bias a proximal portion of heating elements 240a,b against the proximal surface of filtration media 230. Upon being disposed between the pleats, separator 250 may be aligned with the width along the Z axis of the pleated sterilization media 220, such that its length SZis configured to align with an edge of filtration media 230, as can be seen in Fig.5, or the length SZmay extend past the width of the pleated sterilization media 220 along the Z axis. This method of forming a pleated arrangement would continue over the length of the sheet-type arrangement of sterilization media 220, such that the overall width of the pleated arrangement of sterilization media 220 formed in this manner may suitably consume the internal width provided by plenum 211.

[0059] In an alternate embodiment to that shown in Fig.4, sterilization media 220 may comprise only one heating element 240a or 240b in the layered and folded configuration just described. For example, sterilization media 220 may be formed to comprise one heating element 240a in the arrangement shown, such that heating element 240 is positioned against a surface of filtration media 230 which generally faces an upstream direction. In such an alternate embodiment, separator 250 may be formed in two alternate embodiments, wherein a first embodiment of separator 250 may comprise an electrically inert material while a second embodiment may not comprise anAtty Docket No.6400-00702 electrically inert material, such that an electrically inert separator 250 may be positioned between the folds of sterilization media 220 having heating element 240a facing an interior of the fold, while a non-electrically inert separator 250 may be positioned between the folds of sterilization media 220 not having heating element 240a facing an interior or the fold. In such an embodiment, each of the one or more separators 250 may thus comprise an electrically inert material or non- electrically inert material in alternating positions when traversing along the lengthwise direction of the folded arrangement, or in the Y direction as illustrated in Fig.4.

[0060] As previously described, the width of heating element 240 may be selected to be less than the width of filtration media 230, so as to provide an exposed portion of filtration media 230 along at least one side, and thus along the length-wise measure of the folded, or pleated, arrangement of sterilization media 220. As can be seen in Fig.5, this difference in width between heating element 240 and filtration media 230 may serve to electrically isolate heating element 240 from case 210 by providing a desired gap between heating element 240 and one or more surfaces of case 210, for example upstream perimeter face 212a.

[0061] In embodiments of the method of assembly just described, the sheet-type arrangement of sterilization media 220 may be prepared prior to the process of pleating or forming the folded arrangement of sterilization media 220. In such embodiments, a continuous length of the sheet-type arrangement of sterilization media 220 may be provided, for example on a spool or roller, for introduction to a folding or pleating process such as that just described. In an alternate embodiment, continuous lengths of filtration media 230 and / or heating element 240 may be provided, which may be fed to a laminating, or layering, process whereby a continuous feed of sheet-type sterilization media 220 may be formed prior to being provided to the folding or pleating process. In a further alternate embodiment, pre-cut lengths of filtration media 230 or heating element 240 may be provided to a first process which may form the laminate, or layered, sheet- type sterilization media 220, which may then be provided to the folding or pleating process.

[0062] In embodiments, the method of assembly may employ one or more folding tools or jigs, which may assist in forming the alternating arrangement of pleats, or in progressively bundling the folded arrangement, wherein the size or configuration of any such folding tools or jigs may correspond to one or more dimensional aspects of case 210 or plenum 211. In an embodiment of the method of assembly, all or a portion of case 210 may be employed to bundle the pleated sterilization media 220 while the sheet-type sterilization media is folded.Atty Docket No.6400-00702

[0063] Filtration device 200 may be provided with one or more electrical contacts 260, which may provide an electrically conductive path for communicating a current to the one or more heating elements 240 which may be included in a laminate, or layered, sterilization media 220. Figs. 6A-B, Figs. 7A-B, and Figs. 8A-C illustrate an embodiment of an electrical contact 260. In such embodiments, electrical contact 260 may comprise conducting rod 261, conducting plate 262, secondary plate 263, and one or more fasteners 264, electrical isolator 265, and nut 266. In such embodiments, conducting rod 261, conducting plate 262, secondary plate 263, and fastener 264 may be formed from any suitable electrically conductive material capable of supplying a current to heating element 240 which may be capable of heating sterilization media 220 to a desired temperature for a desired duration. Suitable materials may include stainless steel, galvanized steel, or other conductive materials offering electrical properties similar to stainless steel. In such embodiments, electrical isolator 265 and nut 266 may be formed from a suitable electrically inert material capable of electrically isolating case 210 when electrical contacts 260 are disposed within case 210, and attached thereto, for example in the manner shown in Fig.8C, at aperture 214.

[0064] The size and configuration of conducting plate 262 may provide filtration device 200 with a method of distributing current across heating element 240 so as to substantially evenly electrify heating element 240 across its surface, and thereby substantially evenly transfer heat to filtration media 230. In embodiments, the length of conducting plate 262 in the Z direction may correspond to all or a portion of the height of the pleated sterilization media 220 in the Z direction. As can be seen in the embodiment shown in Figs. 6A-B and 7A-B, conducting plate 262 may be provided with at least one aperture 287 adapted to receive conducting rod 261, through which conducting rod 261 may be fastened or riveted to conducting plate 262, and both conducting plate 262 and secondary plate 263 may be provided with one or more apertures 288 through which fastener 264 may secure secondary plate 263 to conducting plate 262. In such an embodiment, one or more of the apertures 288 of conducting plate 262 may align with one or more of the apertures 288 of secondary plate 263, as shown in Fig.6B, such that secondary plate 263 may be fastened to conducting plate 262 in a configuration which may surround a portion of sterilization media 220 as shown in Figs. 7A and 7B. In this manner, an electrical current delivered to conducting plate 262 by conducting rod 261 may be transferred at least in part to secondary plate 263, which may thereby allow the current received via conducting rod 261 to communicate with two heating elements 240 which may be disposed along opposite surfaces of filtration media 230 as shown inAtty Docket No.6400-00702 Fig. 4. In alternate embodiments, conducting rod 261 may be secured to conducting plate 262 through any suitable processes, for example welding.

[0065] In embodiments, conducting rod 261 may provide a threaded surface over at least a portion (or alternatively substantially all) of its surface, which may threadedly accept electrical isolator 265 as shown in Fig. 8B. As shown in Fig. 8C, when disposed within and secured to an aperture 214 of case 210, threaded portion 267 of conducting rod 261 may be exposed, thereby providing a suitable point of threaded connection to an external voltage source (not shown).

[0066] It may be desirable in certain embodiments of filtration device 200 to provide more than one sterilization media 220, as illustrated in Fig. 9, for example to provide a desired electrical resistivity across one or more heating elements 240 which may comprise each of the one or more sterilization media 220a,b. In such embodiments, filtration device 200 may be provided with one or more thermocouples 270 which may allow electrical communication of a current received by one or more electrical contacts 260 to be distributed across the one or more heating elements 240 which may form each of the one or more sterilization media 220a,b.

[0067] Referring now to Figs. 10A-B, an embodiment of thermocouple 270 may comprise two conducting plates 262, each of which may comprise one or more apertures through which a first conducting plate 262 may be fastened to a second conducting plate 262 by one or more fasteners 264. In such an embodiment, one or more of the apertures 284 of the first conducting plate 262 may align with one or more of the apertures 284 of the second conducting plate 262, as shown in Figs. 10A-B, such that the second conducting plate 262 may be fastened to the first conducting plate 262 in a configuration which may surround a portion of sterilization media 220 as shown in Figs. 11A and 11B. In this manner, an electrical current communicated to thermocouple 270 via first sterilization media 220a may be transferred at least in part from first sterilization media 220a to second sterilization media 220b.

[0068] The filtration device 220 just described may provide a method of operation whereby pathogens or contaminants included in an airflow circulating within environmental system 100 may become trapped within all or a portion of filtration media 230 of sterilization media 220 located within plenum 211. Periodically, or at a desired frequency, a current may be applied to the one or more heating elements 240 of sterilization media 220 which may surround and / or be in surface contact with filtration media 230, thereby causing the one or more heating elements 240 to transfer a desired amount of heat to filtration media 230 for a desired duration, and thereby destroy,

Claims

Atty Docket No.6400-00702 or incapacitate, any pathogens or contaminants which may have been trapped by filtration media 230. The current may be provided to the one or more heating elements 240 by applying a voltage to the one or more electrical contacts 260 which may be in electrical communication with the one or more heating elements 240. In certain embodiments comprising one or more thermocouples 270, the method of operation may include measuring one or more temperatures of sterilization media 220, whereby the measured temperatures may be compared to the desired temperature, and based upon which the voltage or current may be adjusted. [0069] Embodiments of filtration device 200 may further comprise one or more dampening apparatuses 300 and / or one or more control systems 400, which may function alone or in cooperation with filtration device 200 in performing the method of operation just described. In an embodiment of filtration device 200 comprising one or more dampening apparatuses 300, the one or more dampening apparatuses 300 may be secured to one or more faces (i.e., upstream face or downstream face) of filtration device 200. Further, embodiments of the method just described may further comprise opening and / or closing one of the one or more dampening apparatuses 300 alone or in coordination with applying the current to the one or more heating elements 240. [0070] In embodiments, the operation of filtration device 200 may be controlled by one or more control systems 400. In embodiments, the one or more control systems 400 may control one or more operational functions of filtration device 200 alone or in coordination with additional filtration devices 200. For example, the one or more control systems 400 may coordinate the method of operating filtration device 200 among each of a plurality of filtration devices 200 individually, in synchronization, or in coordination. [0071] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations may be made herein without departing from the spirit and scope of the invention as defined by the appended claims.Atty Docket No.6400-00702 wherein the sterilization media comprises at least one filtration media and one or more heating elements, the filtration media and the one or more heating elements formed in a laminate, or layered, configuration; one or more electrical contacts in electrical communication with at least a portion of the sterilization media, wherein the electrical communication comprises communication of at least a portion of a current to the heating element of the sterilization media which causes the heating element to heat the filtration media to a desired temperature for a desired duration; circulating the air including the pathogens or contaminants through the filtration device; trapping the pathogens or contaminants in the filtration media of the filtration device; providing a current to the one or more electrical contacts of the filtration device; and heating the filtration media to a desired temperature for a desired duration, thereby destroying or incapacitating the pathogens or contaminants trapped by the filtration media.

4. The method of claim 3, comprising: forming the laminate, or layered, configuration of the at least one filtration media and the one or more heating elements, wherein the forming comprises aligning along a length the one or more heating elements to be in surface contact with all or a portion of at least one surface of the at least one filtration media; folding the laminate, or the layered, along the length so as to form one or more pleats and thereby providing a pleated sterilization media; positioning at least one separator between each of the one or more pleats of the sterilization media; and disposing the pleated sterilization media including the at least one separator in a case; and securing one or more electrical contacts to the pleated sterilization media, thereby forming the filtration device.

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