Air filter substrates

Abstract

A device may include a base media. A device may include an active media, wherein the active media is a particle mixture comprising at least two active ingredients, the particle mixture having a particle size of about minus 200 mesh.

Description

AIR FILTER SUBSTRATESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. provisional patent application No. 63 / 665,301, filed on June 28, 2024, and titled "AIR FILTER SUBSTRATES," the disclosure of which is expressly incorporated herein by reference in its entirety.BACKGROUND

[0002] Air quality is a critical concern in various environments, including residential, commercial, industrial, and medical settings. Effective air filtration systems are essential for removing particulates such as dust, pollen, pet dander, bacteria, viruses, volatile organic compounds (VOCs), and other contaminants from the air. Traditional air filters, while effective to some degree, often face limitations in terms of efficiency, lifespan, and the ability to capture a broad spectrum of particle sizes and types, including but not limited to viruses and bacteria.SUMMARY

[0003] In some aspects, the techniques described herein relate to an air filter substrate, including: a base media; and an active media, wherein the active media is a particle mixture including at least two active ingredients, the particle mixture having a particle size of about minus 200 mesh.

[0004] In some aspects, the at least two active ingredients are an activated carbon-based material and a microporous mineral.

[0005] In some aspects, the activated carbon-based material makes up between about 25% and about 75% of the particle mixture.

[0006] In some aspects, the microporous mineral makes up between about 25% and about 75% of the particle mixture.

[0007] In some aspects, the microporous mineral makes up about 25% of the particle mixture, and the activated carbon-based material makes up about 75% of the particle mixture.

[0008] In some aspects, the microporous mineral makes up about 50% of the particle mixture, and the activated carbon-based material makes up about 50% of the particle mixture.

[0009] In some aspects, the microporous mineral makes up about 75% of the particle mixture, and the activated carbon-based material makes up about 25% of the particle mixture.

[0010] In some aspects, the microporous mineral is capable of ion exchange.

[0011] In some aspects, the microporous mineral is zeolite.

[0012] In some aspects, the activated carbon-based material is activated carbon.

[0013] In some aspects, the air filter substrate has a Minimum EfficiencyReporting Value (MERV) rating between about 5 and about 20.

[0014] In some aspects, the air filter substrate has a MERV rating of between about 8 and about 11.

[0015] In some aspects, the air filter substrate has a MERV rating of between about 11 and about 16.

[0016] In some aspects, the air filter substrate has a MERV rating of between about 17 and about 20.

[0017] In some aspects, the active media is arranged in or on the base media.

[0018] In some aspects, the base media comprises fiberglass.

[0019] In some aspects, the base media comprises synthetic fibers.

[0020] In some aspects, the synthetic fibers comprise polyester.

[0021] In some aspects, the carbon-based material is charcoal.

[0022] In some aspects, the techniques herein relate to an air filtration system, including the air filter substrate described herein and a housing configured to direct air over the air filter substrate.

[0023] Other systems, methods, features and / or advantages will be or may become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features and / or advantages be included within this description and be protected by the accompanying claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The components in the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding parts throughout the several views.

[0025] FIGURE 1 is a diagram illustrating an air filter substrate according to implementations described herein.DETAILED DESCRIPTION

[0026] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure. As used in the specification, and in theappended claims, the singular forms "a," "an," "the" include plural referents unless the context clearly dictates otherwise. The terms "comprising" and variations thereof as used herein is used synonymously with the term "including" and variations thereof and are open, non-limiting terms. The terms "optional" or "optionally" used herein mean that the subsequently described feature, event or circumstance may or may not occur, and that the description includes instances where said feature, event or circumstance occurs and instances where it does not. Ranges may be expressed herein as from "about" one particular value, and / or to "about" another particular value. When such a range is expressed, an aspect includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0027] As used herein, the terms "about" or "approximately" when referring to a measurable value such as an amount, a percentage, and the like, is meant to encompass variations of ±20%, ±10%, ±5%, or ±1% from the measurable value.

[0028] As used herein, "minus 200 mesh" particle size refers to a size specification commonly used in industries that deal with particle characterization, such as mining, materials processing, and particle analysis. Mesh size is a measurement used to describe the size of particles in a sieve or screen. The larger the mesh number, the smaller the openings and the finer the particles that can pass through. For example, mesh 200 has openings of about 74 micrometers (0.074 millimeters) in size, while mesh 400 has openings of about 37 micrometers (0.037 millimeters) in size. The term "minus" in this context indicates that the particles are smaller than the specified mesh size. In other words, "minus 200 mesh" meansthat the particles are smaller than the openings of a mesh screen with 200 openings per linear inch. This corresponds to very fine particles, as the mesh openings are quite small. Particles that are "minus 200 mesh" in size are smaller than 74 micrometers. These are considered very fine particles and might be used in processes or applications where precise sizing is important or where finer materials are required.

[0029] As used herein, "MERV" stands for "Minimum Efficiency Reporting Value," which is a standard rating system developed by the American Society of Heating, Refrigerating, and Air Conditioning Engineers (ASHRAE) to indicate the effectiveness of air filters in removing particles of different sizes from the air. The MERV rating ranges between 1 and 20 with higher numbers indicating better filtration efficiency. The following is a breakdown of particle size ranges and their filtration efficiency for various MERV ratings: MERV 1-4: Common household dust, pollen, and debris; MERV 5-8: Mold spores, pet dander, smaller dust particles; MERV 9-12: Legionella, fine dust, some bacteria; MERV 13- 16: smoke, odors, smaller bacteria, and viruses; MERV 17-20: capturing the smallest particles, including airborne bacteria and viruses, making them suitable for environments where the highest levels of air purity are required (e.g. clean rooms, operating rooms, laboratories, etc.).

[0030] Referring now to Fig. 1, an air filter substrate 100 is shown. This disclosure contemplates that the air filter substrate 100 can be incorporated into devices and systems including, but not limited to, heating, ventilation, and air conditioning (HVAC) systems, air purifiers, clean rooms, paint booths, hospitals / medical facilities, etc. The air filter substrate 100 includes a base media 102 and an active media 104. The base media 102 can be made from various materials. Example materials may include, but are not limited to, fiberglass or synthetic fibers such as polyester. The active media 104 is arranged in or on the base media102. In the implementations described herein, the active media 104 is a particle mixture including at least two active ingredients, where the particle mixture has a particle size of about minus 200 mesh.

[0031] In some implementations, the at least two active ingredients are an activated carbon-based material and a microporous mineral. Optionally, the activated carbon-based material is activated carbon. Optionally, the activated carbon-based material is charcoal. Activated carbon and charcoal are related materials, but they are not the same. They are both derived from carbon-rich sources and are used for various purposes due to their adsorption properties, but they undergo different processes and have distinct characteristics. It should be understood that activated carbon is a more refined and highly porous form with superior adsorption capabilities compared to charcoal. Additionally, the microporous mineral is optionally zeolite. Zeolites are a group of naturally occurring and synthetic minerals that are aluminosilicates with a porous, crystalline structure. They are composed of silicon, aluminum, and oxygen in their framework, and they can contain cations such as sodium, potassium, calcium, and magnesium within their pores. Optionally, the microporous mineral is capable of ion exchange.

[0032] In some implementations, the activated carbon-based material makes up between about 25% and about 75% of the particle mixture. Alternatively or additionally, the microporous mineral makes up between about 25% and about 75% of the particle mixture. For example, the particle mixture may be a 30-70 or 40-60 mixture of activated carbonbased material and microporous mineral. It should be understood that 30-70 or 40-60 mixtures are provided only as examples.

[0033] In some implementations, the air filter substrate 100 is configured for filtering low concentrations of viruses and bacteria. For example, the microporous mineralmakes up about 25% of the particle mixture, and the activated carbon-based material makes up about 75% of the particle mixture.

[0034] In some implementations, the air filter substrate 100 is configured for filtering medium concentrations of viruses and bacteria. For example, the microporous mineral makes up about 50% of the particle mixture, and the activated carbon-based material makes up about 50% of the particle mixture.

[0035] In some implementations, the air filter substrate 100 is configured for filtering high concentrations of viruses and bacteria. For example, the microporous mineral makes up about 75% of the particle mixture, and the activated carbon-based material makes up about 25% of the particle mixture.

[0036] In implementations described herein, the air filter substrate 100 has a MERV rating between about 5 and about 20. In some implementations, the air filter substrate 100 is configured for residential use. For example, the air filter substrate 100 can have a MERV rating of between about 8 and about 11. In some implementations, the air filter substrate 100 is configured for use in cleaner environments (e.g. hospital / medical). For example, the air filter substrate 100 can have a MERV rating of between about 11 and about 16. Optionally, in some implementations, the air filter substrate 100 can have a MERV rating of between about 17 and about 20.

[0037] Although the subject matter has been described in language specific to structural features and / or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.

Claims

WHAT IS CLAIMED:

1. An air filter substrate, comprising: a base media; and an active media, wherein the active media is a particle mixture comprising at least two active ingredients, the particle mixture having a particle size of about minus 200 mesh.

2. The air filter substrate of claim 1, wherein the at least two active ingredients are an activated carbon-based material and a microporous mineral.

3. The air filter substrate of claim 2, wherein the activated carbon-based material makes up between about 25% and about 75% of the particle mixture.

4. The air filter substrate of claim 2, wherein the microporous mineral makes up between about 25% and about 75% of the particle mixture.

5. The air filter substrate of claim 2, wherein the microporous mineral makes up about 25% of the particle mixture, and the activated carbon-based material makes up about 75% of the particle mixture.

6. The air filter substrate of claim 2, wherein the microporous mineral makes up about 50% of the particle mixture, and the activated carbon-based material makes up about 50% of the particle mixture.

7. The air filter substrate of claim 2, wherein the microporous mineral makes up about 75% of the particle mixture, and the activated carbon-based material makes up about 25% of the particle mixture.

8. The air filter substrate of any one of claims 2-7, wherein the microporous mineral is capable of ion exchange.

9. The air filter substrate of any one of claims 2-7, wherein the microporous mineral is zeolite.

10. The air filter substrate of any one of claims 2-9, wherein the activated carbon-based material is activated carbon.

11. The air filter substrate of any one of claims 1-10, wherein the air filter substrate has a Minimum Efficiency Reporting Value (MERV) rating between about 5 and about 20.

12. The air filter substrate of claim 11, wherein the air filter substrate has aMERV rating of between about 8 and about 11.

13. The air filter substrate of claim 11, wherein the air filter substrate has aMERV rating of between about 11 and about 16.

14. The air filter substrate of claim 11, wherein the air filter substrate has aMERV rating of between about 17 and about 20.

15. The air filter substrate of any one of claims 1-14, wherein the active media is arranged in or on the base media.

16. The air filter substrate of any one of claims 1-15, wherein the base media comprises fiberglass.

17. The air filter substrate of any one of claims 1-15, wherein the base media comprises synthetic fibers.

18. The air filter substrate of claim 17, wherein the synthetic fibers comprise polyester.

19. The air filter substrate of any one of claims 2-18, wherein the carbon-based material is charcoal.

20. An air filtration system comprising: the air filter substrate of any one of claims 1-19; and a housing configured to direct air over the air filter sulnstrate.

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