Antimicrobial Air Filter Masterbatch Using Nano-Copper Composite
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Solution Overview
Problem
Current materials used in air conditioning ducts and filters do not effectively eliminate or prevent the presence of microorganisms, such as bacteria and fungi, and are not cost-effective.
Innovation Solution
A masterbatch formulation composed of linear low-density polyethylene (LLDPE), nano-copper, and copper oxychloride, with specific ratios and additives, is used to create an antimicrobial polymeric material that is incorporated into air filters, achieving high antimicrobial activity against relevant bacteria and fungi.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional materials are used in air conditioning ducts and filters, then production cost is reduced, but antimicrobial effectiveness is insufficient
Solution Approach 1:
The patent uses composite materials by combining polyethylene polymer matrix with copper compounds (copper oxide, copper hydroxide, copper carbonate) and nano-copper particles to create an antimicrobial masterbatch. This composite approach provides effective antimicrobial protection while maintaining cost-effectiveness through the synergistic interaction of the polymer matrix and copper-based antimicrobial agents.
Solution Approach 2:
The patent changes the concentration parameters of copper compounds and nano-copper in the masterbatch formulation to optimize antimicrobial effectiveness. By adjusting the ratios of copper oxide, copper hydroxide, copper carbonate, and nano-copper particles within specific ranges, the patent achieves high antimicrobial activity while controlling production costs.
2Reliability
If copper compounds and nano-copper are added to polymeric materials, then antimicrobial properties are improved, but manufacturing complexity increases
Solution Approach 1:
The patent prepares an antimicrobial masterbatch in advance that pre-combines the polyethylene polymer with copper compounds and nano-copper particles in optimized ratios. This preliminary action simplifies subsequent manufacturing processes, as the masterbatch can be directly incorporated into the extrusion process without requiring separate mixing steps for each copper component.
Solution Approach 2:
The patent merges multiple copper-based antimicrobial agents (copper oxide, copper hydroxide, copper carbonate, and nano-copper) into a single integrated masterbatch formulation. This combining approach reduces manufacturing complexity by consolidating multiple additives into one pre-mixed composition that can be easily incorporated into the polymer processing stream.
3Reliability
If high concentrations of copper compounds are used, then antimicrobial activity is improved, but material cost increases
Solution Approach 1:
The patent optimizes the concentration parameters of copper compounds and nano-copper within specific ranges (copper oxide: 0.1-5%, copper hydroxide: 0.1-5%, copper carbonate: 0.1-5%, nano-copper: 0.01-1%) to achieve effective antimicrobial activity while controlling material costs. This parameter optimization prevents excessive copper usage while maintaining high antimicrobial effectiveness.
Solution Approach 2:
The patent uses a composite approach combining multiple copper-based antimicrobial agents in synergistic ratios. By distributing the antimicrobial function across copper oxide, copper hydroxide, copper carbonate, and nano-copper particles, the patent achieves enhanced antimicrobial activity at lower total copper concentrations, thereby reducing material costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The filters demonstrate a 99.99% efficiency in reducing bacterial counts and 2-3 orders of magnitude in fungal growth, effectively eliminating contaminants in air conditioning systems.
Implementation Method 1
Polymeric matrices and derivatives comprising some copper compound or nanometric copper structures have been described to provide an antimicrobial effect
Implementation Method 2
the addition of copper compounds or copper derivatives for such purpose is well recognized
Data Source
AI summary
A polymeric masterbatch is provided to prepare an antimicrobial material and an antimicrobial air filter prepared with said material, which serves to filter air and reduce the growth of bacteria and fungi such as E. coli, S. aureus, Botrytis cinerea, and Aspergillus niger.