Antimicrobial Filter Media With Zeolite Ions for Pathogen Control

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Solution Overview

Problem

Conventional air filters struggle with capturing and neutralizing biological contaminants, leading to biohazard risks, re-entrainment of pathogens, and inefficient air quality improvement due to biological fouling and contamination spread within buildings.

Innovation Solution

Manufacturing antimicrobial fibers embedded with a novel antimicrobial zeolite additive material containing functional metal ions like zinc, copper, and silver, which are incorporated into the zeolite crystalline structure to provide long-lasting antimicrobial activity, especially against biological particles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional air filters are used to capture biological pathogens, then filtration efficiency is improved, but the risk of biohazard and re-entrainment increases

Engineering Contradiction:
Improvefiltration efficiencyVSAvoidbiohazard risk
Core Design Contradiction:
Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful captured pathogens into a beneficial outcome by using antimicrobial agents embedded in the filter media to neutralize and eliminate the pathogens. The harmful biological contaminants that accumulate on the filter are transformed from a biohazard risk into a controlled situation where the pathogens are destroyed by the antimicrobial action, thereby resolving the contradiction between capturing pathogens and preventing biohazard risk.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent introduces antimicrobial agents as an intermediary substance within the filter media structure. These agents act as a mediator between the captured pathogens and the environment, continuously releasing antimicrobial compounds that neutralize pathogens on contact. This intermediary mechanism allows the filter to maintain high filtration efficiency while simultaneously eliminating the biohazard risk of captured contaminants.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Manufacturing precision

If air filters capture finer submicron particulate contaminants, then air quality improvement is enhanced, but the pressure drop increases and filter blockage occurs prematurely

Engineering Contradiction:
Improveparticle capture efficiencyVSAvoidpressure drop
Core Design Contradiction:
Manufacturing precisionVSStress or pressure

Solution Approach 1:

The patent employs porous filter media structures that provide extensive surface area for particle capture while maintaining open pathways for airflow. The porous architecture allows submicron particles to be captured on the vast internal surface area without significantly blocking the flow channels, thereby achieving high particle capture efficiency while minimizing pressure drop and delaying premature filter blockage.

Inventive Principle:
Principle #31Porous materials

Solution Approach 2:

The patent uses composite filter media combining different materials with complementary properties - such as hydrophobic and hydrophilic components, or materials with different pore size distributions - to optimize both particle capture efficiency and airflow performance. The composite structure enables selective capture of submicron particles while maintaining sufficient permeability to reduce pressure drop.

Inventive Principle:
Principle #40Composite materials

3Manufacturing precision

If filter media surface becomes contaminated with biological films, then pathogen capture is improved, but biological fouling causes premature blockage and secondary emissions

Engineering Contradiction:
Improvepathogen captureVSAvoidbiological fouling
Core Design Contradiction:
Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent applies preliminary action by embedding antimicrobial agents within the filter media structure before the filter becomes contaminated. These pre-positioned antimicrobial agents are released upon contact with moisture from captured biological particles, creating a protective effect that prevents biological film formation and fouling before they can occur. This preliminary antimicrobial action maintains filter performance and prevents secondary emissions.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent ensures continuity of useful action through the sustained release of antimicrobial agents from the filter media over time. As moisture from captured particles triggers continuous antimicrobial release, the filter maintains its pathogen-neutralizing capability throughout its service life, continuously preventing biological fouling and secondary emissions rather than providing a one-time effect.

Inventive Principle:
Principle #20Continuity of useful action

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 antimicrobial fibers effectively eliminate captured pathogens, reducing the risk of re-entrainment and biohazard, while maintaining air quality by ensuring the filter's surface hygiene and enhancing filtration efficiency.

Implementation Method 1

a novel antimicrobial zeolite additive material containing functional metal ions like zinc, copper, and silver, which are released in the presence of moisture

Methodology Applied
Scientific EffectIon release: Ion Exchange

Implementation Method 2

effectively neutralize biological particles

Methodology Applied
Scientific EffectAntimicrobial action:

Implementation Method 3

capturing and neutralizing biological pathogens

Methodology Applied
Scientific EffectPhysical filtration: Filter (physical)

Data Source

PatentUS12629621B2Antimicrobial filter media
Publication Date: 2026.05.19 PURAFIL INC
  • US12629621B2 patent drawing
  • US12629621B2 patent drawing
  • US12629621B2 patent drawing

AI summary

A product and method of manufacturing and producing antimicrobial fibers using an antimicrobial additive material. The method comprising using various antimicrobial metals incorporated and embedded into an inorganic material as metal ions within the additive material that can be formulated into a masterbatch precursor material and processed to manufacture fine or synthetic fibers using standard manufacturing processes for use in applications from face masks and respirators to air filters for HVAC and higher efficiency HEPA applications.