Antimicrobial Metal Foam Filter Catalyst
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Solution Overview
Problem
Existing air filtration and personal protection equipment face issues such as buildup of harmful microorganisms on filters and high costs due to the use of expensive materials, necessitating the development of cost-efficient antimicrobial filtration methods.
Innovation Solution
A method involving the preparation of a metal catalyst by contacting a metal salt with a reducing agent like corn syrup, applying the reaction mixture to a substrate, and heating it to produce a high surface area metal catalyst, which can be used in antimicrobial filters or PPE to capture and deactivate microorganisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional filtration materials are used to capture microorganisms, then filtration effectiveness is improved, but material cost increases and microorganism buildup occurs
Solution Approach 1:
The patent changes the chemical state of the filter material by applying a metal catalyst coating that transforms the filter's function from passive capture to active decomposition. This parameter change allows the same filter material to both capture and deactivate microorganisms, resolving the contradiction between filtration effectiveness and material cost by eliminating the need for expensive specialized materials.
Solution Approach 2:
The patent employs a disposable filter design where the entire filter cartridge is replaced rather than cleaned or regenerated. This approach resolves the contradiction by using inexpensive, replaceable filters that capture and decompose microorganisms during their service life, eliminating the need for expensive durable materials while maintaining effective filtration.
2Reliability
If traditional filtration materials are used to capture microorganisms, then filtration effectiveness is improved, but microorganism buildup on filters occurs
Solution Approach 1:
The patent converts the harmful accumulation of captured microorganisms into a beneficial decomposition process. The metal catalyst coating causes captured microorganisms to decompose into harmless substances, transforming the harmful buildup effect into a beneficial self-cleaning function that maintains filtration effectiveness without microorganism accumulation.
Solution Approach 2:
The metal catalyst coating acts as a strong oxidizing agent that accelerates the decomposition of captured microorganisms. This oxidation process breaks down the microorganisms into harmless byproducts, preventing buildup on the filter material and maintaining continuous filtration effectiveness without requiring filter replacement due to contamination.
3Reliability
If high surface area metal catalyst is produced through heating, then catalytic activity is improved, but energy consumption increases
Solution Approach 1:
The patent performs the energy-intensive heating process during the manufacturing stage rather than during filter operation. The metal catalyst is formed with high surface area structure in advance through controlled heating, allowing the finished filter to function at room temperature. This preliminary action resolves the contradiction by front-loading the energy consumption into production, enabling low-energy operation during use.
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 method creates a cost-effective, high surface area metal catalyst that effectively captures and deactivates microorganisms, preventing their buildup and reducing material costs while maintaining filtration efficiency.
Implementation Method 1
contacting a metal salt or a solution comprising the metal salt with a reducing agent comprising corn syrup to produce a reaction mixture
Implementation Method 2
heating the coated or infiltrated substrate to a temperature of at least about 200° C. for a period of time to produce a metal catalyst
Data Source
AI summary
Antimicrobial metallic foams useful in filters, methods of making and using the same, and antimicrobial filters, systems, and articles are described.