Composite Air Purification Filter with Phosphor-Photocatalyst Layers
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Solution Overview
Problem
Existing air purification systems face limitations in utilizing titanium dioxide photocatalyst materials due to their large energy band gap, requiring UV light for activation, and issues with binder decomposition and mass production challenges, as well as particle discharge in bead-type filters.
Innovation Solution
A composite air purification system is developed by hybridizing long-lasting phosphors, silica, and photocatalysts, including titanium dioxide, graphite carbon nitride, and their doped forms, with a porous support and inorganic binder, allowing for photocatalytic activity even in dark environments through a multi-layer coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If titanium dioxide photocatalyst material is used, then strong photolysis function is achieved, but photolysis reaction occurs only by absorbing ultraviolet light which constitutes only 3 to 4% of sunlight
Solution Approach 1:
The patent combines titanium dioxide photocatalyst with long-lasting phosphor powder to create a composite material. The phosphor powder absorbs visible light (which constitutes the majority of sunlight) and transfers energy to the titanium dioxide, enabling the photocatalyst to be activated by visible light in addition to UV light, thereby significantly improving light absorption efficiency while maintaining strong photolysis function.
2Ease of manufacture
If epoxy resin is used as binder on phosphor photocatalyst composite powder, then titanium dioxide can be deposited on phosphor surface, but epoxy resin decomposes by activated species causing strong chemical reactions when used for long period of time
Solution Approach 1:
The patent removes the organic epoxy resin binder from the composite structure and replaces it with an inorganic binder system. This extraction of the problematic organic component eliminates the decomposition issue caused by activated species, while the inorganic binder maintains the necessary binding function for long-term stability.
Solution Approach 2:
The patent changes the chemical composition parameter of the binder from organic (epoxy resin) to inorganic materials. This parameter change transforms the binder's chemical stability characteristics, making it resistant to decomposition by activated species generated during photocatalytic operation, thereby ensuring long-term reliability.
3Manufacturing precision
If atomic layer deposition technique is used to deposit titanium dioxide on phosphor surface, then coating is achieved, but mass production is difficult due to limited coating technology and expensive equipment
Solution Approach 1:
The patent replaces the complex atomic layer deposition (ALD) technique with a simpler dip-coating or spray-coating method. This substitution uses basic mechanical coating processes instead of sophisticated vapor-phase deposition equipment, enabling mass production while achieving sufficient coating uniformity for practical applications.
4Ease of operation
If long-lasting phosphor photocatalyst is manufactured into granular beads, then filter application is enabled, but photocatalytic powder is discharged into indoor air due to collision and friction between beads when external force is applied
Solution Approach 1:
The patent uses a porous support structure (such as porous ceramic or metal foam) instead of granular beads. The photocatalyst-composite is coated on the porous surface, which provides mechanical stability and prevents powder discharge under external forces like vibration or collision, while still allowing air flow for filtration functionality.
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 system effectively photolyzes and removes air pollutants, including VOCs and viruses, under both UV and visible light, and in the absence of light, enhancing the efficiency and durability of air purification.
Implementation Method 1
hybridizing a photocatalyst material, a long-lasting phosphor, and silica... allowing for photocatalytic activity even in dark environments
Implementation Method 2
techniques of purifying air using photocatalyst materials with a strong photolysis function... titanium dioxide known as a representative photocatalyst material may generate radicals with strong oxidizing power when exposed to ultraviolet light
Implementation Method 3
these radicals may decompose various environmental pollutants present in water or air into harmless carbon dioxide and water
Implementation Method 4
a second coating layer disposed on a surface of the first coating layer and including silica (SiO2)
Data Source
AI summary
Disclosed herein are a composite for air purification, a filter including the same, and a method of manufacturing the same. The composite for air purification includes a porous support, a first coating layer disposed on a surface of the porous support and including a long-lasting phosphor, a second coating layer disposed on a surface of the first coating layer and including silica (SiO2), and a third coating layer disposed on a surface of the second coating layer and including a photocatalyst.