Surface-Enhanced Copper Filter for Air Purification

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Solution Overview

Problem

Current air purification systems, such as air filters, Electronic Air Cleaners, ionizers, and ozone generators, are inadequate in removing biological contaminants like bacteria, viruses, and fungi, and are often energy-inefficient and require frequent maintenance, failing to effectively improve indoor air quality in commercial and residential buildings.

Innovation Solution

A surface-enhanced copper filter assembly for air purification systems, comprising a supportive filter housing with a surface-enhanced copper filter made of substantially pure solid elemental copper, which is woven, non-woven, or multi-layered copper mesh, designed to maximize airflow and contact with airborne contaminants, providing anti-microbial and electrostatic properties for effective removal and inactivation of biological pollutants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional air filters are used, then they can capture larger particles like dust and skin cells, but they fail to effectively remove biological contaminants such as bacteria, viruses, and fungi due to large pore sizes

Engineering Contradiction:

Improveremoval of biological contaminantsVSAvoidlarge pore size allowing microorganisms to pass through

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs a copper-based porous material with controlled pore structures that enable capture of biological contaminants while maintaining airflow. The porous configuration allows the material to effectively trap bacteria, viruses, and fungi through surface contact and adhesion mechanisms, resolving the contradiction between pore size and contaminant removal efficiency.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention utilizes composite copper-based materials combining copper fibers, particles, or mesh structures with appropriate binders and coatings. These composite structures provide both mechanical support and high surface area for contaminant capture, enabling effective biological contaminant removal while maintaining structural integrity and optimal pore dimensions.

Inventive Principle:

Principle #40Composite materials

2Reliability

If electronic air cleaners and ionizers are used, then they can reduce airborne contaminants, but they require frequent maintenance, electricity, and have limited effectiveness against biological contaminants

Engineering Contradiction:

Improveeffectiveness against biological contaminantsVSAvoidmaintenance requirements and electricity consumption

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The copper-based filter material exhibits inherent antimicrobial properties that enable self-cleaning and self-maintaining characteristics. The copper surface naturally inhibits biological contaminant adhesion and promotes their degradation through contact, eliminating the need for external power sources, frequent maintenance, or complex electronic components.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces electronic air cleaner mechanisms (electrostatic charges, ionization) with a passive copper-based filtration system that relies on the natural antimicrobial properties of copper. This substitution eliminates the need for electricity and complex electronic components while maintaining effectiveness against biological contaminants through contact-based mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If ozone generators are used, then they can deodorize air and kill some contaminants, but they produce harmful ozone levels and do not effectively remove biological contaminants

Engineering Contradiction:

Improvecontaminant inactivationVSAvoidharmful ozone levels

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful effect of high ozone levels into a beneficial contact-based inactivation mechanism. Instead of using ozone gas that can be harmful, the copper-based filter provides a safe, contact-based antimicrobial action that inactivates biological contaminants through surface interaction, eliminating the harmful byproduct issue while maintaining contaminant removal effectiveness.

Inventive Principle:

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

4Reliability

If ultra-violet lights are used, then they can kill biological contaminants, but they require electricity, have finite bulb life, and can be harmful to humans

Engineering Contradiction:

Improvebiological contaminant inactivationVSAvoidelectricity requirement and maintenance

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The copper-based filtration system provides passive, continuous antimicrobial action without requiring external power sources. The copper surface naturally inactivates biological contaminants through contact, eliminating the need for electricity, bulb replacement, or human exposure risks associated with UV lights.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the electronic UV lighting system with a passive copper-based chemical/biological mechanism. Instead of using high-energy UV radiation that requires electricity and poses safety risks, the system employs the natural antimicrobial properties of copper through direct contact, eliminating electrical requirements and maintenance needs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 surface-enhanced copper filter assembly achieves more effective particulate capture, including smaller sized particles, with reduced energy consumption, improving indoor air quality and extending filter life, while maintaining high integrity and efficiency in air filtration.

Implementation Method 1

said surface-enhanced fibrous copper filter media having anti-microbial and electrostatic properties capable of inactivating said biological contaminants and removing biological contaminants and other pollutants from the air

Methodology Applied

Scientific EffectAnti-microbial properties:

Implementation Method 2

Methodology Applied

Scientific EffectElectrostatic properties: Electrostatics

Data Source

PatentUS11969679B2Surface-enhanced copper filter for air purification and system and method for using

Publication Date: 2024.04.30 MASHBURN MATTHEW

AI summary

A surface-enhanced copper filter for air purification and a filter assembly with a surface-enhanced copper filter composed, at least in part, of substantially pure copper. The surface-enhanced copper filter uses the anti-microbial and electrostatic properties of elemental copper to inactivate biological contaminants and remove biological contaminants and other pollutants from the air. Also disclosed is a system and method using a filter assembly having a surface-enhanced copper filter to purify air. The disclosed surface-enhanced copper filter can be used in a stationary or mobile HVAC system or in a mobile air purification system.