Electrodeposited Copper Nanoparticle Mesh for Antimicrobial Air Filters

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Solution Overview

Problem

Conventional antimicrobial air filters and facemasks often suffer from antimicrobial material detachment, coating degradation, and consumption, leading to reduced effectiveness and potential inhalation risks, especially during cleaning or prolonged use.

Innovation Solution

An antimicrobial air treatment device featuring a steel support mesh coated with copper nanoparticles, which are electrodepositing using a copper (II) salt solution, providing a durable and effective antimicrobial surface for air filtration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional antimicrobial coatings are applied to air filters and facemasks, then antimicrobial effectiveness is achieved, but material detachment and coating degradation occur leading to reduced reliability

Engineering Contradiction:

Improveantimicrobial effectivenessVSAvoidcoating durability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent replaces mechanical/physical coating methods with electrochemical deposition. Copper nanoparticles are deposited onto the filter substrate through electrochemical reduction of copper ions, creating a strongly bonded, durable antimicrobial layer that resists detachment during cleaning and use, while maintaining continuous antimicrobial effectiveness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes electrochemical parameters (voltage, current density, pH, temperature) to control the deposition process. By optimizing these parameters, the copper nanoparticles form a stable, adherent coating with controlled morphology and distribution, ensuring both durability and sustained antimicrobial activity over time

Inventive Principle:

Principle #35Parameter changes

2Reliability

If antimicrobial materials are used in air filters, then antimicrobial efficacy is provided, but material consumption and detachment occur during cleaning and use

Engineering Contradiction:

Improveantimicrobial efficacyVSAvoidantimicrobial material loss

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The electrochemical deposition method creates strong chemical bonds between copper nanoparticles and the filter substrate, replacing weak physical adhesion from conventional coating methods. This prevents material loss during cleaning and prolonged use while maintaining continuous antimicrobial efficacy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates a composite structure where copper nanoparticles are integrated into the filter matrix through electrochemical deposition. This composite material combines the filtration properties of the base material with the antimicrobial properties of copper, ensuring both functions are maintained without material loss

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If copper nanoparticles are electrodepositing on steel mesh, then durable antimicrobial coating is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improvecoating durabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent uses the porous structure of the steel mesh filter as the substrate for copper nanoparticle deposition. The electrochemical process penetrates and coats the three-dimensional porous network, creating durable antimicrobial coverage throughout the filter structure without requiring complex external fixtures or multi-step procedures

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The electrochemical deposition process is self-limiting and automatically forms a uniform coating across the entire mesh surface. The copper ions in solution are reduced and deposited wherever the electric field reaches, eliminating the need for masking, positioning, or manual application steps that would increase manufacturing complexity

Inventive Principle:

Principle #25Self-service

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 air treatment device maintains antimicrobial efficacy through durable copper nanoparticle coatings on the steel mesh, enhancing the filtration efficiency and safety by preventing material detachment and ensuring long-term effectiveness.

Implementation Method 1

copper nanoparticles which are electrodepositing using a copper (II) salt solution

Methodology Applied

Scientific EffectElectrodeposition: Electrodeposition

Data Source

PatentUS11470892B1Antimicrobial metal nanoparticle mesh air filter

Publication Date: 2022.10.18 KING ABDULAZIZ UNIV

AI summary

An antimicrobial air treatment device and a method of its construction. The antimicrobial air treatment device comprises an antimicrobial metal nanoparticle mesh comprising a steel support mesh and a layer of copper nanoparticles disposed on the steel support mesh. The antimicrobial air treatment device may be in the form of a facemask or a component of a moving air filtration system such as an HVAC system, an automobile cabin air filtration system, and an air purifier. The antimicrobial air treatment device may contain one or more filtration layers of filtration medium. The method of constructing the antimicrobial air treatment device involves the preparation of the antimicrobial metal nanoparticle mesh by an electrodeposition technique.