Encapsulated Antimicrobial Coating for Contamination-Resistant Filters
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Solution Overview
Problem
Conventional filtration technologies face issues with microbial colonization and contamination in filters, leading to degraded performance and health risks, while existing antimicrobial solutions like photocatalysis, silver nanoparticles, and irradiation treatments have drawbacks such as high costs, safety concerns, and instability.
Innovation Solution
An antimicrobial coating material is developed using encapsulated biocides within inorganic-organic shells, which are permeable to biocides, allowing for both contact-killing and time-released antimicrobial properties, suitable for porous materials and media.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional filtration technology is used, then air and water purification is achieved, but microbial colonization and contamination occur in the filters
Solution Approach 1:
The patent applies preliminary action by pre-coating the filter material with antimicrobial agents before the filter is put into service. The coating includes biocides embedded in a polymer matrix that provides immediate and sustained antimicrobial protection, preventing microbial colonization before it can occur. This proactive approach ensures the filter maintains its antimicrobial properties throughout its service life.
Solution Approach 2:
The patent implements continuity of useful action through a sustained-release antimicrobial coating system. The biocides are released continuously over an extended period (e.g., 6 months to 2 years), maintaining constant antimicrobial activity in the filter. This ensures uninterrupted protection against microbial colonization while the filter operates, eliminating the need for frequent reapplication or replacement.
2Object-generated harmful factors
If photocatalytic disinfection is added, then microbial killing is enhanced, but device complexity and cost increase due to additional light sources
Solution Approach 1:
The patent extracts and eliminates the need for external light sources, power supplies, and control systems by using a chemical-based sustained-release antimicrobial coating. The biocides in the coating provide passive, autonomous antimicrobial protection through diffusion and contact killing, removing the complexity of active photocatalytic systems while maintaining effective microbial control.
Solution Approach 2:
The patent employs a cost-effective polymer-based coating formulation using readily available biocides and common polymers. The coating is applied as a simple surface treatment that provides long-lasting protection without requiring expensive equipment, materials, or maintenance infrastructure associated with photocatalytic systems.
3Object-generated harmful factors
If silver nanoparticles are used, then antimicrobial activity is improved, but manufacturing cost increases
Solution Approach 1:
The patent substitutes expensive silver nanoparticles with cost-effective alternative biocides such as organic compounds, phenolics, quaternary ammonium salts, or natural extracts. These biocides are incorporated into a polymer matrix that enables sustained release, providing comparable or superior antimicrobial activity at a fraction of the material cost, making the coating economically viable for large-scale filter production.
Solution Approach 2:
The patent creates a composite coating material combining biocides with a polymer matrix. This composite structure allows the biocides to be released gradually over time, extending their effectiveness and reducing the need for high initial concentrations. The polymer carrier also improves stability and controls release kinetics, enhancing overall cost-efficiency.
4Object-generated harmful factors
If irradiation treatments are applied, then rapid disinfection is achieved, but device cost and energy consumption increase
Solution Approach 1:
The patent implements self-service by designing a coating system that automatically provides antimicrobial protection without external energy input. The biocides are released passively through diffusion, concentration gradients, or contact with microbes, performing disinfection autonomously. This eliminates the need for electricity, UV lamps, or other energy-consuming devices while maintaining continuous protective action.
Solution Approach 2:
The patent uses inexpensive chemical biocides that provide rapid disinfection through direct contact and chemical action. These biocides work immediately upon release from the polymer matrix, achieving fast microbial killing without the high energy costs of irradiation systems. The coating is applied once and provides long-term protection, reducing operational expenses.
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 coating effectively inhibits microbial growth and contamination in filters, maintaining performance and safety over extended periods without increasing costs or stability issues.
Implementation Method 1
The biocides are encapsulated in inorganic-organic shells which are permeable to the biocides
Implementation Method 2
The inorganic materials may be, as non-limiting examples, titania sol, titanium peroxo complex sol, silica sol, alumina sol or combinations thereof
Data Source
AI summary
The antimicrobial coating material for surface coating is formed from encapsulated biocides. The biocides include at least one antimicrobial component. The biocides are encapsulated in inorganic-organic shells which are permeable to the biocides. The organic materials may include at least one nonionic polymer. The inorganic-organic shells encapsulate and contain the biocides to form capsule structures for storage and release of the biocides. The capsule structures may be single capsules or capsule-in-capsule structures. The inorganic materials may be present in a concentration of 0.5-95 wt % of the inorganic-organic shells. Alternatively, the inorganic materials may be present in a concentration of 5-60 wt %. The inorganic materials and the organic materials are each intermixed, with respect to one another, in structures of the inorganic-organic shells. These structures may be an attachment structure, a hybrid structure or a multi-layered structure.