Patent Application
20240401824
This invention relates generally to air purification systems, and more specifically, to air purification systems and devices that use ultraviolet light to induce oxidation to destroy germs, microbes and other small airborne pathogens.
Air purifiers are a known tool for not only removing odors but also for helping to sterilize and cleanse the air in a room. They have become more prevalent and in demand after the recent COVID-19 pandemic, and as there are more concerns over airborne pathogens. The simplest and traditional form of an air purifier is simply a fan and a filter captured within a housing. The fan draws air in, passes it through a filter to remove dust and other larger particles, and circulates the cleaner air back out into the room. Essentially all residential and commercial HVAC systems include serviceable/replaceable air filters that perform this air cleaning function. However, filters only catch larger particles and do nothing to halt the spread of smaller microbes, viruses, and bacteria.
To cleanse the air of these smaller particles, a process of oxidation can be performed. Oxidation is a chemical reaction that combines a substance with oxygen to change its properties. This chemical reaction can be used to kill or render inert bacteria, mold, viruses and other small harmful products that may exist in residential or commercial room air. While oxidation occurs naturally in the presence of sunlight, air and water, it can be greatly accelerated in the confines of an air purification device using a process called photohydroionization or “PHI.” PHI is a rapid, forced oxidation process where broad spectrum ultraviolet light is cast upon a hydrophilic surface coated with a catalyzing agent that absorbs moisture from the surrounding air to produce hydrogen peroxide ions. These ions quickly break down into water and air, and in the process reduce air pollutants and neutralize viruses. An example of this process is disclosed in U.S. Pat. No. 7,988,923 to Fink, which is incorporated herein by reference in its entirety. Though other agents can be used, Fink discloses use of a “quad metallic” catalyzing agent on the hydrophilic surface that includes titanium oxide (TiO2), copper, sulfur and rhodium combined with a hydrating agent such as silica gel.
PHI has been harnessed and used in large, industrial air purification systems, and has proven effective at reducing or eliminating deadly viruses such as SARS-COV-1 (protein jacketed), H1N1 (Swine Flu), H5N1 (Bird flu), as well as to quickly and effectively remove odors in the air. However, it has not been harnessed in a suitable residential air purification device. This is, at least in part, because of the cost and maintenance requirements of traditional systems, as well as the hazards from the ultraviolet light source itself, which is very bright and can be harmful to the human eye and skin. What is needed is a practical design that brings this process of photohydroionization within reach of the common consumer.
The present invention provides for air purification systems and devices that provide photohydroionization in a consumer-friendly form that is capable of both protecting users from harmful UV light exposure and cleansing a large amount of room air with a compact device that is easily serviced.
In some embodiments, the air purification system includes air purification unit with an ultraviolet light source and an ionization cell having an inner surface coated with a catalyst. The inner surface forms a series of ridges and valleys where each valley has at least one foldable seam that allows the ionization cell to fold at least partially around the ultraviolet light source. A fan assembly is positioned to create an airflow along the inner surface of the ionization cell. The ionization cell may be fitted within a rigid sleeve that fits into a housing to position it around the ultraviolet light source. The air purification unit may include a base structure for housing the fan and containing a motor and electric source for powering the fan. The base structure may be configured to allow air to flow in through the fan and through the ionization cell. An opaque removable cover may be placed over the ionization cell to block exposure to ultraviolet light.
In other embodiments, the air purification system includes an air purification unit having an air inlet, an air outlet separated a distance from the air inlet, and an ultraviolet light source positioned along a length of the distance. The unit has a removable ionization cell with an inner surface coated with a catalyst and an outer surface, where the removable ionization cell has an unfolded position in which the outer surface is substantially flat and a folded position in which the inner surface is configured to substantially surround the ultraviolet light source. The unit may include a fan to move air along the ionization cell, and may include a switch to control the flow of electricity to the ultraviolet light source, wherein the switch only allows the flow of electricity to the ultraviolet light source when a substantially opaque removable cover is fit over the ultraviolet light source.
In still other embodiments, the air purification system includes an air purification unit with a base structure, a removable outer cover configured to fit to the base structure, an ultraviolet light source connected to the base structure, and an ionization cell positioned substantially surrounding the ultraviolet light source, the ionization cell having an inner surface facing the ultraviolet light source and an outer surface facing away from the ultraviolet light source, wherein the inner surface is coated with a catalyst and forms a series of ridges and valleys such that the ridges extend toward the ultraviolet light source and the valleys extend away from the ultraviolet light source. The ionization cell may have at least one foldable seem along at least one valley such that, when the ionization cell is removed from the air purification unit, it can be unfolded along the at least one foldable seam.
As will be understood and appreciated by those of skill in the art from a review of the full written description below, variations may be made to the component configurations described above in some embodiments, and additional components may be used in some particular embodiments. For example, some embodiments may be incorporated into a mobile air purifier unit designed to sit on a table or in a fixed air purifier unit designed to be mounted to a wall. Still other embodiments and/or features are identified in the disclosure and claims below, in combination with the associated figures.
The present invention can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Where dimensions are provided, they are used for reference and understanding, and are not limiting unless the feature in question expressly claimed to be of a particular dimension. In the drawings, like reference numerals designate corresponding parts throughout the several views.
The description that follows describes, illustrates and exemplifies one or more particular embodiments of the present invention in accordance with its principles. This description is not provided to limit the invention to the embodiments described herein, but rather to explain and teach the principles of the invention in such a way to enable one of ordinary skill in the art to understand these principles and, with that understanding, be able to apply them to practice not only the embodiments described herein, but also other embodiments that may come to mind in accordance with these principles. The scope of the present invention is intended to cover all such embodiments that may fall within the scope of the appended claims, either literally or under the doctrine of equivalents.
The air purification units described herein may take on various physical forms and still fall within the scope of the claims set forth herein. For purposes of example, a subset of possible formats are disclosed. The units may be portable or fixed in position, depending on the physical form and other characteristics such as disclosed herein. One of ordinary skill in the art of mechanical systems will understand that the size of the exemplary embodiments disclosed, and of the air purification units claimed, are scalable. That is, a larger unit would be able to cleanse a larger volume of air in a given period of time than a smaller unit. Moreover, larger or smaller units could be built based on the teachings herein simply by scaling the components of the unit, such as the ultraviolet light source, the fan, and the core assembly, as discussed further below. Testing shows that a unit having a core assembly 120 mm in length can sufficiently cleanse the air in an 800 square foot room with a standard 8-foot ceiling.
Air purification unit 100 is designed to be a portable embodiment that can be placed on a table (typically smaller units) or on the floor (typically larger units). It requires a power source, which in this case is supplied by an electrical cable 195 that plugs into a standard wall outlet. The other end of the cable 195 plugs into a power receptacle 131 near the bottom of the base structure 130. The air purification unit sits on a bottom surface 135 of the base structure 130. In some embodiments, the base structure 130 may alternatively or additionally house a battery pack that may store electricity such that the air purification unit 100 may operate temporarily in the absence of external power. It will be understood that the unit 100 could alternatively be powered via an adapter via a USB port, a cigarette lighter of a vehicle, or other common power source.
Air purification unit 100 is further equipped with a power button 132 for turning the unit “on” by supplying electricity to the internal components. Alternatively or additionally, the unit 100 could contain an air quality sensor that determines when to automatically turn the unit on and off based on a variety of metrics such as air density, temperature, or the detection of certain types of dust or other particles in the air. Alternatively or additionally, the unit 100 could be equipped with a timer that causes the unit to operate during certain times of the day and for certain periods. In some instances, the operational timing could be adjusted manually by a user either via on-unit controls (not shown) or via a computer-based application that presents a control interface, such as on a user's mobile computer device (e.g., an i-phone from Apple). In such a case, the mobile computer device would convey instructions provided by the user to the air purification device via a wireless connection such as Bluetooth or the like, as is well known in the art of smart home appliances. In such cases, the air purification unit 100 would be further equipped with a receiver or transceiver for receiving and/or sending communications, such as via Bluetooth, from and/or to the mobile device.
Another feature of air purification unit 100 visible in
The bulb 160 fits inside core assembly 150, which is further exploded above and away from the bulb in
Off to the right is a filter assembly 170 that operates like a filter in a standard air duct. When installed, the filter assembly 170 fits into the filter tray housing 175 carved out of the base structure 130. The filter assembly 170 can be positioned on either side of a fan (as shown below) and used to cleanse the air of larger inert particles, leaving only smaller viruses, microbes, odor-causing agents, etc., to pass through the core assembly 150. In some embodiments the air filter (and or the fan) may be located on the other side of the core assembly 150
The lower perimeter 126 is large enough in diameter to fit down over the fan housing 145 of the base structure 130, and comes to rest just over the set of undulating ridges formed into the outer wall of the base structure 130. The ridges form a series of undulating base structure extensions 136 and protrusions 147 around the perimeter of base structure 130, which provide channels (along the protrusions) for the passage of room air up and under the lower perimeter 126 of the outer cover 10. The lower perimeter 126 has an inner diameter that approximately matches the distance from one base structure extension 136 laterally across to an opposing extension 136 on the far side of the base structure 130.
In
The ionization cell 157 has a series of flexible seams 167, also called “living hinges,” that allow the cell 157 to transition between a folded configuration or position and an unfolded configuration or position. The seams may be made of the same material as the rest of the ionization cell 157, but have a necked-down, thinner profile that allows for a high level of flexibility. For example, while scalable, the regular thickness of the ionization surfaces is preferably between 1 and 2 millimeters, while the thickness of the “living hinge” seam 167 is preferably between 0.3 to 0.5 millimeters.
The ionization cell 157 is coated, at least on its upper surface (as shown in
In between each foldable seam 167 is a cell component 111 that features an upward-extending (in the unfolded position) or inward-extending (in the folded position) central ridge 165 and opposing slopes 112 falling away to either side of the ridge 165 into a trough 166 formed between each cell component 111. Each cell component 111 is hollow underneath the ridge 165, and has a backing element 113 that forms an arc connecting the two opposing slopes 112 and extending slightly beyond the slope ends to a foldable seam 167 on either side. When in the folded configuration, these backing elements 113 approximately form a cylinder with a diameter configured to fit inside the sleeve 152. Also in this configuration, the ridges 165 combine to form a relatively tight pocket for the UV bulb 160 to drop into (See
The hollow sections 159 formed by each cell component 111 allow for additional passage of air through the core assembly. Air passing through these sections 159 does not come into as intense contact with the oxidizing agents created by the UV light reacting with the surface coating, but does still get sufficiently ionized and allows for greater output and quieter operation. This is assisted by holes 153 positioned along the ridges 165 of the cell components 111, which allow air to pass back and forth on either side of the ridges and also allows hydrogen peroxide and other ionization elements to pass through to the backside of the ridges 165. This air exchange through the holes 153 also helps to dissipate heat generated by the bulb 160. In some embodiments, the ends of the hollow sections 159 and the holes 153 may be closed off such that essentially all airflow is passed through the troughs 166 that are hit directly with the UV light. However, it should be noted that even airflow not in contact with the UV light at all can still be sufficiently cleansed by the device because the ions and charged particles created travel through the air medium and are chemically attracted to organic compounds that within the air. Once attached to these compounds, the oxidation process takes place leaving them inert.
As shown in
The purpose of having two plugs 390 is to allow access to electricity for other devices despite the outlet being fully covered by the device. That is, one of the plugs 390 is used to receive power to operate the air purifier unit 300, while the other plug 390 connects power to the pass through socket 395 on the side of the unit 300. This pass through socket 395 is then available for use by other devices. Air purifier unit 300 may also be equipped with batteries to power the device during times of electrical failure. As shown a battery compartment cover 397 conceals where the batteries could be installed.
Once through the fan, air is directed up through a harness 380, which has a perforated bottom and is used to mount the core assembly 350. Core assembly 350 can be interchangeable with core assembly 150 of the mobile unit 100. That is, it features a sleeve 352 that contains an ionization cell 357 having a quad-metallic catalyst coating on an inner surface, troughs and ridges, and seams that allow it to fold around a UV light source. While the size and dimensions of these components may vary, the same description provided in association with
A key difference between the mobile unit and the wall unit is the presence and function of harness 380. With the mobile unit, there is no upper blockage when the outer cover 120 is removed. However, even when face plate 310 is removed, the bulb 360 and ionization cell 357 may not be removed for servicing or replacement because the top panel of the unit 300 is still in the way. To overcome this, wall unit 300 features harness 380, which takes the place of the fixed core assembly housing 139 of the mobile unit. Instead, as shown in
Though not shown, wall air purifier unit 300 is equipped with a circuit board, motor, and electrical switches connected to the fan assembly 340 and the UV bulb 360 just as in the previously-disclosed mobile unit 100. However, it will be understood that different motor and circuit board geometries could be designed or selected to fit within the different physical space provided. Also, the wall unit 300 can utilize a pressure switch 334 that operates like the safety catch 134 of the mobile unit 100. That is, when the face plate 310 is removed from the unit, the pressure switch 334 is released, which opens a switch and shuts off the flow of electricity to the bulb 360 so as to prevent external exposure to ultraviolet light from the bulb 360.
Though a reasonably compact wall unit is disclosed, the size of the wall unit is easily scaled. For example, while still using the same size bulb 360, core assembly 350 and harness 380, a number of these components could be positioned side by side, each with individual fan assemblies 340 and air filters 370 underneath them, separated by structure similar to forward panels 312 to create independent air flow paths through each modular unit. A number of these could be positioned side by side within a longer panel wall unit to effectively cleans a much larger open area.
Those skilled in the mechanical arts will appreciate that various changes may be made and equivalents may be substituted without departing from the scope of systems and methods disclosed in this application. For example, the air purification units can take other exterior physical shapes without departing from the internal components of the present invention discussed herein. As mentioned, the unit may be scaled to handle larger or smaller volumes of air. The order of the fan, air filter and light bult/ionization cell combination can be in any order so long as they are positioned between an air inlet and an air outlet, and a generally closed channel is provided for air to pass from inlet to outlet. Various cell geometries could also be used without departing from the spirit of the invention, the general effort being to maximize the exposed surface area while minimizing distance to the ultraviolet light source. The quad metallic catalyst coating could be varied in several respects such as parts per million and ratio of metals so long as it still produces the charged ions to inspire oxidation. The selection of materials for the physical components of the device may be altered based on cost, appearance, and durability requirements. Thus, it is intended that the novel techniques of the present invention not be limited to the particular embodiments explicitly disclosed, but that they include all techniques falling within the scope of the appended claims.
