Honeycomb air filter and methods thereof

Patent metadata

Field	Value
Publication number	US-10188975-B2
Application number	US-201514876104-A
Country	US
Kind code	B2
Filing date	Oct 6, 2015
Priority date	Jun 19, 2014
Publication date	Jan 29, 2019
Grant date	Jan 29, 2019

Abstract

An air filter, including:
at least one wall-flow honeycomb particulate filter having at least one coat on at least a portion of the interior surface of the filter, wherein the at least one coat comprises at least one of: a sorbent; a catalyst; or a combination thereof, and the air filter, in-use, retains from filtered air at least one of: a particulate, a volatile organic compound, or a combination thereof.

Also disclosed is an interior air purification system including the air filter, and methods of making and using the air filter.

First claim

What is claimed is:

1. An air filter, comprising:
at least one wall-flow honeycomb particulate filter having at least one coat on at least a portion of an interior surface of the at least one wall-flow honeycomb particulate filter, the at least one coat comprising a sorbent and a Pt/TiO 2 catalyst, wherein the sorbent forms islands or clusters dispersed within pores of the at least one wall-flow honeycomb particulate filter and the Pt/TiO 2 catalyst forms separate islands or clusters that are dispersed within the pores of the at least one wall-flow honeycomb particulate filter; and
the air filter, in-use, retains from filtered air a particulate and a volatile organic compound, wherein the volatile organic compound is formaldehyde.

2. The air filter of claim 1 wherein the at least one wall-flow honeycomb particulate filter comprises a first uncoated particulate filter portion, and a second coated filter portion in series and in fluid communication with the first particulate filter portion.

3. The air filter of claim 1 wherein the sorbent comprises at least one of: activated carbon, alumina, zeolite, silica gel, or combinations thereof.

4. The air filter of claim 1 wherein the wall-flow honeycomb particulate filter comprises a ceramic, the filter having:
a % porosity of from 50 to 90 vol %;
a cell density of from 100 to 1600 cpsi; and
at least one dimension and geometry of:
a diameter of from 4 to 20 inches and a length of from 0.5 to 10 inches, for a filter having a circular end face geometry;
a major end face axis of from 4 to 20 inches, a minor end face axis of from 2 to 15 inches, and a length of from 0.5 to 10 inches, for a filter having an oval end face geometry;
a length of from 1 to 20 inches, a width of from 1 to 20 inches, and a height of from 0.5 to 20 inches, for a filter having a rectilinear end face geometry; or combinations thereof.

5. The air filter of claim 1 wherein the walls of the wall-flow honeycomb particulate filter comprise at least one of a ceramic, a glass, a composite, a polymer, a cellulosic, a natural or synthetic fiber, or a combination thereof.

6. The air filter of claim 1 , further comprising two or more of the filters configured in parallel, in series, or combinations thereof.

7. A method of making the air filter of claim 1 , comprising at least one of:
dipping a portion of at least one wall-flow honeycomb particulate filter into a liquid containing at least one sorbent, at least one catalyst, or a combination thereof;
extruding a ceramic batch mixture comprising at least one sorbent, at least one catalyst, or a combination thereof, through a honeycomb forming die;
exposing at least one wall-flow honeycomb particulate filter to a vapor containing at least one sorbent;
exposing at least one wall-flow honeycomb particulate filter to an aerosol containing the at least one sorbent, at least one catalyst, or a combination thereof;
or a combination thereof.

8. The method of claim 7 wherein the dipping coats substantially the entire interior surface of the wall-flow honeycomb particulate filter with the at least one sorbent, at least one catalyst, or a combination thereof.

9. An interior air purification system, comprising:
at least one air handler having a holder for at least one air filter of claim 1 , wherein the air handler directs ambient indoor source air through the at least one air filter and expels filtered air having from 80 to 90% reduction in the particulate content, and from 80 to 90% reduction in the volatile organic compound content, compared to the ambient interior source air.

10. The air purification system of claim 9 wherein the at least one air handler has an air throughput capacity of from 50 m 3 /hr to 1000 m 3 /hr.

11. The air purification system of claim 9 further comprising a housing including two or more of the air filters configured in parallel, in series, or combinations thereof.

Assignees

• Corning Inc

Inventors

• Fu Xiaodong Robert
• Hu Wenhuan
• Yu Weizheng

Classifications

• B01D2255/20738

  Iron · CPC title

• B01D2255/20715

  Zirconium · CPC title

• B01D2255/106

  Gold · CPC title

• B01D2253/102

  Carbon · CPC title

• B01D2255/104

  Silver · CPC title