Air treatment system and method of use
10933158 ยท 2021-03-02
Assignee
Inventors
- Karen Benedek (Winchester, MA, US)
- Philip C. Carbone (North Reading, MA, US)
- Peter J. Loftus (Cambridge, MA, US)
- Anna Cheimets (Medford, MA, US)
- David Hensel (Boston, MA, US)
Cpc classification
B60H3/0071
PERFORMING OPERATIONS; TRANSPORTING
B01D2257/708
PERFORMING OPERATIONS; TRANSPORTING
B01D2257/90
PERFORMING OPERATIONS; TRANSPORTING
A61L2209/134
HUMAN NECESSITIES
B01D2258/0275
PERFORMING OPERATIONS; TRANSPORTING
B01D2259/4508
PERFORMING OPERATIONS; TRANSPORTING
F24C15/205
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
A61L2209/111
HUMAN NECESSITIES
A61L2209/212
HUMAN NECESSITIES
B01D53/8678
PERFORMING OPERATIONS; TRANSPORTING
A61L2209/22
HUMAN NECESSITIES
B01D2255/10
PERFORMING OPERATIONS; TRANSPORTING
A61L9/014
HUMAN NECESSITIES
International classification
A61L9/04
HUMAN NECESSITIES
B01D53/00
PERFORMING OPERATIONS; TRANSPORTING
F24C15/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
A61L9/014
HUMAN NECESSITIES
Abstract
A built-in apparatus and method for treating air including a housing with an air inlet and an air outlet. An air mover positioned near the air outlet is configured to draw the air through the air inlet. The housing encloses an air treatment zone, such as including an oxidizing zone, and an ozone removal zone positioned downstream of the air treatment zone and oxidizing zone. The air treatment zone includes UV light and/or ozone that partially oxidizes the chemical contaminants in the air treatment zone. A catalyst in the oxidizing zone oxidizes elements within the air treatment zone. The ozone removal zone includes a second, different catalyst material. A UV bulb that may or may not generate ozone is positioned within or downstream of the first and/or second catalyst materials to assist catalyst oxidation and/or self-clean the apparatus.
Claims
1. An apparatus for treating air, comprising: a housing with an air inlet positioned at a first end of the housing and an air outlet positioned at a second end of the housing opposite the first end, the air inlet and the air outlet being positioned on a same lateral side of the housing, the housing enclosing an air treatment zone and an ozone removal zone, wherein the ozone removal zone is positioned downstream of the air treatment zone with respect to a flow direction of the air being treated; a first UV light in the air treatment zone and arranged to generate ozone; a bulb reflector and a UV baffle positioned between the first UV light and the air inlet and arranged to prevent UV illumination from exiting the first end of the housing, the bulb reflector having a concave shape that faces the first UV light and a convex shape that faces the UV baffle, the UV baffle having a curved surface that matches a portion of the convex shape of the bulb reflector; a grease filter in the air treatment zone and arranged to remove grease and smoke from the air being treated, the grease filter being arranged downstream of the first UV light and to receive UV illumination from the first UV light; a plurality of first catalyst layers downstream of the grease filter in the air treatment zone and including a first catalyst material, the plurality of first catalyst layers being spaced from each other and arranged to oxidize organic and/or inorganic compounds; a plurality of second catalyst layers in the ozone removal zone and including a second catalyst material that is different from the first catalyst material, wherein the second catalyst material is arranged to remove ozone from the air being treated; and a fan downstream of the plurality of second catalyst layers and arranged to move air to be treated into the air inlet, through the air treatment zone and ozone removal zone and out the air outlet.
2. The apparatus of claim 1, further comprising an ozone generator and/or an ultraviolet source disposed downstream of, or between at least two of the first catalyst layers.
3. The apparatus of claim 2, wherein the ozone generator and/or ultraviolet source is downstream of the plurality of first catalyst layers and is configured to promote oxidation of chemical contaminants via the first catalyst material and/or to clean at least one of the plurality of first catalyst layers.
4. The apparatus of claim 1, further comprising a second UV light in the ozone removal zone and positioned between at least two of the second catalyst layers, the second UV light arranged to clean the at least two second catalyst layers.
5. The apparatus of claim 1, a heater within the air treatment zone and in combination with the first catalyst layer.
6. The apparatus of claim 1, wherein each of the first and second catalyst materials comprises manganese.
7. The apparatus of claim 6, further comprising a first ozone generator upstream of the plurality of first catalyst layers, and a second ozone generator and/or an ultraviolet source disposed downstream of the plurality of first catalyst layers.
8. The apparatus of claim 1, further comprising spacers between adjacent first or second catalyst layers for preventing or disrupting a linear air flow through the catalyst layers.
9. The apparatus of claim 1, wherein the apparatus comprises is adapted to operate in a self-clean mode for the grease filter, wherein the self-clean mode includes direct contact of the grease filter with ozone and/or ultraviolet light.
10. The apparatus of claim 9, wherein the self-clean mode includes operating the fan at a lower flow rate than an air cleaning mode, operating the first UV light to deliver ozone to the plurality of first and second catalyst layers at concentrations higher than delivered in the air cleaning mode; and operating the first UV light to apply ultraviolet light into the plurality of first and second catalyst layers.
11. The apparatus of claim 1, wherein the apparatus is controlled by outputs from a surrounding environment, selected from environment sensors and/or operation of fans, motors, or appliances, separate and independent from the apparatus.
12. The apparatus of claim 1, further comprising an adsorbent layer upstream of the plurality of first catalyst layers.
13. The apparatus of claim 1, wherein the housing comprises module attachments, and further comprising a first attachable module including an ozone generator, and a second attachable module including the plurality of first and/or second catalyst layers.
14. An apparatus for treating air, comprising: a housing with an air inlet positioned at a first end of the housing and an air outlet positioned at a second end of the housing opposite the first end, the air inlet and the air outlet being positioned on a same lateral side of the housing, the housing enclosing an air treatment zone and an ozone removal zone, wherein the ozone removal zone is positioned downstream of the air treatment zone with respect to a flow direction of the air flow being treated; a first ultraviolet source within the air treatment zone; a bulb reflector and a UV baffle positioned between the first ultraviolet source and the air inlet and arranged to prevent UV illumination from exiting the first end of the housing, the bulb reflector having a concave shape that faces the first ultraviolet source and a convex shape that faces the UV baffle, the UV baffle having first and second portions at opposed walls of the housing, each of the first and second portions having a curved surface that matches a portion of the convex shape of the bulb reflector; a grease filter in the air treatment zone and arranged to remove grease and smoke from the air being treated, the grease filter being arranged downstream of the first ultraviolet source and to receive UV illumination from the first ultraviolet source; a pair of first catalyst layers separated by an air space and each extending across the air treatment zone, and each including a first catalyst material; and a second catalyst layer extending across the ozone removal zone, the second catalyst layer including a second catalyst material that is different from the first catalyst material.
15. The apparatus of claim 14, each of the first and second catalyst materials comprises manganese.
16. An apparatus for treating air, comprising: a housing with an air inlet positioned at a first end of the housing and an air outlet positioned at a second end of the housing opposite the first end, the air inlet and the air outlet being positioned on a same lateral side of the housing, the housing enclosing an air treatment zone and an ozone removal zone, wherein the ozone removal zone is positioned downstream of the air treatment zone with respect to a flow direction of the air flow being treated; a first UV light in the air treatment zone and arranged to generate ozone; a bulb reflector and a UV baffle positioned between the first UV light and the air inlet and arranged to prevent UV illumination from exiting the first end of the housing, the bulb reflector having a concave shape that faces the first UV light and a convex shape that faces the UV baffle, the UV baffle having a curved surface that matches a portion of the convex shape of the bulb reflector; a plurality of first catalyst layers each spaced apart from each other and extending across the air treatment zone, and each including a first catalyst material; a plurality of second catalyst layers extending across the ozone removal zone, each spaced apart from each other and the first catalyst layers, the second catalyst layers each including a second catalyst material that is different from the first catalyst material, wherein each of the first and second catalyst materials comprises manganese; an ozone and/or ultraviolet source disposed within an air flow space between the first and second catalyst layers or between the second catalyst layers and a downstream further catalyst layer, wherein the further catalyst layer comprises the first catalyst material or the second catalyst material; and a heater disposed between the first UV light and the plurality of first catalyst layers.
17. The apparatus of claim 16, further comprising a particulate filter between the first UV light and the heater.
18. The apparatus of claim 16, wherein the heater is configured to increase a temperature of air through the first catalyst material.
19. The apparatus of claim 14, further comprising a heater disposed downstream of the first ultraviolet source and upstream of the pair of first catalyst layers.
20. The apparatus of claim 1, wherein the UV baffle includes first and second portions extending inwardly from opposed walls of the housing, each of the first and second portions including a panel that extends inwardly and upwardly from a respective wall of the housing to a concave curved surface that extends upwardly and outwardly to the respective wall.
21. The apparatus of claim 1, wherein the air inlet and the air outlet are arranged so that air enters the air inlet in a horizontal direction and turns upwardly to flow towards the air treatment zone and air exits the ozone removal zone upwardly and turns horizontally to exit the air outlet.
22. The apparatus of claim 1, further comprising a controller arranged to operate the apparatus in a self-clean mode in which the first UV light and the fan are operated to generate ozone in the air treatment zone at a self-clean level of 500 ppb to 2 ppm and to provide a self-clean space velocity in the catalyst of less than 100,000/hr to clean the grease filter and the plurality of first catalyst layers of organic material, and in a normal mode in which the first UV light and fan are operated to generate ozone in the air treatment zone at a normal level that is less than the self-clean level and a normal space velocity that is greater than the self-clean space velocity.
23. The apparatus of claim 1, further comprising a second UV light in the ozone removal zone and positioned between at least two of the second catalyst layers, the second UV light arranged to clean the at least two second catalyst layers.
Description
DESCRIPTION OF DRAWINGS
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(17) Throughout this specification and in the claims, like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION OF THE INVENTION
(18) Throughout this specification and in the claims, the terms air cleaning unit and atmosphere treating unit are intended to relate to an apparatus for sanitizing, filtering, decontaminating, deodorizing, purifying, conditioning, heating, humidifying, drying and/or otherwise treating, cleaning, modifying and/or improving an atmosphere within a space.
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(20) Downstream of the filter 130 are catalyst layers, such as formed of a plurality of catalyst sheets, which may be one or more formulations and structures, depending on the desired performance of the air treatment unit. A first set of catalyst layers 140 may be oxidizing catalysts that break down chemical contaminants, and extend across an air treatment zone. A second catalyst layer 150 may be ozone removal catalysts and extend across an ozone removal zone. In embodiments of this invention, each catalyst layer is spaced apart from an adjacent catalyst layer, such as by spacer elements 142. The resulting air space 144 between adjacent catalyst layers desirably acts to allow or create a more mixed or turbulent air flow through the catalyst layers. This prevents or disrupts a linear air flow through the catalyst material, such as when the catalyst layers have a matching honeycomb passageway configuration. A further catalyst layer 155 is downstream of the second catalyst layer 150. The further catalyst layer 155 can include the first catalyst material, the second catalyst material, or a third catalyst material. In
(21) A heater 160 may be positioned upstream of the catalysts 140. A fan 162 is positioned downstream of the catalyst layers 140 and 150.
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(26) In embodiments of this invention, the ozone and UV light together create active species that support continued oxidation of chemical bound to the active sites in the catalysts. These active species also serve to help the oxidized chemicals desorb from the catalyst. There may be multiple layers of both catalyst types in the apparatus. The air flow is drawn through a fan 262 and exits through a set of baffles 264 designed to allow free flow of clean air while preventing any backflow or penetration back into the fan area. The outlet grill 264 distributes the air flow so that it exhausts slowly and evenly and does not blow noticeably on a person standing close to the apparatus.
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(31) In some embodiments, the apparatus for treating air 300 can be mounted inside the automobile HVAC system next or close to the air conditioning evaporator. In operation, the air is drawn from the cabin of the automobile 310 into the apparatus for treating air 300. After treatment, the air is emitted from the apparatus 300 into the car cabin or into the HVAC system of the automobile. The air can flow back into the cabin of the automobile through the existing HVAC ducting of the automobile. In some embodiments, the apparatus 300 itself can include no active air mover component. Instead, the apparatus 300, when mounted near or next to HVAC system of the car, can leverage the fan of the ventilation system to function as an air mover. Alternatively, the apparatus 300 can be self-contained with its own fan that draws air from the cabin 310 into the apparatus 300 and back into the cabin 310. In some embodiments a second air mover could be used to mix the exhaust air from apparatus 300 into the cabin 310 and mix the cabin air.
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(33) The apparatus for treating air 4200 can include a housing with an air inlet (e.g., 4216) and an air outlet (e.g., 4242). In some embodiments, the enclosure for the air treatment zone 4227, the catalyst housing 4230, and the housing for the air mover 4238 can form a multi-section or unibody housing for the apparatus for treating air 4200. The apparatus for treating air 4200 can include an air treatment zone (e.g., 4226) and an ozone removal zone (e.g., 4231). As illustrated in
(34) The apparatus for treating air 4200 can include an UV light source (e.g., 4220) in the air treatment zone 4226 configured to generate ozone from the air. The UV light from the UV light source and the ozone generated by the UV light source can treat (e.g., clean, sanitize, or deodorize) the air in the air treatment zone 4226.
(35) The apparatus for treating air 4200 can include catalyst in the ozone removal zone 4231 that removes at least a portion of the ozone generated by the UV light source (e.g., 4220). As illustrated in
(36) The apparatus for treating air 4200 can include an air mover (e.g., 4230) positioned near the air outlet (e.g., 4242) that can draw the air through the air inlet (e.g., 4216) into the air treatment zone (e.g., 4226) from outside the housing, moving the air through the air treatment zone (e.g., 4226) and the ozone removal zone (e.g., 4231), and then emitting the air through the air outlet (e.g., 4242) out of the apparatus 4200.
(37) The apparatus for treating air 4200 can include a proximity sensor (e.g., 4214). The proximity sensor can be attached to the housing. The proximity sensor can detect the presence of a cover outside the housing of the apparatus 4200. The cover can be protective (e.g., to provide additional shield of the UV light) or decorative. The apparatus 4200 can turn off the UV light source if a cover is not detected. In some examples, the proximity sensor can be magnetic.
(38) The apparatus for treating air 4200 can include a power connector (e.g., 4228). The power connector can be connected to a power source inside a container (e.g., a refrigerator) to provide power to the apparatus 4200. In some embodiments, the apparatus for treating air 4200 can also include one or more sensors to detect the condition of the ambient environment (e.g., temperature, air quality, contaminant content and/or level, etc.).
(39) In some embodiments, the interior surface of the housing of the apparatus 4200 (e.g., in the air treatment zone 4226) can be at least partially coated with a reflector layer (e.g., metal layer such as aluminum). The components of the apparatus can be made in various materials, such as metal or plastics. Certain structural materials (e.g., plastics) can reduce the weight and/or cost of the apparatus 4200, but can deteriorate over time, especially in the presence of UV light. Coating the interior surface of the housing with a reflector layer can shield the structural materials from UV light and extend its usage life; it can also reduce the absorption of UV by the interior surface of the apparatus and enhance the UV light intensity inside the air treatment zone, thus improving the performance of the air treatment zone.
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(46) It is to be understood that the disclosed subject matter is not limited in its application to the details of construction and to the arrangements of the components set forth in the description or illustrated in the drawings. The disclosed subject matter is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of illustration and should not be regarded as limiting.
(47) As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods, and systems for carrying out the several purposes of the disclosed subject matter. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the disclosed subject matter.
(48) For example, the term air is used in general in this document and it can be interpreted to include both natural air and/or any gaseous or vaporous matter.
(49) With the method and apparatus according to different embodiments of this invention, the modularity of the system can be arranged so that a manufacturer can add or remove elements into a common platform to achieve different products.