APPARATUS FOR INACTIVATION OF AIRBORNE PATHOGENS

Abstract

An apparatus and method for inactivation of airborne pathogens to include a reactor space with an intake opening, an exhaust opening, and an airflow path disposed between the intake and exhaust openings for air to continuously transit throughout the reactor space. The apparatus also includes at least one of (i) a corona discharge unit with a pressure swing adsorption unit, or (ii) a UV-C germicidal lamp to generate a sufficient concentration of ozone and UV light to inactive pathogens. The apparatus also includes a catalyst disposed within the path of the airflow to convert ozone to oxygen following the inactivation step and an adsorbent to remove nitrogen oxides from the air. The apparatus also includes sensors for measuring ozone and nitrogen oxides concentrations at the exhaust opening.

Claims

1. A method for inactivation of pathogens suspended in a fluid, the method comprising: providing an enclosed reactor space having an intake opening and an exhaust opening, said reactor space including: an ozone generator generating ozone within said reactor space; and at least one layer of catalyst; flowing a fluid containing pathogens into said intake opening; while said fluid is within said reactor space, mixing said ozone into said fluid to inactivate said pathogens; passing said fluid and ozone mixture to said at least one layer of catalyst to convert said ozone into oxygen; allowing said fluid to pass out said exhaust opening after said ozone is converted into oxygen.

2. The method of claim 1 wherein said reactor space further comprises a plurality of baffles imparting turbulence to said fluid within said reactor space.

3. The method of claim 1, wherein said plurality of baffles partially obstructs flow of said fluid within said reactor space.

4. The method of claim 1 further comprising providing a pre-filter outside said reactor space, said fluid passing through said pre-filter before flowing into said intake opening.

5. The method of claim 1 further comprising providing a filter within said reactor space, said fluid passing through said filter prior to passing out through said exhaust opening.

6. The method of claim 1 further comprising measuring ozone concentration within the air at said exhaust opening.

7. The method of claim 1, further comprising an ozone backflow preventer disposed within said reactor space said backflow preventer comprising at least one layer of catalyst said backflow preventer inhibiting said fluid and ozone mixture from flowing out of said reactor space through said intake opening without said backflow preventer converting said ozone in said fluid and ozone mixture into oxygen.

8. The method of claim 1, wherein said ozone generator comprises a corona discharge unit including a heat sink cooling said corona discharge unit.

9. The method of claim 1, wherein said ozone generator comprises at least one UV-C light.

10. The method of claim 1, wherein a pressure swing adsorption unit exhausts oxygen to said ozone generator to enhance production of ozone and to reduce conversion of nitrogen in said fluid into nitrogen oxides within said reactor space.

11. The method of claim 10, wherein said exhaustion of said oxygen to said ozone generator by said pressure swing adsorption unit to the ozone generator is regulated.

12. The method of claim 11, wherein said regulation of said exhaustion of said oxygen is involves at least one of: an ozone sensor, a nitrogen oxides sensor, or a control device.

13. The method of claim 12, wherein said control device includes at least one of a microcomputer, a micro-controller, or a programmable logic controller.

14. The method of claim 1, wherein each layer of catalyst in said at least one layer of catalyst comprises a monolithic substrate coated with an ozone decomposition catalyst.

15. The method of claim 14, wherein said monolithic substrate is formed in a honeycomb configuration with a first side and a second side and with a plurality of open channels extending between the first side and the second side.

16. The method of claim 15 wherein said plurality of open channels are circular channels.

17. The method of claim 14 wherein said monolithic substrate is also coated with an NOx adsorbing compound.

18. The method of claim 1, wherein said at least one layer of catalyst includes at least one layer comprising manganese dioxide (MnO2).

19. The method of claim 1, wherein said at least one layer of catalyst includes at least one layer consisting of manganese dioxide (MnO2).

20. The method of claim 1, wherein an adsorbent is disposed within said reactor space, said adsorbent selected from the group consisting of: barium oxide, potassium oxide, alkali, alkaline earth metals, activated carbons, molecular sieves, metal organic frameworks, zeolites, noble metals, soda lime (NaOH-CaO mixtures), activated alumina and combinations thereof.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the drawing figures, wherein like numerals denote like elements.

[0048] FIG. 1 is a graph of experimental data illustrating the concentration of ozone at the outlet of the apparatus relative to the number of catalyst layers;

[0049] FIG. 2 is a graph of experimental data illustrating the concentration of the ozone at the outlet of the apparatus relative to the number of catalyst layers;

[0050] FIG. 3 is a graph of experimental data illustrating the concentration of nitrogen dioxides relative to the amount of reaction time;

[0051] FIG. 4 is a bar graph illustrating test results for a Model DI-SC3 ECO ozone sensor to include ozone concentration (PPM), temperature (oC), and relative humidity (%);

[0052] FIG. 5 is a series of graphs illustrating the survival fraction of pathogens relative to ozone concentration;

[0053] FIG. 6 is a front elevation view of an embodiment of the pathogen inactivation apparatus with the front panel and pre-filter removed to show the backflow preventer and inlet fan;

[0054] FIG. 7 is a rear elevation view of an embodiment of the pathogen inactivation apparatus illustrating functional components;

[0055] FIG. 8 is a top cutaway perspective view of an embodiment of the pathogen inactivation apparatus illustrating functional components;

[0056] FIG. 9A is a perspective view of an embodiment of a backflow preventer with the flapper valve in the open position;

[0057] FIG. 9B is a perspective view of an embodiment of a backflow preventer with the flapper valve in the closed position;

[0058] FIG. 10 is a perspective view of an embodiment of a corona discharge device;

[0059] FIG. 11 is a perspective view of an embodiment of a corona discharge device with an associated heat sink secured thereto;

[0060] FIG. 12A is a perspective view of an embodiment of an oxygen concentrator;

[0061] FIG. 12B is a further perspective view of an embodiment of an oxygen concentrator;

[0062] FIG. 13A illustrates a schematic the operation of an embodiment of a pressure swing adsorption apparatus with the left side being regenerated while the right side adsorbs nitrogen and releases concentrated oxygen out the top;

[0063] FIG. 13B is a schematic of the operation of an embodiment of a pressure swing adsorption apparatus with the right side being regenerated while the left side adsorbs nitrogen and releases concentrated oxygen out the top;

[0064] FIG. 14 is an embodiment of a bank of UV-C ozone generators;

[0065] FIG. 15 is a schematic of a ballast and wiring to provide high voltage to the UV-C ozone generators;

[0066] FIG. 16A is a perspective view of an embodiment of a monolithic substrate in a honeycomb configuration with a circular channel coated with an ozone decomposition catalyst and/or NOx adsorbing compound shown in a perspective view;

[0067] FIG. 16B is a front elevation view of an embodiment of a monolithic substrate in a honeycomb configuration with a circular channel coated with an ozone decomposition catalyst and/or NOx adsorbing compound;

[0068] FIG. 17A is a perspective view of an embodiment of a monolithic substrate in a honeycomb configuration with a corrugated channel coated with an ozone decomposition catalyst and/or NOx adsorbing compound;

[0069] FIG. 17B is an elevation view of an embodiment of a monolithic substrate in a honeycomb configuration with a corrugated channel coated with an ozone decomposition catalyst and/or NOx adsorbing compound;

[0070] FIG. 18 is a perspective view of an embodiment of the assembly of a plurality of ozone catalyst layers and NOx adsorbing layers held in position with spacers;

[0071] FIG. 19 is a side perspective view of an embodiment of the ozone decomposition catalyst stack showing spacing between the substrate layers;

[0072] FIG. 20 is a perspective view of an embodiment of the stacked assembly of four ozone decomposition catalyst layers held in place with spacers to maintain a gap between each layer;

[0073] FIG. 21 is a perspective view of an embodiment of the ozone decomposition catalyst stack showing spacing between each layer and using multiple stacks of catalysts to fill the cross-section of the apparatus;

[0074] FIG. 22 is a perspective view of an embodiment of the assembled ozone catalyst and NOx adsorbing layers held together with an outer shrink sleeve;

[0075] FIG. 23A is a cutaway view of an embodiment of the apparatus incorporated into an HVAC system with an external oxygen concentrator supplying a corona discharge ozone generator with injection site for releasing ozone into the reactor;

[0076] FIG. 23B is perspective cutaway view of an embodiment of the apparatus incorporated into and HVAC system with an external oxygen concentrator supplying a corona discharge ozone generator through an injection site for releasing ozone into the reactor;

[0077] FIG. 24 is an elevation view of an embodiment of a filter located in the exhaust region of the apparatus;

[0078] FIG. 25A is a cutaway view of an embodiment of the apparatus incorporated into an HVAC system with heating and cooling elements disposed proximate the exhaust opening;

[0079] FIG. 25B is a perspective cutaway view of an embodiment of the apparatus incorporated into an HVAC system with heating and cooling elements disposed proximate the exhaust opening;

[0080] FIG. 26A is a cutaway view of an embodiment of the apparatus incorporated into an HVAC system with heating and cooling elements disposed within the reactor;

[0081] FIG. 26B is a perspective cutaway view of an embodiment of the apparatus incorporated into an HVAC system with heating and cooling elements disposed within the reactor;

[0082] FIG. 27A is a cutaway view of an embodiment of the apparatus incorporated into and HVAC system with an external oxygen concentrator supplying a UV-C ozone generator with injection site for releasing ozone into the reactor;

[0083] FIG. 27B is perspective cutaway view of an embodiment of the apparatus incorporated into and HVAC system with an external oxygen concentrator supplying a UV-C ozone generator with injection site for releasing ozone into the reactor;

[0084] FIG. 28 is a cutaway view of an embodiment of the apparatus incorporated into an HVAC system with a transparent sleeve surrounding the UV-C ozone generator; and

[0085] FIG. 29 is an elevated cutaway view of an embodiment of the apparatus incorporated into an HVAC system with an external oxygen concentrator supplying a UV-C ozone generator with an additional fan for reaching a desired flow rate.

DESCRIPTION OF PREFERRED EMBODIMENT(S

[0086] The detailed description of exemplary embodiments herein refers to the accompanying drawings, which show exemplary embodiments by way of illustration and their best mode. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the inventions, it should be understood that other embodiments may be realized and that logical, chemical, and mechanical changes may be made without departing from the spirit and scope of the inventions.

[0087] The detailed description herein is presented for purposes of illustration only and not of limitation. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full, and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact.

[0088] To inactivate pathogens, the apparatus as disclosed herein produces ozone using either a corona discharge device in conjunction with an oxygen concentrator or one or more UV-C lamps. The ozone mixes with pathogens in the airstream, causes them to be inactivated. Once the pathogens are inactivated, ozone and any other by-products such as nitrogen oxides are removed. The apparatus has undergone extensive testing to ensure uniform ozone production, high pathogen inactivation, and removal of both ozone and nitrogen oxides.

[0089] FIG. 1 shows the performance of the ozone decomposition catalyst in removing 30 parts per million ozone from an airstream at 100 linear feet per minute (LFM) air velocity. The number of catalyst layers, and thus the total volume of catalyst, are varied to illustrate increased ozone removal per layer. Each catalyst layer is 6 inch by 6 inch by 1 inch in size. At 5 catalyst layers, up to 99.9% of the ozone is removed from the airstream. FIG. 2 illustrates the same data as described in FIG. 1 but is expanded to show the performance of a single layer of catalyst in removing ozone from the airstream.

[0090] FIG. 3 illustrates the performance of the NOx adsorbent in removing any nitrogen oxides, in this case nitrogen dioxide, which are produced along with ozone in the apparatus. An airstream containing 1.2 parts per million nitrogen dioxide was passed through the NOx adsorbent at 85 LFM for 180 minutes. The concentration of nitrogen dioxide was monitored at the outlet of the NOx adsorbent and shown to be at 0.05 parts per million for the entire test, well below the one-hour maximum concentration of 100 parts per billion (PPB) set by the U.S. EPA.

[0091] The mg/m3 ratings for ozone generators are measured when they are used with a concentrated oxygen supply of 90% to 99%. Since ambient air contains only around 21% oxygen, ozone generators often produce far less ozone than the rating supplied by their manufacturer. To account for this and other environmental conditions, sensors for Temperature (°C), Relative Humidity (%), and Ozone (PPM) were built into the Test Device. As seen in FIG. 4, the ozone sensor (ECO Sensor Model DL-SC3) measured a range of 25 to 55 parts per million across the tests.

[0092] Concentrations of ozone below 25 parts per million have likewise been shown in published academic studies to inactivate over 99% of airborne pathogens. One study in particular -- Chun-Chieh Tseng & Chih-Shan Li (2006) Ozone for Inactivation of Aerosolized Bacteriophages, Aerosol Science and Technology, 40:9, 683-689, published by the American Association for Aerosol Research, disclosed that for 99% virus inactivation of phi 6, phi X174, MS2, and T7 required ozone doses of 2.50 parts per million, 3.84 parts per million, 6.63 parts per million, and 10.33 parts per million, respectively with a contact time of 13.8 seconds. FIG. 5 depicts the survival fraction of airborne MS2, phi X174, phi 6, and T7 exposed to different ozone concentrations at relative humidities of 55% and 85%.

[0093] The apparatus 10 as illustrated in FIG. 6, may be located anywhere a continuous stream of air requires the inactivation of airborne pathogens. Such locations may include residential, commercial, and industrial settings. This apparatus may also be employed in mobile settings such as on planes and trains that experience a substantial turnover of passengers frequently, some of whom may be carriers of contagious pathogens.

[0094] The apparatus 10, as further illustrated in FIG. 7, includes a reactor 12 that forms an enclosed chamber in which the pathogen inactivation and catalytic conversion/ adsorption functions to be described below occur. The reactor may be of many different cross sections such as round, square, or rectangular. The exterior of the reactor is preferably fabricated from sheet metal; however, other materials such as plastic or composites are contemplated by this disclosure. The interior of the reactor 12 and resident components must be composed of materials that are compatible with ozone, as ozone is capable of oxidizing many materials, leading to their degradation.

[0095] The reactor 12 has an intake opening 14 and an exhaust opening 16. Ambient air 18 is drawn into the reactor 12 through the intake opening 14 and after passing through the various zones of the reactor 12 passes out through the exhaust opening 16 with a high percentage of the airborne pathogens inactivated and therefore substantially reducing the potential for infecting those in the surrounding spaces.

[0096] As shown in FIG. 8, ambient air 18 is drawn into the reactor 12 by an internally mounted fan 20. The fan 20, as disclosed herein, preferably covers the cross-sectional opening of the interior of the reactor 12; however, alternative configurations are also contemplated by this disclosure. The fan 20 is preferably mounted inside of the reactor 12 opening to allow installation of a removable pre-filter 22 in front of the fan 20. However, some embodiments may use a fan 20 mounted outside of the reactor 12, such as those that integrate within existing HVAC systems. The pre-filter 22 may be readily removed and replaced and is not of such a tight weave to adversely impact the ability of the fan 20 to draw ambient air past the pre-filter 22.

[0097] As illustrated in FIGS. 9A and 9B the apparatus 10 also employs a backflow preventer 26 that restricts the ability of air that has entered the reactor 12 from escaping back out through the intake opening 14. The backflow preventer 26 may be as simple as a flapper valve 28 configuration that can flex inwardly on three sides with the top edge 30 secured to the reactor interior space 32. Should there be a reversal of airflow, for whatever reason, the outer edges 36 of the flapper valve 28 will seal against a flange 38 on the three sides that are unconnected to the reactor interior space 32 thereby preventing outward airflow. The objective of installing a backflow preventer 26 is to prevent the release of highly ozonated air, or air containing high levels of nitrogen oxides, from entering the room or space that is undergoing pathogen inactivation with the disclosed apparatus 10. A separate backflow preventer 26 embodiment is also contemplated below for removing ozone from air without limiting airflow through the intake.

[0098] Ozone generation occurs in area 40 interior to the reactor 12 away from the intake opening 14 and beyond the backflow preventer 26. In this area 40, as illustrated at FIG. 7 there are multiple embodiments of ozone generating equipment that are contemplated. A first embodiment, as illustrated in FIG. 10, utilizes a corona discharge device 42. A corona discharge device operates by applying a voltage between two electrodes, causing air between the electrodes to be ionized. This ionization splits diatomic oxygen, producing an oxygen molecule that reacts to form ozone.

[0099] In operation, the fan 20 moves the airstream 98 into the space gap 44 between the corona discharge plates 50 where the high voltage, high frequency and alternating current results in the generation of ozone molecules 76. It is ozone that serves to inactivate the airborne pathogens within the reactor 12. In an alternative embodiment, as further illustrated in FIG. 11, a heat sink 48 is optionally secured to the corona discharge device 42. The heat sink 48 serves to cool the plates 50 of the corona discharge device by radiating heat through fins 52 of the heat sink 48 resulting in the production of a higher concentration of ozone and thereby increased inactivation of the airborne pathogens.

[0100] Alternative cooling of the heat sink such as with a supplemental fan or water-cooling device yields even higher ozone concentrations and therefore increased inactivation of airborne pathogens. The methodologies described above for cooling the corona discharge device 42 are all contemplated by this disclosure.

[0101] An alternative embodiment of the apparatus 10 employs a corona discharge device 42 in combination with an oxygen concentrator 54 utilizing “pressure swing adsorption.” An exemplary oxygen concentrator configuration is shown in FIGS. 12A and 12B. An oxygen concentrator 54 is disposed proximate to the corona discharge device 42 to facilitate the introduction of highly concentrated oxygen between the plates 50 of the discharge device 42. As is discussed in greater detail below, a significant percentage of the nitrogen is removed from the oxygen airstream exiting an oxygen concentrator.

[0102] With a substantially reduced percentage of nitrogen passing between the plates 50 of the corona discharge device 42 there is a greatly reduced potential for nitrogen oxides to be produced from the corona discharge device 42. Since nitrogen oxides are considered air pollutants and are regulated by the U.S. Environmental Protection Agency at 40 CFR § 50.11, there is a human health based reason, specifically a pulmonary concern, to increased exposure to high concentrations of nitrogen oxides. The 8-hour standard for the National Primary ambient air quality standard for nitrogen oxides codified at 40 CFR § 50.11 provides that the concentration of nitrogen oxides in the ambient air shall not exceed 53 parts per billion and the one-hour standard provides that the concentration of nitrogen oxides shall not exceed 100 parts per billion. The airstream 98 exiting the apparatus 10 as disclosed herein ejects the airstream to the ambient air 18 with a concentration of nitrogen oxides less than 100 parts per billion.

[0103] As illustrated in FIGS. 13A and 13B, the oxygen concentrator 54 relies upon at least two vessels 58, 60 that alternate being under pressure usually from 50 to 150 psi and the second being at or near atmospheric pressure. While the first vessel is being pressurized the second vessel is depressurized, hence the reason for the use of the term “swing” in the name of the identified technology. Zeolite 62 is a mineral consisting of aluminum and silicon compounds that contain micropores that absorb nitrogen from the air. The zeolite serves to separate the nitrogen from the oxygen at a molecular level.

[0104] FIG. 13A illustrates the initial adsorption step of the right vessel 60. In the right vessel, the unwanted nitrogen is adsorbed by the Zeolite 62 which is positioned in the form of a bed 63 at the base of each vessel 58, 60. What remains in the vessel space 65 above the zeolite bed 63 is primarily oxygen 64. This oxygen 64 can then be routed out of the top 70 of the pressurized vessel 60 and into the corona discharge device without concern for the formation of significant concentrations of nitrogen oxides, i.e., NO2, NO, N2O5, etc. The oxygen from the pressurized vessel enters the corona discharge device 42 at a flow rate that optimizes the production of ozone and minimizes the production of nitrogen oxides. The nitrogen 66 adsorbed in the zeolite bed 63 can also be routed for discharge, for example, into the building space without threat of harm to human health as the nitrogen 66 entering into the room atmosphere does not present a pulmonary risk as do nitrogen oxides.

[0105] Once Zeolite 62 has adsorbed a maximum concentration of nitrogen 66, the left vessel 58 is pressurized and the process is repeated within the left vessel 58. As shown in FIG. 13B, the Zeolite 62 absorbs nitrogen 66 from the pressurized air and the concentrated oxygen 64 is evacuated near the top 70 of the vessel for routing to the corona discharge device 42. During this time, the pressure is released within the right vessel 60, allowing adsorbed nitrogen to desorb from the surface of the Zeolite 62 and into the atmosphere. Nitrogen 66 is evacuated at the bottom 72 of both vessels 58, 60 through an exhaust port 69 that leads to the environment. The exhausting of nitrogen 66 to the ambient air does not contribute to pulmonary distress because the atmosphere already contains roughly 78% nitrogen.

[0106] It is contemplated by this disclosure that, in at least one embodiment, a portion of the overall airstream passing through the corona discharge device 42 is the oxygen continuously routed from the vessels of the oxygen concentrator 54. With highly purified oxygen entering the corona discharge device 42 from the oxygen concentrator 54 the corona discharge device 42 is capable of producing ozone at concentrations ranging from 1,000 to 60,000 parts per million. This highly concentrated ozone is commingled with the airstream 98 passing through the reactor 12 thereby reducing the overall concentration of ozone for inactivating the pathogens. To minimize the production of nitrogen dioxide and other nitrogen oxides in the corona discharge device 42 an optimal configuration directs the delivery of oxygen 64 from the oxygen concentrator 54 and minimizes the delivery of ambient air that passes through the plates 50 of the corona discharge device 42. The rationale for this being that ambient air contains roughly 78% nitrogen while the gas supplied by the oxygen concentrator 54 contains a very high percentage of oxygen 64 with little nitrogen 66 available for conversion to nitrogen oxides in the corona discharge unit.

[0107] In another embodiment, the oxygen concentrator 54 utilizes a continuously variable control valve, also known as a proportional isolation valve 71, is illustrated at FIGS. 13A and 13B. The valve 71 is operable to meter the volume of oxygen per unit of time delivered from the oxygen concentrator 54 to the corona discharge device 42. This type of valve 71 is well known in the industry. An exemplary valve is the Eclipse proportional isolation valve model EIVU-M-V sold by Clippard.

[0108] This embodiment may also employ a microcomputer, a microcontroller, or a programmable logic controller 70A that is in communication with the valve 71 to control the volumetric flow of oxygen 64 through the valve 71 to the corona discharge device 42. Implementation of such controllers is well known in the industry and need not be detailed herein. Fine variable control of the valve 71 facilitates control of the production of ozone by the corona discharge device 42 as well as limiting the production of nitrogen oxides. An exemplary programmable logic controller 70A for use in this application is sold by Clippard such as the SCPVD-1 Stepper-Controller Proportional Valve Driver.

[0109] This fine level of control is accomplished by utilizing the valve 71 to balance the displacement of ambient air with oxygen 64 from the oxygen concentrator 54. Signals from the ozone and nitrogen oxides sensors (discussed in greater detail below) mounted within the reactor 12 will provide input to the programmable logic controller, microcomputer, or microcontroller to optimize operational inflow of oxygen 64 to the corona discharge device 42.

[0110] Another embodiment contemplated by the disclosure for ozone generation within the reactor 12 is by using ultraviolet light. Lamps that produce ozone from ultraviolet light maximize the production of wavelengths around 185 nm. These lamps also produce many other wavelengths of light in the UV-C spectrum. In contrast to ozone generators using corona discharge, UV-C lamps produce little to no nitrogen oxides, although they are less efficient, producing smaller concentrations of ozone for a given airstream. The ultraviolet light embodiment preferably utilizes UV-C germicidal lamps that produce, for example, between 2.5 to 20 g/hour of ozone and with an airflow rate of about 200 CFM for a 500 to 1,500 ft3 space in a residence, office, or industrial setting. FIG. 14 shows an example of an array of UV-C lamps 74 comprising the ozone generator within the apparatus 10. The array of UV-C lamps is powered using devices called ballasts, which increase the lower input voltage to a higher output voltage to ensure the mercury gas is excited to release UV light. An exemplary ballast 126 is shown in FIG. 15.

[0111] The size of the UV-C device may be scaled accordingly to accommodate larger volumes. Multiple vendors produce UV-C lamps that can produce up to 3 g/hour of ozone. As illustrated in FIG. 8, the UV-C ozone generator lamps 74 are positioned within the reactor 12 and intake air 18 is passed around the plurality of ozone generator lamps 74 thereby creating ozone 76 for use in inactivation of airborne pathogens.

[0112] Following generation of the ozone 76, the ozonated and the pathogen laden air is moved over and around at least one baffle 78 within the reactor 12 to provide for thorough mixing and contact of the pathogens with ozone. The concentration of ozone 76 within the reactor 12, proximate the ozone generator, is in the range of 1 to 55 parts per million, a concentration that is sufficient to inactive a very high percentage of the airborne pathogens transiting through the reactor 12. A single plate baffle 78 with multiple channels or a plurality of long cutouts may suffice to create the desired mixing. Multiple baffles in series are also contemplated to achieve thorough mixing; however, with increasing baffle placement comes the need for increased fan output to drive the airflow through the reactor. Additional baffle configurations are contemplated by this disclosure and multiple configurations may be employed to increase the exposure of the pathogens to ozonated air. As indicated above, when the airborne pathogens are exposed to an ozone concentration of between 1 and 55 parts per million, they are rapidly inactivated by such exposure.

[0113] Once thorough mixing has been completed and sufficient residence time has passed for the ozone to inactivate the pathogens in the airstream, the airstream containing the inactivated pathogens and their components and any excess ozone 76 is exposed to an ozone conversion decomposition catalyst 82 for converting the ozone 76 to oxygen. It is critical to remove as much ozone as possible from the airstream because ozone is considered an air pollutant according to federal regulation at 40 CFR § 50.19 and exposure of 1 hour is limited to a concentration no greater than 70 parts per billion.

[0114] As illustrated in FIGS. 16A and 16B, an ozone decomposition catalyst 82 such as manganese dioxide (MnO2) is coated on a honeycomb monolithic substrate 88 for converting ozone to oxygen. The ozone decomposition catalyst monolith 88 is made of a ceramic such as cordierite containing honeycomb shaped channels 90 allowing for maximum contact between the catalyst and the advancing airstream 98, optimizing ozone conversion. FIGS. 17A and 17B show an alternative monolithic substrate made of metal in a configuration with corrugated channels 90A. As illustrated in FIGS. 7 and 8, the ozone decomposition catalyst 82 is preferably disposed within the reactor 12 in such a manner that it can be easily withdrawn and replaced such as through a slot 92 in the top or side 94, 96 of the reactor 12. Catalysts other than MnO2 and configurations other than a monolithic substrate 88 with channels 90, 90A are also contemplated by this disclosure.

[0115] Once the airstream 98 advances beyond the ozone decomposition catalyst 82 it may still be laden with nitrogen dioxide and other associated nitrogen oxides, i.e., NO, N2O5, etc., that are harmful to human pulmonary function. Both the ceramic and metallic monolithic substrates 88 as shown in FIGS. 16A, 16B, 17A and 17B can support a coating with an NOx adsorbent compound 102 such as barium oxide or potassium oxide or combinations of the two compounds, as well as the previously described ozone decomposition catalyst 82. In this way, the uniform nature of the ozone decomposition catalyst 82 and the NOx adsorbent 102 allows for easier maintenance and replacement. Other catalysts for adsorption of the nitrogen dioxide, and associated nitrogen compounds, are also contemplated by this disclosure, such as various alkali and alkaline earth metals, activated carbons, molecular sieves, metal-organic frameworks, zeolites, noble metals, soda-lime (NaOH-CaO mixtures), and activated alumina. FIG. 18 shows a module 123 containing various layers of ozone decomposition catalyst monoliths 88 and NOx adsorbing monoliths 100. Each layer contains a monolithic substrate as shown in FIGS. 16A, 16B, 17A, or 17B coated with one ozone decomposition catalyst 82 or NOx adsorbent compound 102. In this way, the number of ozone decomposition catalyst monoliths 88 and NOx adsorbing monoliths 100 may be varied depending on the requirements of the application.

[0116] FIG. 19 illustrates monolithic layers containing several ozone decomposition catalyst-coated 82 monolithic substrates 88 separated by spacers 122 within the same module stack 123. FIG. 20 illustrates how a module 123 may be fabricated to scale for increases in air flow rate as well as ozone concentrations. FIG. 21 illustrates a module 123 with nominally and preferably half-inch spacers 122 between each monolith containing both ozone decomposition catalyst monoliths 88 and NOx adsorbing monoliths 100.

[0117] In a preferred embodiment, several ozone decomposition catalyst monoliths 88 are placed before the nitrogen oxides adsorbing monoliths 100 to ensure that ozone does not compete with nitrogen oxides for adsorption sites. FIG. 22 illustrates the combined module 123 of FIG. 18 wrapped within a shrink sleeve 124 to ensure stability and maintain performance. The shrink sleeve 124 prevents exfiltration of the airstream 98 out and around the catalytic and adsorption processes thereby improving the overall performance of the apparatus 10.

[0118] With the combined monoliths 88, 102 within a module 123 and the stacking of such modules, both the ozone decomposition catalyst monoliths 88 and the NOx adsorption monoliths 100 are preferably positioned within the reactor 12 in such a manner that they can be extracted from the reactor 12 through a slot 104, as illustrated at FIGS. 7 and 8, for replacement or refurbishment, should such maintenance be required.

[0119] Once the adsorption of the nitrogen oxides has been accomplished the airstream 98 optionally advances to an exhaust filter 110, such as illustrated at FIG. 24. As illustrated at FIGS. 7 and 8, the exhaust filter 110 is incorporated into the design to capture any entrained particulates that may have passed through the pre-filter or become entrained in the airstream 98 through tiny gaps or openings in the walls 112 of the reactor 12. The exhaust filter 110 may also include a coating such as activated carbon to remove any odor producing compounds that are present within the airstream 98.

[0120] The exhaust filter 110 is preferably in the range of a minimum efficiency reporting value (MERV) of 7-16 and is capable of trapping air particles in the 0.3 to 1.0-micron size range but of not such a high MERV rating that it is difficult for the apparatus 10 to exhaust the airstream 98 out of the reactor 12. The exhaust filter 110 is preferably disposed within the reactor 12 in such a manner as with the ozone decomposition catalyst monolith 82 and NOx adsorbent monolith 100 that it can be readily removed from the reactor for replacement or cleaning.

[0121] As illustrated at FIGS. 7 and 8, disposed adjacent to the exhaust opening 16 of the reactor 12 is at least one sensor bank 116 for measuring the concentration of both nitrogen oxides and ozone. This sensor bank 116 will serve to alert the operator of the apparatus 10 that adequate conversion of ozone to oxygen and adsorption of nitrogen oxides has occurred at the time of exhausting the airstream 98 from the reactor 12. Additional ozone and nitrogen oxides sensor banks 118, 120 are preferably disposed throughout the reactor 12 to capture measurements of the concentration of these pollutants. Exemplary locations for the sensors are proximate entering the intake opening 14 of the reactor 12, at the corona discharge device 42 or the UV-C device 74 as well as immediately after the ozone decomposition catalyst monolith 82 and NOx adsorption monolith 100.

[0122] These concentration measurements are beneficial in alerting the operator to the proper operation of the apparatus 10 and whether maintenance, or system tuning, may be required to adjust the concentration of ozone produced by the apparatus. When an oxygen concentrator 54 is used, the data from these sensors may optionally but preferably be fed to a microprocessor, microcontroller, or a programmable logic controller 70A for adjusting as necessary, the continuously variable control or proportional control valve 71 that feeds oxygen from the oxygen concentrator 54 as illustrated at FIGS. 13A and 13B.

[0123] If the concentration of ozone in the airstream 98 exiting the apparatus is higher than the maximum concentration limit, the sensor 116, 118 relays to the microcomputer, PLC, or microcontroller 70A the measured concentration, and a pre-programmed instruction is executed by the control device 70A to reduce the magnitude of ozone produced by the ozone generator 42. Similarly, if the concentration of nitrogen oxides, whether nitrogen dioxide or any similar compound, exceeds a set maximum concentration limit as measured by the designated sensor 118, the ozone generator 42 in concert with the oxygen concentrator 54 can adjust flow rate accordingly to increase the output of the oxygen concentrator or reduce the output of the ozone generator. Other electronic components may be used in combination with those described above to ensure proper control of ozone and nitrogen oxides, such as printed circuit boards, transistors, capacitors, resistors, and diodes.

[0124] FIGS. 23A, 23B, 25A, 25B, 26A, 26B, 27A, 27B, 28 and 29 illustrate embodiments of the apparatus for integration into HVAC ducting. FIGS. 25A and 25B illustrate the apparatus 10 as integrated within a duct with heating and cooling elements 132, 134 placed proximate to the exhaust opening 16. The heating and cooling elements 132, 134 are shown to portray potential integration with the apparatus 10 disclosed herein but are not necessarily integral to the operation of the apparatus.

[0125] As illustrated in FIGS. 25A and 25B, the apparatus 10 may be integrated with heating and cooling elements 132, 134 that already exist within an HVAC system. In this way, the apparatus for HVAC ducting may be placed either before or after the existing heating and cooling elements 132, 134. The airstream 98 passes through the intake opening 14 and through the removable pre-filter 22, removing larger particles such as dust. After passing through the removable pre-filter 22, the airstream 98 flows into the UV-C ozone generator 74, where ozone 76 is generated. The ozone 76 mixes within the airstream 98, inactivating pathogens. The air and ozone mixture then passes through the baffles 78, further improving mixing and pathogen inactivation.

[0126] The airstream 98 carrying a high percentage of inactivated pathogens then flows past the ozone decomposition catalyst 82 to convert ozone 76 in the airstream to oxygen and past the NOx adsorption monolith 100. Finally, the airstream 98 passes through the exhaust filter 110, around the heating and cooling elements 132, 134, and out the exhaust opening 16. Ozone and nitrogen oxides sensor banks 116, 118, and 120 disposed within and around the reactor 12 monitor the concentration of ozone and nitrogen oxides leaving the apparatus to ensure the maximum concentration limits set by the U.S. EPA are not exceeded. Throughout the process, the fan 20 pulls the airstream 98 through the reactor 12 and out the exhaust opening 16. FIG. 25B illustrates a perspective view of the same process as described above.

[0127] In an alternative configuration for integration in HVAC ducting, the heating 132 and cooling 134 elements may also be placed within the reactor 12, as opposed to after the reactor 12. FIGS. 26A and 26B illustrate a side elevation and a perspective view of the apparatus 10, with heating 132 and cooling 134 elements moved from after the ozone decomposition catalyst 82 to closer to the reactor intake opening 14. In a further embodiment, FIGS. 23B and 27B illustrate similar configurations to FIGS. 26A and 26B, with the apparatus integrated in HVAC duct work. In both the configurations illustrated in FIGS. 23A and 23B and 27A and 27B, an oxygen concentrator 54 is used to increase the oxygen supply for the ozone generator. FIGS. 27A and 27B illustrate the combination with a UV-C ozone generator, while FIGS. 23A and 23B shows the combination with a corona discharge ozone generator. In each configuration, the airstream 98 enters the reactor proximate to the intake 14.

[0128] The reactor 12 contains an inlet pipe or tubing for injection of ozone 76 from the oxygen concentrator 54 fed corona discharge 42 or UV-C ozone generator 74. The oxygen concentrator releases a highly concentrated stream of oxygen into the space surrounding the corona discharge generator 42 or UV-C ozone generator 74, limiting the production of NOx compounds and increasing the production of ozone. Once the ozone 76 is injected into the airstream, the airstream passes over the baffles which increase mixing and improves pathogen inactivation, until moving to the ozone decomposition catalyst which removes the ozone.

[0129] As shown in FIG. 28, in an alternate embodiment of the same configuration as described in FIGS. 27A and 27B, the oxygen concentrator 54 injects a concentrated ozone stream into the reactor zone 12, with the UV-C ozone generator contained within the reactor 12 as opposed to outside the reactor 12. In this configuration, the UV-C ozone generator lamps 74 are mounted perpendicular to the airstream 98 flow, with a transparent sleeve in front of the UV-C ozone generator limiting contact with the airstream and the UV-C ozone generator. The concentrated oxygen 64 leaving the oxygen concentrator 54 is injected between the lamps of the UV-C ozone generator 74, creating ozone which flows out and into the airstream 98 that is rerouted around the UV-C generator.

[0130] In a final embodiment, the configuration as illustrated at FIG. 29 shows the same configuration as that of 27A and 27B, with the oxygen concentrator 54 and the UV-C ozone generator 74 mounted externally to the reactor 12, with ozone injected into the reactor by a pipe or tubing. In this configuration, an additional fan 20 is placed upstream of the ozone injection site to ensure the desirable flow rate is reached as the airstream travels through the reactor.

[0131] The disclosed apparatus, and systems should not be construed as limiting in any way. Instead, the present disclosure is directed toward all novel and nonobvious features and aspects of the various disclosed embodiments, alone and in various combinations and sub-combinations with one another. The disclosed apparatus and systems are not limited to any specific aspect or feature or combination thereof, nor do the disclosed embodiments require that any one or more specific advantages be present or problems be solved.

[0132] In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only examples of the disclosure and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope of these claims.

[0133] The disclosure presented herein is believed to encompass at least one distinct invention with independent utility. While the at least one invention has been disclosed in exemplary forms, the specific embodiments thereof as described and illustrated herein are not to be considered in a limiting sense, as numerous variations are possible. Equivalent changes, modifications, and variations of the variety of embodiments, materials, compositions, and methods may be made within the scope of the present disclosure, achieving substantially similar results. The subject matter of the at least one invention includes all novel and non-obvious combinations and sub-combinations of the various elements, features, functions and/or properties disclosed herein and their equivalents.

[0134] Benefits, other advantages, and solutions to problems have been described herein regarding specific embodiments. However, the benefits, advantages, solutions to problems, and any element or combination of elements that may cause any benefits, advantage, or solution to occur or become more pronounced are not to be considered as critical, required, or essential features or elements of any or all the claims of at least one invention.

[0135] Many changes and modifications within the scope of the instant disclosure may be made without departing from the spirit thereof, and the one or more inventions described herein include all such modifications. Corresponding structures, materials, acts, and equivalents of all elements in the claims are intended to include any structure, material, or acts for performing the functions in combination with other claim elements as specifically recited. The scope of the one or more inventions should be determined by the appended claims and their legal equivalents, rather than by the examples set forth herein.

[0136] Benefits, other advantages, and solutions to problems have been described herein regarding specific embodiments. Furthermore, the connecting lines, if any, shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the inventions.

[0137] The scope of the inventions is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. Different cross-hatching is used throughout the figures to denote different parts but not necessarily to denote the same or different materials.

[0138] In the detailed description herein, references to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a feature, structure, or characteristic, but every embodiment may not necessarily include the feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a feature, structure, or characteristic is described relating to an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic relating to other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.

[0139] Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. § 112(f) unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.