DEVICE AND METHOD FOR PURIFYING A VEHICLE CABIN
20230165998 · 2023-06-01
Assignee
Inventors
Cpc classification
B60H3/0078
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A device and method for purifying a vehicle cabin is provided. The device comprises a housing, a plurality of light emitting diode (LED) modules each containing an LED, wherein the LED modules are positioned at least partially within the housing, a catalytic target structure, wherein the structure is located below at least one of the LED modules in the plurality of LED modules, a plurality of reflectors, wherein the reflectors are located below at least one of the LED modules in the plurality of LED modules, a plurality of fans, wherein the fans are located at least partially within the housing, a plurality of photocatalyst filters positioned at least partially within the housing, wherein at least one of the plurality of photocatalyst filters is in parallel with at least one of the LED modules in the plurality of LED modules, and a control unit located at least partially within the housing, wherein the control unit is operatively connected to the plurality of LED modules.
Claims
1. A device for purifying a vehicle cabin, the device comprising: a housing; a plurality of light emitting diode (LED) modules each containing an LED, wherein the LED modules are positioned at least partially within the housing; a catalytic target structure, wherein the structure is located below at least one of the LED modules in the plurality of LED modules; a plurality of reflectors, wherein the reflectors are located below at least one of the LED modules in the plurality of LED modules; a plurality of fans, wherein the fans are located at least partially within the housing; a plurality of photocatalyst filters positioned at least partially within the housing, wherein at least one of the plurality of photocatalyst filters is in parallel with at least one of the LED modules in the plurality of LED modules; and a control unit located at least partially within the housing, wherein the control unit is operatively connected to the plurality of LED modules.
2. The device according to claim 1, wherein the plurality of LED modules comprises: a first LED module positioned at least partially within the housing, wherein the first LED module emits ultraviolet light at a first wavelength; a second LED module positioned at least partially within the housing, wherein the second LED module emits ultraviolet light at a second wavelength; a third LED module positioned at least partially within the housing, wherein the third LED module emits ultraviolet light at a third wavelength.
3. The device according to claim 2, wherein the first LED module and the third LED module emit ultraviolet light at a wavelength between 300 and 400 nm and the second LED module emits ultraviolet light at a wavelength between 200 and 300 nm.
4. The device according to claim 3, wherein the first LED module and the third LED module emit ultraviolet light at a wavelength of 365 nm and the second LED module emits ultraviolet light at a wavelength of 265-275 nm.
5. The according to claim 2, wherein the catalytic target structure is located below the second LED module.
6. The according to claim 2, wherein the plurality of reflectors comprises: a first reflector located above the second LED module; and a second reflector located below the second LED module.
7. The device according to claim 1, wherein at least one of the plurality of reflectors is a flat surface comprising a highly UV reflective material.
8. The device according to claim 7, wherein the reflective material is selected from a group consisting of aluminum, aluminum foil, stainless steel, and polytetrafluoroethylene.
9. The device according to claim 6, wherein the first reflector is located above the second LED module, the catalytic target structure is located below the second LED module and the second reflector is located below the catalytic target structure.
10. The device according to claim 2, wherein the plurality of photocatalyst filters comprises a first photocatalyst filter and a second photocatalyst filter, wherein the first LED module is in parallel with the first photocatalyst filter and the second LED module is in parallel with the second photocatalyst filter.
11. The device according to claim 1, wherein the control unit is configured to control at least one of the plurality of LED modules. the fan series, and the catalytic target structure.
12. The device according to claim 11, wherein the control unit is configured to control ambient conditions within the housing.
13. The device according to claim 12, wherein the ambient conditions are selected from a group consisting of humidity, temperature, selective gases, noise level, and air quality.
14. The device according to claim 1, wherein the plurality of fans are positioned in a series.
15. The device according to claim 1, wherein the device emits zero to near zero ozone.
16. The device according to claim 1, wherein the device is configured such that the device generates 10-70 parts per billion of ROS compounds in the vehicle cabin the device is purifying.
17. The device according to claim 1, wherein at least one of the plurality of photocatalyst filters is in a honeycomb configuration.
18. The device o according to claim 1, wherein at least one of the plurality of photocatalyst filters is composed of a material selected from a group consisting of aluminum oxide, silicon dioxide, magnesium oxide, and titanium oxide.
19. A method for purifying a vehicle cabin, the method comprising: supplying an air product; receiving the air product within a purification device; processing the air product within the purification device by means of a photocatalytic configuration which initiates a chemical reaction utilizing airborne oxygen and water producing a plurality of reactive oxygen species, wherein the reactive oxygen species chemically react with gases, particles, and surface contaminants within the vehicle cabin; and outputting the processed air product into a vehicle cabin.
20. The method according to claim 19, wherein the reactive oxygen species is selected from a group consisting of hydrogen peroxide, hydroxyls, hydroperoxyls, and singlet oxygen.
21. A system for purifying a vehicle cabin, the system comprising: an air supply that supplies an air product; a purification device configured to receive the air product and output processed air, the device comprising: a housing; a plurality of light emitting diode (LED) modules each containing an LED, wherein the LED modules are positioned at least partially within the housing; a catalytic target structure, wherein the structure is located below at least one of the LED modules in the plurality of LED modules; a plurality of reflectors, wherein the reflectors are located below at least one of the LED modules in the plurality of LED modules; a plurality of fans, wherein the fans are located at least partially within the housing; a plurality of photocatalyst filters positioned at least partially within the housing, wherein at least one of the plurality of photocatalyst filters is in parallel with at least one of the LED modules in the plurality of LED modules; and a control unit located at least partially within the housing, wherein the control unit is operatively connected to the plurality of LED modules; and a vehicle cabin that receives the processed air output from the purification device.
22. The system according to claim 22, wherein the purification device is disposed in at least one of a vehicle air conditioning system, a vehicle pillar, and a vehicle cabin.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings, which are incorporated herein and form part of the specification, illustrate various embodiments.
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DETAILED DESCRIPTION
[0048] While aspects of the subject matter of the present disclosure may be embodied in a variety of forms, the following description and accompanying drawings are merely intended to disclose some of these forms as specific examples of the subject matter. Accordingly, the subject matter of this disclosure is not intended to be limited to the forms or embodiments so described and illustrated.
[0049] Unless defined otherwise, all terms of art, notations and other technical terms or terminology used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. All patents, applications, published applications and other publications referred to herein are incorporated by reference in their entirety. If a definition set forth in this section is contrary to or otherwise inconsistent with a definition set forth in the patents, applications, published applications, and other publications that are herein incorporated by reference, the definition set forth in this section prevails over the definition that is incorporated herein by reference.
[0050] Unless otherwise indicated or the context suggests otherwise, as used herein, “a” or “an” means “at least one” or “one or more.”
[0051] This description may use relative spatial and/or orientation terms in describing the position and/or orientation of a component, apparatus, location, feature, or a portion thereof. Unless specifically stated, or otherwise dictated by the context of the description, such terms, including, without limitation, top, bottom, above, below, under, on top of, upper, lower, left of, right of, in front of, behind, next to, adjacent, between, horizontal, vertical, diagonal, longitudinal, transverse, radial, axial, etc., are used for convenience in referring to such component, apparatus, location, feature, or a portion thereof in the drawings and are not intended to be limiting.
[0052] Furthermore, unless otherwise stated, any specific dimensions mentioned in this description are merely representative of an exemplary implementation of a device embodying aspects of the disclosure and are not intended to be limiting.
[0053] As used herein, the terms “substantially” and “substantial” refer to a considerable degree or extent. When used in conjunction with, for example, an event, circumstance, characteristic, or property, the terms can refer to instances in which the event, circumstance, characteristic, or property occurs precisely as well as instances in which the event, circumstance, characteristic, or property occurs to a close approximation, such as accounting for typical tolerance levels or variability of the embodiments described herein.
[0054] Embodiments of the devices and methods for purifying environments disclosed herein can be implemented and used within any vehicle and disposed, for example, in a vehicle's air conditioning system, in a pillar within the vehicle cabin, under a seat in the vehicle cabin, or within any available space within the vehicle cabin. Moreover, while exemplary embodiments are described with reference to an automobile, it should be understood that the devices and methods disclosed herein may be beneficial and applicable to other types of vehicles, including trucks, buses, railed vehicles (trains, trams), watercraft (ships, boats), amphibious vehicles (screw-propelled vehicle, hovercraft), aircraft (airplanes, helicopters, aerostat) and spacecraft.
[0055] Embodiments of the devices and methods for purifying environments disclosed herein can be implemented and controlled either by the vehicles integrated control circuits, thereby allowing selective control of the device during any conceivable control mode, or their inputs and outputs, using either standard installed or available installed vehicle sensors, e.g., computer system control modules, air quality sensors, (including but not limited to temperature, humidity, particle, O2, CO2, and CO gas sensors), and the like. Or standalone control modes controlled by either semi-automatic (e.g., vehicle occupancy sensors, window position sensors), or completely manually by electric control circuits operated by standalone in cabin manually activated switches.
[0056] Embodiments of the devices and methods for purifying environments disclosed herein can use both integrated fans, of any type suitable for the designated install location and condition (axial, linear, AC/DC, PWM controlled, etc.). Either controlled by the vehicle's computer or any secondary control and input circuits. Or, in other embodiments, have no integrated fans. Whereby the unit is installed within a vehicle's modified or unmodified existing HVAC duct system (in dash, under floor, in ceiling, etc.) and uses the fans of the HVAC system to also move air through the AOP air purifying device to be treated and then dispersed into the cabin.
[0057] Any two or more embodiments described in this disclosure may be combined in any way with each other. Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0058] The purification devices and methods disclosed herein may be used for purifying a vehicle cabin using ultraviolet LEDs and catalytic target structures configured in an arrangement that generates advanced oxidation products that react with and neutralize compounds in the air and on surfaces in the vehicle cabin, including microbes, such as bacteria, viruses and mold, odor causing chemicals, and other organic and inorganic chemicals.
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[0060] In some embodiments, the device 100 may include a housing 120. In some embodiments, the housing 120 may have several surfaces, including a lower housing shell 121, an upper housing shell 122, a lower housing door 124, an LED housing bottom 126, and an LED housing top 128. It will be understood that the various components of the housing 120 may fit together in several ways. For example, in some embodiments the components of the housing 120 may be snap-fit together.
[0061] In some embodiments, the housing 120 may house one, some, or all of the components of the device 100 described herein. It will be understood that the components of the device 100 may fit into the housing 120 in a variety of ways. For example, and without being limiting, the components of the device 100 may be snap-fit into the housing 120. In some embodiments, the components of the device 100 may be fixed to the housing 120 by means of, for example, screws.
[0062] In some embodiments, the device 100 may include a circuit board 110. The circuit board 110 in some embodiments may operate as a control unit for the device 100. As shown in
[0063] It will be understood by those of ordinary skill in the art that multiple components of the device 100 may be powered by the circuit board 110 simultaneously. It will be further understood by those of ordinary skill in the art that the inputs 112 of the circuit board 110 may vary according to the needs of the device 100.
[0064] In some embodiments, the circuit board 110 may also control various aspects of the device 100. For example, the circuit board 110 may have control features that turn off the system 100 as a response to a high humidity environment or to high temperature. It will be understood that the circuit board 110 may control a variety of ambient conditions within the system 100 by means of controlling, for example, the plurality of fans 130 and/or the LED modules 140. In at least this way, it will be understood, the circuit board 110 may control ambient conditions such as temperature, humidity, noise level, and air quality in the device 100.
[0065] In some embodiments, the device 100 may include a fan series 130. As shown in
[0066] In some embodiments, as will be understood by those skilled in the art that the plurality of fans 132 may vary in number based on the design of the system 100. For example, in some embodiments, a greater number of fans 132 may be used for increased air flow and cooling through the device 100. It will be understood that the number of fans 132 may be constrained by the size of the device 100.
[0067] In some embodiments, the device 100 may include a plurality of light emitting diode (LED) modules 140 as shown in
[0068] In some embodiments, as shown in
[0069] In some embodiments, as shown in
[0070] In some embodiments, as shown in
[0071] It will be understood that the device 100 may use a variety of different wavelengths for its LED modules 140, and that the wavelengths may vary between modules 140. It will be understood that the use of different wavelengths of UV light by different LED modules 140 in the system 100 will lead to greater efficiencies of purification for the device 100.
[0072] In some embodiments, two LED modules 140 may have LEDs emitting a wavelength of 365 nm and a third LED module 140 may have LEDs emitting a wavelength of 275 or 265 nm. Considering
[0073] In some embodiments, the device 100 may include a series of photocatalyst filters 150. In some embodiments, the filters 150 may be ceramic. The filters 150 may have a “honeycomb” design with square holes 152 in the filter 150, as shown in
[0074] In some embodiments, the photocatalyst filters 150 may be composed of aluminum oxide, silicon dioxide, magnesium oxide, and titanium oxide. In some embodiments, the filters 150 may be 40-50% aluminum oxide, 35-45% silicon dioxide, 2-9% magnesium dioxide, and 10-15% titanium dioxide. It will be understood that the filters 150 may be composed of a variety of materials, however.
[0075] In some embodiments, the filters 150 may be free of chemicals and toxins, and the filters 150 may not rely on short-lasting filters (such as activated carbons). In some embodiments, the filters 150 may: have high removal efficiency for volatile organic compounds, be designed for stable immobilizing of titanium oxide, may be reusable by dipping in boiling water, may be free of toxic residue, and may be free of restrictive hazardous substances.
[0076] In some embodiments, the photocatalyst filters 150 may be a commercially available product, such as the T1 Photocatalyst Filter produced by Seoul Viosys Co., Ltd. However, it will be understood by those of ordinary skill in the art that there a variety of commercially available photocatalyst filters that may be used.
[0077] In some embodiments, the device 100 may include a plurality of reflectors 160. As shown in
[0078] In some embodiments, the reflectors 160 reflect ultraviolet light to assisted in purifying the environment and improving purification efficiencies. It will be further understood that the reflectors 160 may be configured in a variety of different geometries such that the reflectors 160 optimally distribute ultraviolet light throughout the device 100. The use of a plurality of reflectors 160 as shown in
[0079] In some embodiments, the reflective surface 162 receives ultraviolet light from the LED module 140. In some embodiments, the reflective surface 162 may be composed of a variety of materials, including but not limited to aluminum, aluminum foil, stainless steel, and polytetrafluoroethylene. It will be understood that the reflective surface 162 may be composed of a mixture of materials in some embodiments.
[0080] In some embodiments, the device 100 may include a catalytic target structure 180. In some embodiments, and as shown in
[0081] In some embodiments, the structure 180 is also a hydrophilic structure that absorbs water molecules. In some embodiments, as shown in
[0082] In some embodiments, the structure is approximately 50% active catalytic surface with the remaining area being open area, such as the holes 182, to allow the ultraviolet light to pass through the target structure 180. It will be understood that, depending on the requirements of the system 100, the target structure 180 can vary from 0% open area (holes 182) to 95% open area (holes 182).
[0083] In some embodiments, the LED modules 140 may be parallel to the structure 180 as shown in
[0084] In some embodiments, the catalytic target structure 180 may be composed of a plurality of compounds particularly at the surface of the catalytic target structure 110. Preferably the catalytic target structure 180 may be composed of five compounds: four metallic compounds and a hydrating agent. These compounds preferably include titanium dioxide (TiO2), copper metal (Cu), silver metal (Ag), Rhodium (Rh), and a hydrating agent (such as Silica Gel (tetraalkoxysilanes TMOS, tetramethoxysilane, tetraethoxysilane TEOS)). The hydrating agent may also comprise any suitable compound or combination of compounds that have an affinity to attract or absorb ambient water (i.e., a hydrophilic and hydrating agent).
[0085] Some embodiments may use super hydrophilic compounds integrated with TiO2. The catalytic target structure 180 may comprise a base material including a hydrophilic material, a catalytic material, and a ceramic matrix. The base material may be full of tiny channels and connected pores equating to a huge internal surface area, in excess of 750 m.sup.2 per gram. The higher the porosity of the base material, the more effective the hydraulic attraction (water absorption), and the more surface area available for photocatalytic reactions to occur.
[0086] The catalytic target structure 180 may be provided in several different forms configured, for example, to contain hydrophilic granules. The granules may have a diameter in the range of 0.05 mm to 2.5 mm, or a diameter that is greater than or equal to than 2.5 mm.
[0087] The hydrophilic material of the catalytic target structure 180 may be formulated to have the unique ability to absorb high quantities of water vapor (i.e. to be extremely hydrophilic). Notably, the hydrophilic material is formulated to also re-release the vast majority of this absorbed water back into the air. It is preferred that the hydrophilic material comprises anhydrous magnesium carbonate. Additionally, it is preferred that the magnesium carbonate is amorphous. In testing performed by the inventors, it was found that the magnesium carbonate can be formulated to re-release up to 95% of the absorbed water, in exemplary embodiments of the instant invention.
[0088] The catalytic material in the catalytic target structure 180 may play a key role in catalyzing the formation of advanced oxidation products within and at the surface of the structure. The catalytic material is preferably titanium dioxide. At least a portion of the titanium dioxide is in anatase crystal form. In exemplary embodiments, almost all of the titanium dioxide is in anatase crystal form, i.e. at least 90%, at least 95%, or at least 99% of the titanium dioxide is in anatase crystal form. In exemplary embodiments, at least a portion of the titanium dioxide is in the form of nanoparticles.
[0089] The ceramic matrix provides structural support, and allows for production of a more rigid final material. Preferably, the ceramic matrix comprises cerium oxide and aluminum oxide (Al.sub.2O.sub.3). The cerium oxide acts as a binder with the Al.sub.2O.sub.3. Additionally, the cerium oxide has inherent hydration properties, i.e. it is hydrophilic, and thus further enhances the effect of the MgCO.sub.3 described above. The cerium oxide also has inherent catalytic properties.
[0090] In addition, one or more known catalytic enhancers or dopants can optionally be added during the process of forming the wick structure, such that the catalytic enhancer(s) or dopant(s) are integrated into the final wick structure. Known catalytic enhancers and dopants appropriate for inclusion in the catalytic target structure 180 may include, but are not limited to, rhodium, silver, copper, zinc, platinum, nickel, erbium, yttrium, fluorine, sodium, ytterbium, boron, nitrogen, phosphorus, oxygen, thulium, silicon, niobium, sulfur, chromium, cobalt, vanadium, iron, manganese, tungsten, ruthenium, gold, palladium, cadmium, and bismuth, and combinations thereof.
[0091] The above-described device and method offers several distinct advantages. In some embodiments, the device incorporates a photocatalytic configuration which initiates a chemical reaction utilizing airborne oxygen and water producing reactive oxygen species including hydrogen peroxide, hydroxyls, hydroperoxyls, singlet oxygen and others as gases. With the exception of hydrogen peroxide these can be short lived compounds which chemically react with gases and particles, as well as surface contaminants.
[0092] In some embodiments, the device 100 may include sensors that receive inputs from the environment. These inputs may be used when needed to control the device 100 and subsequently improve the lifetime operation of the device 100 by optimizing the device's 100 functions to the environment.
[0093] In some embodiments, the device 100 has reflectors 150 that are positioned perpendicular to the air flow (see, e.g.,
[0094] In some embodiments, as shown in
[0095] As shown in
[0096] As shown in
[0097] As shown in
[0098] As shown in
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[0100] Step s2202 comprises supplying an air product.
[0101] Step s2204 comprises receiving the air product within a purification device.
[0102] Step s2206 comprises processing the air product within the purification device by means of a photocatalytic configuration which initiates a chemical reaction utilizing airborne oxygen and water producing a plurality of reactive oxygen species, wherein the reactive oxygen species chemically react with gases, particles, and surface contaminants within the vehicle cabin.
[0103] Step s2208 comprises outputting the processed air product into a vehicle cabin.
[0104] While the subject matter of this disclosure has been described and shown in considerable detail with reference to certain illustrative embodiments, including various combinations and sub-combinations of features, those skilled in the art will readily appreciate other embodiments and variations and modifications thereof as encompassed within the scope of the present disclosure. Moreover, the descriptions of such embodiments, combinations, and sub-combinations is not intended to convey that the disclosed subject matter requires features or combinations of features other than those expressly recited in the embodiments. Accordingly, the scope of this disclosure is intended to include all modifications and variations encompassed within the spirit and scope of the following appended embodiments.
[0105] Embodiments of the present invention have been fully described above with reference to the drawing figures. Although the invention has been described based upon these preferred embodiments, it would be apparent to those of skill in the art that certain modifications, variations, and alternative constructions could be made to the described embodiments within the spirit and scope of the invention.