System and method for photocatalytic oxidation air filtration using a substrate with photocatalyst particles powder coated thereon

1. An air filtration system comprising:

a. a particulate filter operably coupled to a substrate;

b. substrate powder coated with a solvent-free and heat-cured binary photocatalyst-resin mixture comprised of about 60% to 85% by weight of only titanium dioxide and about 15% to 40% by weight of polymer resin, wherein the binary photocatalyst-resin mixture is electrically charged and sprayed onto the substrate, and the binary photocatalyst-resin mixture is cured by heating onto the substrate to form a photocatalyst powder coated-substrate; and

c. a UV light source for irradiating UV light on the photocatalyst powder-coated substrate to remove contaminants from the surface of the photocatalyst powder coated-substrate once the contaminants bind to the photocatalyst powder coated-substrate.

2. The air filtration system of claim 1 , wherein the substrate comprises aluminum.

3. The air filtration system of claim 2 , wherein the substrate is woven.

4. The air filtration system of claim 1 , wherein the titanium dioxide has an average particle size of about 134 μm on the substrate.

5. The air filtration system of claim 1 , wherein the polymer resin further comprises a terephthalate ester-based resin.

6. The air filtration system of claim 1 , further comprising a control panel that comprises an infrared motion detector and an air quality sensor.

7. The air filtration system of claim 1 , wherein the control panel further comprises a negative ion generator.

8. An air filtration system comprising:

a. an aluminum substrate powder coated with a solvent-free heat-cured binary photocatalyst-resin mixture consisting essentially of only titanium dioxide and a terephthalate ester-based resin;

b. wherein the binary photocatalyst-resin mixture is electrically charged and sprayed onto a substrate, and the binary photocatalyst-resin mixture is cured by heating onto the aluminum substrate to form a photocatalyst powder coated-substrate; and

c. a UV light source for irradiating UV light on the photocatalyst powder coated-substrate to remove contaminants from the surface of the photocatalyst powder coated-substrate once the contaminants react with the photocatalyst powder coated-substrate.

9. The air filtration system of claim 8 , further comprising a motor fan for propelling airflow.

10. The air filtration system of claim 9 , further comprising at least one reflector positioned adjacent the at least one UV light source for reflecting UV light toward the substrate.

11. The air filtration system of claim 10 , further comprising a particulate filter.

12. The air filtration system of claim 11 , wherein the photocatalyst-resin mixture comprises about 60% to 85% by weight of titanium dioxide and about 15% to 40% by weight of terephthalate ester-based resin.

13. An air filtration system comprising:

a. an aluminum substrate powder coated with a solvent-free heat-cured binary photocatalyst-resin mixture consisting essentially of only titanium dioxide and a terephthalate ester-based resin, wherein the binary photocatalyst-resin mixture is electrically charged and sprayed onto the aluminum substrate, and the binary photocatalyst-resin mixture is cured by heating onto the aluminum substrate to form a photocatalyst powder coated-substrate;

b. at least one UV light source for irradiating UV light on the photocatalyst powder coated-substrate; and

c. at least one reflector positioned adjacent the at least one UV light source for reflecting UV light toward the photocatalyst powder coated-substrate to remove contaminants from the surface of the photocatalyst powder coated-substrate once the contaminants bind to the surface of the photocatalyst powder coated-substrate.

14. The air filtration system of claim 13 , further including a pleated particulate filter.

15. The air filtration system of claim 13 , wherein the substrate has a structure selected from the group consisting of: a honeycomb, fins, a mesh, a fibrous structure, or a filamentous structure.

16. The air filtration system of claim 13 , wherein the titanium dioxide has an average particle size of about 134 μm on the substrate.

17. The air filtration system of claim 16 , wherein the photocatalyst-resin mixture consists essentially of about 60% to 85% by weight of titanium dioxide and about 15% to 40% by weight of terephthalate ester-based resin.