System and method for photocatalytic oxidation air filtration using a substrate with photocatalyst particles powder coated thereon
The present invention relates to an air filtration system and a method for making a photocatalytic oxidation substrate by powder coating a photocatalyst onto a metal substrate.
1. A method for applying a photocatalyst onto a substrate useful in a photocatalytic oxidation air filtration system comprising the steps of:
a. mixing a metal oxide photocatalyst with a polymeric resin to form a photocatalyst-resin mixture comprised of about 70% by weight of titanium dioxide and about 30% by weight of polymeric resin;
b. electrically charging the photocatalyst-resin mixture;
c. spraying the photocatalyst-resin mixture onto the substrate to form a photocatalyst powder-coated substrate; and
d. heating the photocatalyst powder-coated substrate.
2. The method of claim 1 , wherein the photocatalytic oxidation air filtration system further comprises:
a. a particulate filter;
b. a motor fan for propelling airflow;
c. the photocatalyst powder-coated substrate; and
d. a UV light source for irradiating UV light on the photocatalyst powder-coated substrate.
3. The method of claim 2 , wherein the substrate is woven.
4. The method of claim 1 , wherein the photocatalytic oxidation air filtration system further comprises:
a. a particulate filter;
b. the photocatalyst powder-coated substrate;
c. at least one UV light source for irradiating UV light on the substrate; and
d. at least one reflector positioned adjacent the at least one UV light source for reflecting UV light toward the substrate.
5. The method of claim 4 , wherein the particulate filter is a MERV 8 or higher pleated filter.
6. The method of claim 1 , wherein the substrate has a structure selected from the group consisting of: a honeycomb, fins, a mesh, a fibrous structure, or a filamentous structure.
7. The method of claim 1 , wherein the titanium dioxide is P25 titanium dioxide having an average particle size of about 134 μm on the substrate.
8. The method of claim 1 , further comprising the step of heating the substrate for a time and at a temperature sufficient to cure the photocatalyst-resin mixture on the substrate.
9. The method of claim 1 , wherein the substrate comprises aluminum.
10. The method of claim 1 , wherein the polymer resin further comprises a terephthalate ester-based resin.