ORGANIC POLLUTANT REMOVAL SYSTEM AND METHOD

Technical Field The present invention relates to the removal of organic pollutants from an enclosed environment and particularly from air within an enclosed environment such as a room, vehicle, aircraft, spacecraft, submarine, etc.

Background of the Invention Volatile organic compounds including low molecular weight gases, condensable vapors, environmental tobacco smoke, bio-aerosols, among others, including, but not limited to, 1 ,3-butadiene, formaldehyde, acetaldehyde, benzene, toluene, acetone, methyl-ethyl ketone, hydrogen sulfide, triethylamine, phthalates, mineral oils, volatile fire retardants, etc. and irritants such as pollens or fungus spores, which are commonly referred to as organic pollutants, often constitute both a comfort concern and health hazard in an enclosed environment. Conventionally active cleaning systems such as filters, thermal catalytic beds and others, remove these organic pollutants from the environment. These systems, however, are neither energy nor cost efficient due to the pressure drop across the system or the energy required for thermal oxidation, the post conditioning of the air to acceptable temperatures, and the limited life of the system.

Treatment of organic pollutants is particularly problematic in relatively small or confined spaces. For example, within an automobile, organic pollutants contribute to passenger discomfort, windshield fogging, and the "blue haze" film which builds on the interior windows and windshield. However, due to the automobile's size and geometry, the use of an active cleaning system is neither practical nor cost effective for the majority of automobiles in the "normal" price range; i.e. below about $15,000.

What is needed in the art is a system for efficiently and effectively removing organic pollutants from a closed environment.

Disclosure of the Invention The present invention discloses a method for removing organic pollutants from an enclosed environment, a system therefore, and a method for applying a photocatalytic semiconductor coating to a substrate. The coating method comprises: forming an admixture of a photocatalytic semiconductor, water, an anti-agglomerating agent, and a homogenizing agent; removing sufficient water from said admixture to form a gel; coating said cleaned substrate with the gel, cleaning the substrate to remove contaminants; and heating the coated substrate to a temperature sufficient to convert said photocatalytic semiconductor to its active form.

The system for removing organic pollutants from an enclosed environment comprises: a window or windshield having a Ti0 ₂ coating; a UV source oriented such that during operation said UV source illuminates said Ti0 ₂ coating; and a means for supplying water to said Ti0 ₂ coating. Essentially, UV source illuminates the Ti0 ₂ coating, activating the coating and causing the Ti0 ₂ to dissociate water on its surface to form hydroxyl radicals. The hydroxyl radicals then oxidize organic pollutants adsorbed on the Ti0 ₂ coating.

The foregoing and other features and advantages of the present invention will become clear from the following description and drawings.

Brief Description of the Drawings

Figure 1 is a cut-away, side view of one embodiment of the present invention where a Ti0 ₂ coating and a UV lamp are used in the removal of organic pollutants from the interior of an automobile.

Figure 2 is another embodiment of the present invention where organic pollutants in a room are oxidized by a UV illuminated Ti0 ₂ coating on a window in the room.

Best Mode for Carrying Out the Invention

The present invention comprises a method and system for removing organic pollutants from an enclosed environment such as a room or the interior of a vehicle, including an automobile, airplane, spacecraft, train, bus, food transportation system, etc. Essentially, the organic pollutants contact an illuminated photocatalytic semiconductor. Water molecules on the photocatalytic semiconductor surface dissociate to form hydroxyl radicals which oxidize the organic pollutants.

The photocatalytic semiconductor is a compound activated by light within its band width and capable of dissociating water molecules to form hydroxyl radicals which oxidize the organic pollutants. Some such photocatalytic semiconductors include metal oxides such as: tin dioxide (Sn0 ₂ ), titanium dioxide (Ti0 ₂ ), zinc oxide (ZnO), tungsten trioxide (W0 ₃ ), lead oxide (PbO), iron titanium trioxide (FeTi0 ₃ ), vanadium pentoxide (V ₂ 0 ₅ ), iron oxide (Fe ₂ 0 ₃ ), and others such as cadmium sulfide (CdS). Preferably the photocatalytic semiconductor has an optical absorption band close to visible light, is not readily poisoned by compounds in air such as organic pollutants, and does not itself readily oxidize or evaporate. One such photocatalytic semiconductor is Ti0 ₂ which is inexpensive, stable, environmentally sound, resistant to poisoning, and readily activated and regenerated by ultraviolet (UV) with wavelengths less than about 400 nanometers (nm).

Production of the organic pollutant removal system comprises forming a photocatalytic semiconductor suspension and coating a cleaned substrate therewith. The suspension can be the type utilized in a sol-gel process or any other suspension capable of coating the substrate to attain a

photocatalytic semiconductor coating having sufficient thickness to oxidize the organic pollutants, and a resistance to abrasion.

The sol-gel process comprises applying a colloidal sol to the substrate such as fused silica, the coating is then partially dewatered to form a gel which is sintered in a controlled heating process to convert the coating to a durable ceramic material.

For example, preparation of a colloidal sol can comprise forming an admixture of titanium tetra isopropoxide (TTIP), nitric acid, or other anti- agglomerating agent, isopropyl alcohol, or another homogenizing and reaction rate reducing agent, and water by adding TTIP to distilled water at a molar ratio of water to alkoxide in excess of the stoichiometric value of 4, preferably nearing 100. Sufficient acid to preferably attain a pH below about 4, with a pH of about 3 or less especially preferred and molar ratio of acid/TTIP of about 0.1 to about 0.6, is then added to the sol to prevent the titanium tetrahydroxide particulates from agglomerating and thereby precipitating from solution. Small quantities of isopropyl alcohol of at least about 2% by volume (based upon the total solution volume), with up to about 10% preferred, can then be added as a homogenizing agent and as a TTIP and water reaction rate reducing agent which slows down the agglomeration process. Then, while continuously stirring to disperse the particles and to protonate the titanium tetrahydroxide particles, the solution is heated, at below boiling, and typically about 60°C to about 90°C, for up to about 72 hours or more, with up to about 12 hours typically sufficient to form a well dispersed gel. The substrate, once cleaned, is then coated with the gel by dipping, spin-coating, painting, spraying, flow coating, or a similar coating technique.

Cleaning the substrate requires removal of substantially all of the contaminants thereon, i.e. greater than about 95% removal. Contaminant removal comprises washing the substrate with water and detergent, such as ALCONOX®, phosphate based detergent, produced by Alconox, Inc., New

York, New York, or other common detergent capable of removing oils, greases, fats, and soils. The substrate is then immersed in a strong acid solution, such as CHROMERGE™, a sulfochromic solution produced by Monostat Corporation, New York, New York, or another solution capable of removing fixed deposits. Typically, the substrate is immersed in the acid solution, which can be heated to facilitate the cleaning process, for a period sufficient to dissolve the fixed deposits, typically less than about 2 hours. The substrate is then rinsed with bidistilled water followed by acetone, and dried, preferably a vacuum oven to prevent new contamination. The photocatalytic semiconductor coating can be applied to a wide variety of substrates such as glass such as quartz, plastic, ceramics, and metals, among others. However, for use in a vehicle or room, it is preferable to coat a substrate which is transparent to visible light such as glass such as quartz or plastic, with substrates transparent to both visible and UV light especially preferred. Substrates transparent to both visible and UV light can serve a dual function; the substrate for the photocatalytic semiconductor and the windows, windshields, etc. for the vehicles. Such dual use both minimizes the "size" of the organic pollutant removal means and enables the use of natural, atmospheric, UV. Once coated, the substrate is heated to dewater the sol, to chemically and physically bond the coating to the substrate, and to form an adherent, substantially anatase ceramic, i.e. preferably greater than about 90% anatase with a coating comprising as little as 60% anatase being feasible but much less efficient. The coated substrate is heated to a temperature sufficient to convert the coating to anatase, at a sufficiently slow rate to prevent cracks and/or flaking of the coating due to out-gassing of the water vapor, alcohol, and other volatile compounds. Typically the Ti0 ₂ can be converted to anatase at a temperature of about 300°C to about 600°C, with about 300°C to about 500°C, and about 375°C to about 425°C especially preferred. Generally, heating the sol at a rate of less than about 10°C/min. is sufficient,

with a rate of less than about 5°C/min. preferred, and a rate up to about 3°C/min. especially preferred.

The desired thickness of the coating, which can be adjusted during the coating process, is a function of the coating location. For example, when applied to a windshield, the coating must be substantially clear such that a vehicle operator's vision is not impaired by the coating. Typically, a thickness up to about 1 micron (μ) is used on a window or windshield, with about 0.25μ to about 3.0μ acceptable. Coatings on substrates whose visible light transparency is not relevant, organic pollutant removal systems located in heating/ventilation ducts for example, can be up to or exceeding about 10μ, with about 2.0μ to about 5.0μ preferred. In such cases, the coating thickness is a factor of the oxidation rate and possible weight constraints.

Use of the coated substrate in the oxidation of organic pollutants comprises activating the photocatalytic semiconductor by illuminating it with light having a wavelength in the same band gap as the photocatalytic semiconductor. For example, illumination of the photocatalytic semiconductor can be accomplished via atmospheric UV, or the use of a UV source such as a lamp, laser, or similar device having a wavelength within the band gap of the photocatalytic semiconductor. Since UV below about 200 nanometers promotes the formation of ozone, for Ti0 ₂ , the UV wavelength of about 200 nm to about 400 nm, with about 220 nm to about 360 nm is preferred, and about 300 to about 360 nm is especially preferred, (see Figure 1) The utilization efficiency of the UV source can be improved via the employment of a reflective device which reflects stray UV back at the coating. Possible reflective devices include polished aluminum surfaces and any mirrored surfaces, among others.

Upon contact between the illuminated photocatalytic semiconductor coating and the organic pollutants, hydroxyl radicals, formed by the dissociation of water adsorbed on the photocatalytic semiconductor from the

organic pollutant stream or other source, oxidize the organic pollutants down to carbon dioxide, water, and minor amounts of byproducts.

Over time organic pollutants and products thereof can build up on the surface of the photocatalytic semiconductor thereby decreasing its efficiency. Regeneration thereof however, is readily accomplished by decreasing or ceasing contact with the organic pollutant while continuing to illuminate the photocatalytic semiconductor for a sufficient period to oxidize any residual organic pollutants thereon. Regeneration can also be accomplished by heating the photocatalytic semiconductor; i.e. to between about 100°C to about 500°C for a period of about 1.5 hours, and/or rinsing the photocatalytic semiconductor with a mild acid solution; i.e. a vinegar and water solution.

Figures 1 and 2, which are meant to be exemplary, not limiting, show two possible embodiments of the present invention. Figure 1 illustrates the use of the present invention in a car (9) where UV light from natural sources (11) and from a UV lamp (1 ) both directly and indirectly, via the use of a reflective surface (3), illuminate a Ti0 ₂ coating (7) located on the interior surface of the windshield (5). The illuminated Ti0 ₂ coating (7) oxidizes organic pollutants which have condensed on the windshield (5), such as phthalates, fire retardants and oils from the upholstery and dashboard, and hydrogen sulfide, methyl-ethyl ketone, 1 ,3-butadiene, toluene, and acetone from external sources drawn into the car through the ventilation system and/or windows.

In Figure 2, organic pollutants in a room (21) which have condensed on the interior surface of a window (23) are oxidized by a Ti0 ₂ coating (25) located thereon. UV from natural sources (31 ) and from a UV lamp (27) illuminate, and thereby activate, the Ti0 ₂ coating (25) via the assistance of a reflective surface (29) such that the Ti0 ₂ oxidizes the organic pollutants thereon.

Alternatively, organic pollutants can also be removed from enclosed environments such as within vehicles, aircraft, spacecraft, and submarines

using the ventilation systems thereof. For example, substrates, such as blades in squirrel blowers, within the ventilation systems can be coated with the photocatalytic semiconductor. The coating can then be illuminated by a UV source placed similarly located within that system. In such an embodiment, the blades would move the air through the blower, the coating on the blades would adsorb water and organic pollutants in the air and oxidize the organic pollutants with hydroxyl radicals formed by the dissociation of water molecules on the illuminated photocatalytic semiconductor coating. The following example demonstrates the present invention without limiting its broad scope.

Example The following example was used to coat glass with a 1 μ coating of Ti0 ₂ .

In a three neck distilling flask 275 cc of water was mixed with 4 cc of nitric acid. While vigorously stirring, a mix of 50 cc TTIP and 8 cc isopropyl alcohol was slowly added using a dropping funnel. With the assistance of a reflux condenser which captures and returns any water vapor generated, the resulting solution was then heated to 80°C for about 12 hours while continuing to stir to form a gel. The cooled gel was then sonicated for 1 hour.

Meanwhile, the substrate was washed with water and ALCONOX®, and then immersed in CHROMERGE™, sulfochromic solution for 2 hours at 60°C. The cleaned substrate was then rinsed with bidistilled water followed by acetone, and dried in vacuum oven for 1 hour.

The cleaned substrate was then coated with the gel via spin-coating and heated at a rate of 2°-3°C/min. to a temperature of 400°C for 1 hour in order to dewater the gel to a thin, translucent, adherent, anatase ceramic. The coating formed using the above technique was tested using tests similar to the standard military specification MIL-C-675C to determine the

durability. The coating passed both the adhesion test and the moderate abrasion test.

The advantages of the present invention include: the ability to use ambient UV to activate the photocatalytic semiconductor in the removal of organic pollutants from buildings and the interior of vehicles, the reduced energy use versus prior art filter systems such as carbon bed devices, the size and simplicity of the system, and the ability to use the windows/windshields of the buildings and vehicles as the photocatalytic semiconductor substrate. The coating of the present invention is sufficiently adherent to withstand normal contact (i.e. human contact) and sufficiently optically clear such that coating a windshield, for example, does not result in diminution of the optical visibility through the windshield; the coating is clear.

An additional advantage of the prevent invention is the reduction of harmful natural UV within the enclosed environment. Since the photocatalytic semiconductor coating absorbs the UV, the amount of UV in the enclosed environment is reduced. Consequently, in an automobile, for example, the rate of degradation of the upholstery, dash board, etc., is reduced.

We claim: