Antimicrobial Air Filter Fabrication Using a Continuous High-Throughput Aerosol-Based Process

Joon Sang Kang,Jeongan Choi,Hanna Kim,Gwi-Nam Bae,Sung Chul Seo,Hak Yi,Jae Hee Jung

doi:10.4209/aaqr.2015.10.0598

Abstract

ABSTRACTA continuous high-throughput aerosol-based method for fabrication of antimicrobial air filters using natural antimicrobial nanoparticles was developed. We used the nebulization and electrospray methods for deposition of nanosized antimicrobial substances on pristine filter media. The roll-to-roll process was introduced for high-throughput fabrication of antimicrobial filters, and electrospray generation and dispersion equipment were used for high performance. The present method covers a filter area of 4500 mm2 at one time with uniform deposition. The characteristics of the airborne particles generated by nebulization and the electrospray method were evaluated using a scanning mobility particle analyzer (SMPS) and scanning electron microscopy (SEM). Furthermore, filter performance, such as the pressure drop and antimicrobial efficiency, was examined. The pressure drop of the antimicrobial filter showed a general increasing trend with amount of deposited antimicrobial particles. When 2.64 and 3.52 µg mm–2 of antimicrobial particles were loaded on pristine filter media, the measured antimicrobial efficiency of the filter was over 99.5% based on a 24-h contact time. This study provides useful information for the development of a high-throughput production process for antimicrobial air filtration systems.

Highlights

Bioaerosols, such as airborne viruses, bacteria, fungi, and pollen, are widespread in the air, and can cause various adverse health effects when inhaled, such as infectious diseases and allergy (Bush and Portnoy, 2001; Douwes et al, 2003; Lee and Liao, 2014)
The roll-to-roll process was introduced for high-throughput fabrication of antimicrobial filters, and electrospray generation and dispersion equipment were used for high performance
The characteristics of the airborne particles generated by nebulization and the electrospray method were evaluated using a scanning mobility particle analyzer (SMPS) and scanning electron microscopy (SEM)

Summary

INTRODUCTION

Bioaerosols, such as airborne viruses, bacteria, fungi, and pollen, are widespread in the air, and can cause various adverse health effects when inhaled, such as infectious diseases and allergy (Bush and Portnoy, 2001; Douwes et al, 2003; Lee and Liao, 2014). Aerosol and Air Quality Research, 16: 2059–2066, 2016 deformation As their pore size is small, the filter pores can be blocked by deterioration during the liquid dip-coating process, which results in an increased pressure drop. To overcome the drawbacks outlined above, this study was performed to develop a fabrication method for aerosolbased HEPA antimicrobial filters with high throughput, enabling economically viable mass production. This technique uses nebulization and electrospray methods simultaneously to deposit antimicrobial particles on a large filter surface area to maintain the advantages and avoid the disadvantages of the electrospray method. After completion of mixing and dispersion, a roll-to-roll machine is used to move the filter at a constant speed (~2 mm s–1) for continuous high-throughput filter production

MATERIALS AND METHODS

Findings

CONCLUSIONS