ACI Manufacturing makes custom activated carbon air filters to capture odors, gases and VOCs (Volatile Organic Compounds). Sometimes activated carbon is used as a pre-filter to other materials that filter out pollutants like dust.
How Activated Carbon Air Filters Work
Activated carbon air filters adsorb the odors and gases. Adsorption means the molecules of the odors and gases will adhere to the surfaces in the many pores of the air filter. This is different from absorption. Absorption means the molecules are dispersed throughout the absorbing material, like a sponge soaking up water.
How Activated Carbon Filter Material is Made
The process starts with any raw material that contains a high degree of carbon. These materials may be peat, coal, coconut shells or wood. These materials undergo a thermal process to extract the pure carbon. This process also produces many microscopic pores in the carbon.
Gases or chemicals are then used to begin the oxidation process. This “activates” the carbon and makes it an excellent material for the filtering and adsorption of toxic chemicals, gases and odors from the air.
Now, the carbon can be ground down to different sizes for different uses. For air filter material, (aka media), the activated carbon is impregnated onto other filter materials or substrates. A thermal bonding process keeps the carbon from brushing off.
Airborne Chemicals in the Home
According to the EPA (Environmental Protection Agency), home sources of chemicals and VOCs include aerosol sprays, air fresheners, pesticides, paints, solvents and stored fuels. The irritating chemical compounds may include acrolein, benzene, toluene and xylene.
Many of these chemical compounds and more can be found in workplaces. Cigarette smoke is known to release all sorts of irritating chemical compounds into the air.
How We Manufacture Custom Activated Carbon Air Filters
We start with a large roll of activated carbon filter media. We cut it down to the correct size. From this point, the media is available as carbon pads. We also have the capability to frame the media in aluminum.
We manufacture all sorts of custom air filters for OEMs and commercial uses. We have metal fabrication and industrial sewing capabilities. Often, activated carbon filter media is combined with other types of filter media to produce a custom air filter.