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WO2015195103A1 - Sorbant souple fortement chargé et procédé de fabrication - Google Patents

Sorbant souple fortement chargé et procédé de fabrication Download PDF

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Publication number
WO2015195103A1
WO2015195103A1 PCT/US2014/042801 US2014042801W WO2015195103A1 WO 2015195103 A1 WO2015195103 A1 WO 2015195103A1 US 2014042801 W US2014042801 W US 2014042801W WO 2015195103 A1 WO2015195103 A1 WO 2015195103A1
Authority
WO
WIPO (PCT)
Prior art keywords
sorbent
binder
micronized
film
layers
Prior art date
Application number
PCT/US2014/042801
Other languages
English (en)
Inventor
Stanislav E. Solovyov
Brian Kenneth BRADY
Original Assignee
Multisorb Technologies, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Multisorb Technologies, Inc. filed Critical Multisorb Technologies, Inc.
Priority to PCT/US2014/042801 priority Critical patent/WO2015195103A1/fr
Publication of WO2015195103A1 publication Critical patent/WO2015195103A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/22—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising organic material
    • B01J20/26—Synthetic macromolecular compounds
    • B01J20/261—Synthetic macromolecular compounds obtained by reactions only involving carbon to carbon unsaturated bonds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
    • B01J20/20—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising free carbon; comprising carbon obtained by carbonising processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/22—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising organic material
    • B01J20/26—Synthetic macromolecular compounds
    • B01J20/264—Synthetic macromolecular compounds derived from different types of monomers, e.g. linear or branched copolymers, block copolymers, graft copolymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
    • B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
    • B01J20/28026—Particles within, immobilised, dispersed, entrapped in or on a matrix, e.g. a resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
    • B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
    • B01J20/28033—Membrane, sheet, cloth, pad, lamellar or mat
    • B01J20/28035—Membrane, sheet, cloth, pad, lamellar or mat with more than one layer, e.g. laminates, separated sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/30—Processes for preparing, regenerating, or reactivating
    • B01J20/3035—Compressing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/30—Processes for preparing, regenerating, or reactivating
    • B01J20/3042—Use of binding agents; addition of materials ameliorating the mechanical properties of the produced sorbent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/14—Layered products comprising a layer of synthetic resin next to a particulate layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/22—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of both discrete and continuous layers
    • B32B37/223—One or more of the layers being plastic
    • B32B37/226—Laminating sheets, panels or inserts between two continuous plastic layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/02—Synthetic macromolecular particles
    • B32B2264/0214—Particles made of materials belonging to B32B27/00
    • B32B2264/0228—Vinyl resin particles, e.g. polyvinyl acetate, polyvinyl alcohol polymers or ethylene-vinyl acetate copolymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/102—Oxide or hydroxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/107—Ceramic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/107—Ceramic
    • B32B2264/108—Carbon, e.g. graphite particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/04—Polyethylene
    • B32B2323/046—LDPE, i.e. low density polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2331/00—Polyvinylesters
    • B32B2331/04—Polymers of vinyl acetate, e.g. PVA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2553/00—Packaging equipment or accessories not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details

Definitions

  • This disclosure relates generally to flexible sorbents and more particularly to a highly loaded non-dusting flexible sorbent in the form of a sheet or film, and a method for making the sorbent.
  • the packaging often does not completely seal the device from the environment and some kind of a breather filter is then used to control air exchange between the device and the environment as well as to relieve gas pressure buildup.
  • Even hermetically sealed devices with modified atmosphere within the enclosu re, where pressure buildup is not a concern, may still suffer from VOC vapors, e.g. generated due to friction and elevated temperature of lubricated internal moving parts.
  • Activated carbon has been extensively used in construction of filtering and absorbing media to control harmful moisture and VOCs in design of HDDs and other electronic devices. While effective in removing VOCs and moisture, AC presents its own problems such as fine carbon dust particles potentially present in a filter construction. These particles, either present initially or generated due to abrasion and rough handling of the filter assembly, can become easily detached from the filter structure and contaminate the device headspace. The presence of loose AC particles can lead to a premature failure of the device being protected.
  • Finely divided AC especially micronized carbon having a particle size in the range of 1 0 to 20 ⁇ is an effective sorbent.
  • finely divided silica gel and to a lesser extent molecular sieve can be employed.
  • Sintered AC suffers from brittleness and insufficient flexibility , thus preventing production of clean, dust-free, flexible filtering media due to difficulties in forming and cutting thin webs.
  • Highly porous AC webs made with thermoplastic binders like PTFE still suffer from significant dusting due to abrasion and dusting from cut edges.
  • thermoplastic binders to form a continuous resin phase in a non-porous AC composite is limited by the requirement to have a large absorbing capacity in a small volume available within a device. As a result, the AC content of such a composite has to be as high as 80-95 wt.% to be cost effective.
  • Conventional melt extrusion of thin sheets using such highly loaded composites is out of question due to a lack of a contiguous resin phase and resulting poor quality and breakdown of the extruded sheet.
  • Fusing AC-binder mixture to an unmodified substrate also requires the use of specially prepared porous webs (such as specialty paper and various non-wovens).
  • a flexible sorbent in the form of a non-dusting web comprises first and second relatively thin layers of a material that is permeable to the compound being absorbed and a relatively thicker layer of sorbent in a major proportion combined with a minor proportion of a binder that is the same as or compatible with the material forming the first and second layers.
  • the sorbent may be micronized activated carbon
  • the first and second layers may be ethylene vinyl acetate
  • thermoplastic binder is used and processed in such a way as to eliminate most of the cited disadvantages of AC composites based on them and produce flexible, essentially non-dusting, high volume fraction carbon webs, suitable for manufacturing breather filter media.
  • the prepared mixture of fine polymer powder such as EVA with micronized AC (supported and transported through the process with permanent or temporary plastic webs) is repeatedly compressed and heated above the binder melting temperature via passage through a series of preheated temperature-controlled compression rollers. The repeated compression, plastic deformation and melting of the binder causes the low volume fraction of a binder to essentially flow under stress, fill the gaps between AC particles and fuse them together.
  • the result of consecutive downgauging is a thin AC composite sheet that may exhibit at least one of increased apparent density, reduced dusting, significant remaining porosity, and improved flexibility and crack resistance.
  • the sheet After calendering, the sheet may be characterized by highly evolved and deformed plastic binder morphologies with significantly improved interparticle adhesion, however without fully encapsulating the AC particles.
  • the produced AC web can be further processed into individual filter pieces by cutting it with preheated dies. This technique allows one to smooth and seal the cut edges of the individual pieces and prevent subsequent dusting.
  • Low melting temperature polymeric webs can be used for supporting and encapsulating the AC composite during thermal processing.
  • the advantage of using polymeric films with melting temperatures comparable to the softening temperature of the thermoplastic binder is that the supporting webs will be partially molten during compression and heating cycle. If the supporting web is thin enough, its contiguous morphology may also be controllably disrupted, resulting in partial web breakdown and the increased porosity of the composite article surface, while retaining the flexibility and non- dusting property of the composite. Control of the solid encapsulating film surface disruption level may be achieved via one or more of applied pressure, roller temperature and dwell time.
  • Partial web surface breakdown causes formation of micron scale openings in the surface film, thus increasing its permeability and at the same time retaining encapsulation integrity to prevent dusting.
  • temporary su pporting webs that do not adhere to the AC composite during processing and that are eventually removed to leave a pure AC web as a product may be used.
  • This disclosure is not limited to production of encapsulated carbon webs: other active ingredients such as micronized silica gels, clays, molecular sieves and other natural and synthetic zeolites can be encapsulated via the described techniques.
  • the end product die cut strips and/or other shapes
  • Figure 1 is a section view of an absorber in accordance with an aspect of the invention.
  • Figu re 2 is a diagrammatic view of an apparatus for making an absorber in accordance with an embodiment of this disclosure.
  • Figure 1 A shows a mixture indicated generally at 1 02 of sorbent particles 1 04 and binder particles 1 06 before calendering. While the mixture is generally homogeneous, the particles are not bound together.
  • Figure I B shows the absorber 1 00 after calendering between two films 1 08 and 1 1 0 that are compatible with the binder. The mixture of sorbent particles 1 04 and binder particles 1 06 is bound together so that the sorbent particles cannot escape. This substantially reduces or eliminates dusting by the activated carbon particles by bonding and encapsulating the activated carbon/binder blend between solid film lalyers. The calendered layers are still flexible.
  • the starting powders need to be sufficiently fine.
  • the preferred particle sizes of AC powder are within 1 - 20 micron. That usually means having the source AC powder micronized via a suitable milling process.
  • the thermoplastic binder powder particle sizes may be comparable or smaller than that of AC powder. This may facilitate deformation and melting of the smaller binder particles trapped between larger AC particles and also increase the number of contact points.
  • binder resins such as EVA and phenolic resins can be obtained with mean particle sizes within 1 0-20 micron. This fact correspondingly puts a lower limit on the mean size of milled AC powder around the same numbers. Smaller ( ⁇ 5- 1 0 micron and nanoscale powders) sizes of active ingredients and binder particles can be used in the described process if a thinner finished web is desired (e.g. thinner than 50 micron).
  • Micronized activated carbon powder (1 - 20 micron mean particle size), which may be coconut shell carbon.
  • Flexible binder micronized EVA powder, phenolic resin powder, etc. (1 - 20 micron mean)
  • additives compatibilizers, surfactants, surface treatments and treatment agents for improving interparticle contact and reducing surface tension of molten binder particles. These additives can be incorporated into the binder resin at the manufacturing stage. Alternatively, the binder resin powder can be treated with one or more of the additives before mixing with the sorbent. Suitable compatiblizers include: functionalized organic oligomers terminated with functional groups such as carboxylic acids, esters, amines, and tackifiers, such as acrylics.
  • Encapsulating film 1 mil thick EVA film (0.5 - 2 mil range).
  • Temporary web supports flexible plastic films such as PET, nylon and others with melting temperature higher than the AC composite processing temperature.
  • Making the web flexible requires multiple contact points between the binder and the solid, high affinity between the carbon and the binder, and high flexibility of the binder itself at the conditions of use.
  • Some residual porosity of the finished web product is inevitable due to a high solids content and a low fraction of deformable binder which cannot fill all volume between AC particles.
  • this porosity contributes to the improved finished sheet flexibility and higher rates of absorption.
  • micronized carbon powder with micronized polymeric binder such as fine EVA powder
  • micronized polymeric binder such as fine EVA powder
  • batch mixing and calendering type processing can induce formation of multiple contact points between the binder and carbon particles, however, many carbon particles will be left uncontacted by the binder. The resulting web will still be dusty.
  • a system 200 for making an absorbent web 202 will be described.
  • the system 200 includes a supply of a first web 204, a supply of a second web 206, and a hopper/dispenser 208 containing a mixture 21 0 of the binder particles and carbon.
  • the dispenser 208 places the mixture on the second web 206, and the first web 204 is subsequently placed over the mixture 21 0 to sandwich the mixture 21 0 between the first and second webs 204, 206.
  • the system 200 compresses, densifies, and melts the binder particles between the first and second webs 204, 206.
  • the rollers 21 2 may cause deformation of the binder and allow it to flow into interparticle (i.e., between the activated carbon particles) spaces, which may result in partially encapsu lating the carbon particles.
  • the mixture compression and rearrangement during rolling and binder melting phase may also serve to collapse the pores and voids between the particles and increase the apparent specific gravity of the web.
  • the compressive force on each set of heated rollers 21 2 is preferably balanced to maximize interparticle space reduction but simultaneously to prevent collapse of carbon particle internal pores, so as to not affect its capacity as an adsorbent.
  • Subsequent cooling of the heated rolled web at cooling rollers 21 4 will solidify the developed morphology which may be characterized by one or more of the partial binder melt flowing into the interparticle spaces (deformed and starburst-like binder patterns with significantly reduced interparticle free volume), higher specific gravity of the web vs. cold pressed carbon-binder mixtures, and /or greatly reduced dusting due to inducing binder contact with majority of the carbon particles (which is impossible to achieve in cold pressing operations such as tableting).
  • small amounts of the sorbent/binder mixture may be placed in spaced apart locations between the sealing sheets prior to calendering. This will produce spaced apart sorbent regions on the sheet that can be cut into individual elements.
  • a pocketed calendering roller would be used to manufacture sorbents in this way. This would permit discrete products to be made without the need for cutting through the sorbent/binder blend and resealing the edges. The discrete products would already be sealed at their edges.
  • Another process implementation includes a batch mixing first step to combine the AC and binder powders and disperse the binder in a mixture.
  • the second step is the web forming step in which the powder mixture is placed between two webs.
  • the webs may be the webs 204, 206 described above, which will become part of the sorbent, as in Figure I B, or they may be non- sticking support webs arranged for subsequent removal. In the latter arrangement, only compressed mixture remains.
  • the mixture may be encapsulated in a sleeve type support. The web/mixture or sleeve/mixture is then drawn through a series of vertically arranged heated roller pairs 21 2 (top and bottom roller) with a preset gap between each pair.
  • Each pair of heated temperature-controlled rollers will have a reduced gap relative to the previous pair in order to build up the web morphology and downgauge the web thickness.
  • the roller temperature is to be set above the melting temperature of the binder resin.
  • the cooling rollers 21 4 can also be used in the end of the forming process.
  • the supporting web can be removed at a later stage or by the final user.
  • a blend of the activated carbon (such as that commercially available from Carbon Activated Corp.) with EVA powder (such as that commercially available as Equistar Microthene FE53200) was weighed in an 85 / 1 5 ratio of C/EVA (carbon/EVA) in a small lab mixer until well blended.
  • EVA powder such as that commercially available as Equistar Microthene FE53200
  • 5 grams of this blended powder was put onto a l mil thick EVA sheet that was on a Teflon sheet on the flat plate of a mold. This mold was 4 inches in diameter.
  • the second sheet of EVA was put over the powder that had been spread evenly over the bottom sheet.
  • a second sheet of Teflon sheet was put over the top and then the top circular part of the mold was put on top.
  • the assembly was put into a heated Carver Press that had been heated to 400T (204 ° C).
  • the force on the press was then slowly increased to 24,000 lbs. and held for 1 0 sec.
  • the force was removed, the mold removed from the press and the sample removed from the mold.
  • Other variations were done with 3.5-8.0 grams of material, temperatures were varied from 300T to 425T and the force was varied between about 20,000lbs. to 24,000lbs. (the maximu m of this particular press).
  • the surface modification binder resin additives for improving carbon particle encapsulation by the binder can also be used if the porosity of the resulting web is still high and the starburst-type binder dispersion pattern has not been obtained.
  • the final web can provide an adsorbing capacity equal to that of the pure carbon powder of the same volume, since nearly all binder powder in the web is distributed between the carbon particles without affecting their packing density.
  • Self-adhesive backing can be applied to one or both web surfaces to facilitate adhesion of die cut parts to the package interior if desired.

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  • Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dispersion Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Solid-Sorbent Or Filter-Aiding Compositions (AREA)

Abstract

Selon l'invention, un sorbant souple fortement chargé comprend une première et une seconde couche de copolymère d'éthylène-acétate de vinyle ou de film polyéthylène basse densité; et un mélange comprimé de sorbant micronisé et d'un liant micronisé de copolymère d'éthylène-acétate de vinyle (EVA) disposé entre la première et la seconde couche de film.
PCT/US2014/042801 2014-06-17 2014-06-17 Sorbant souple fortement chargé et procédé de fabrication WO2015195103A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2014/042801 WO2015195103A1 (fr) 2014-06-17 2014-06-17 Sorbant souple fortement chargé et procédé de fabrication

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2014/042801 WO2015195103A1 (fr) 2014-06-17 2014-06-17 Sorbant souple fortement chargé et procédé de fabrication

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WO2015195103A1 true WO2015195103A1 (fr) 2015-12-23

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
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