Adsorption element and methods
AssigneeDonaldson Company, Inc.
InventorsKevin John Seguin, Steven Alan Carter, Andrew James Dallas, Lefei Ding, Brian Nghia Hoang, Jon Dennis Joriman
Life of this patent
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Abstract
An adsorbent article having a base body or matrix onto which is applied an adsorptive coating. The body or matrix can be a honeycomb matrix or structure having a plurality of cells defining a plurality of passages extending through the body. The adsorptive coating comprises an adsorptive media, such as activated carbon or ion exchange resin, that is bound by a polymeric adhesive or resin. The adsorbent article has a minimal pressure loss therethrough.
Claims57
A method of filtering a contaminant from a gas phase, the method comprising:
- (a) installing a contaminant removal article in a pathway for a gas phase, the device comprising:
- (i) a body having a thickness of at least 1 cm;
- (ii) a plurality of passages extending through the body in a side-by-side array, the passages having a cross-sectional width of no more than about 5 mm, the passages baying an interior surface area and a coating substantially covering the passages within the body;
- (iii) the coating comprising a polymeric binder and an adsorbent particulate, the coating having a thickness of no more than about 0.5 mm;
- (iv) the article free of catalytic activity;
- (b) contacting an input gas stream with the article, the input gas stream containing at least about 1000 ppm of a contaminant;
- and
- (c) after contacting, obtaining an output gas stream, the output gas stream containing no more than 10% of the contaminant from the input gas stream.
A method of removing a contaminant from a gas phase, the method comprising:
- (a) installing a contaminant removal article in a pathway for a gas phase, the article comprising a body having a thickness of at least 1 cm, the body comprising a plurality of passages extending through the body in a side-by-side array, the passages having a cross-sectional width of no more than about 5 mm, the passages having an interior surface and a coating substantially covering the interior surface, the coating comprising a polymeric binder and an adsorptive particulate, the coating having a thickness of no more than 0.5 mm, and die article having only incidental catalytic properties;
- (b) contacting a gas-phase with the article, the gas-phase having contaminant present at a level of 50 ppm-volume to 2 ppb-volume;
- and
- (c) removing at least 99% of the contaminant from the gas-phase with a pressure drop of no greater than 1 inch water at an airflow filter face velocity of 0.5 m/s.
A contaminant adsorbing article, the article comprising:
- (a) a body having a thickness of at least 1 cm comprising a plurality of parallel passages extending therethrough in a side-by-side array, the passages having a cross-sectional width of no more than about 5 mm;
- and
- (b) a coating substantially covering the passages within the body, the coating comprising a polymeric binder and an adsorbent particulate, the thickness of the coating being no more than 0.5 mm;
- wherein the article is substantially free of any catalytic activity.
A system for removing a contaminant from a gas stream, the system comprising:
- (a) an adsorptive article comprising:
- (i) a body having a thickness of at least 1 cm and having a plurality of passages extending along the thickness, the passages having an interior surface and a cross-sectional width of no more than 5 mm;
- the passages defining an inlet of the article and an outlet;
- and
- (ii) a coating present on the interior surface of the passages, the coating comprising a polymeric binder and an adsorbent particulate and having a thickness less than 0.5 mm, the coating being substantially free of catalytic activity;
- and
- (b) a particulate filter in air flow communication with the inlet of the article.
An apparatus for removing a contaminant from an atmosphere in a semiconductor production locus, the apparatus comprising:
- (a) an adsorptive element comprising a body having a thickness of at least 1 cm and comprising a plurality of passages extending thererhrough in a side-by-side array the passages having a cross-sectional width no greater than about 5 mm, the element comprising a coating less than about 0.5 mm thick substantially covering the passages, the coating comprising a polymeric binder and an adsorptive particulate and having only incidental catalytic activity;
- (b) a housing having an inlet, an outlet, a receiving volume for the adsorptive element, each of the inlet and outlet in air flow communication with the passages of the adsorptive element;
- and
- (c) means to move the atmosphere through the element.
An air induction system in a vehicle engine, the induction system comprising:
- (a) a tubular member having an air intake and an opposite outflow directed to an engine intake, the tubular member comprising an installation locus;
- and
- (b) a contaminant adsorbing element comprising a body having a thickness of at least 1 cm and comprising a plurality of passages extending therethrough in a side-by-side array, the passages having a major width less than about 5 man and a coating substantially covering the passages, the coating comprising a polymeric binder and a carbon particulate, the coating having a thickness of no greater than about 0.5 mm, the article free of catalytic activity, the adsorbing element positioned within the installation locus.
A method of manufacturing an adsorptive coated article, the article comprising a body having a thickness of at least 1 cm and comprising a plurality of passages extending therethrough in a side-by-side array, the passages having a cross-sectional width of no more than about 5 mm, the method comprising:
- (a) forming a dispersion comprising a polymer composition and a particulate adsorbent;
- (b) contacting the passages with the dispersion to form a wet coating;
- and
- (c) removing the solvent from the wet coating leaving an active adsorbent layer;
- wherein the adsorbent layer is substantially free of catalytic activity.
A method of manufacturing an adsorptive coated article, the article comprising a body having a thickness of at least 1 cm and comprising a plurality of passages extending therethrough in a side-by-side array, the passages having a cross-sectional width no greater than about 5 mm, the method comprising:
- (a) forming a mixture comprising an adsorbent particulate and a polymeric adhesive, the polymeric adhesive present at a temperature above the melting point of the polymeric adhesive;
- (b) contacting the passages with the mixture to form a melt coating;
- and
- (c) cooling the melt coating to at least partially solidify the polymeric adhesive, leaving an active adsorbent layer.
Dependencies are inferred from the claim text.