# US 8,772,363 B2 · Carrier for fluid treatment and method of making the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,772,363 B2 - Document ID: US8772363B2 - Status: Granted - Kind: B2 - Application number: 12/193,998 - Filed: 2008-08-19 - Published: 2009-05-14 - Granted: 2014-07-08 - Earliest claimed: 2007-08-23 - Assignees: Nisshinbo Industries, Inc. - Applicants: Tsutomu Uehara - Inventors: Tsutomu Uehara - Web page: https://patentgrep.com/patent/US8772363B2 ## CPC - B29C 44/3461: {Making or treating expandable particles} - C02F 3/10: Packings; Fillings; Grids (packing elements in general B01J19/30, B01J19/32) - C08J 9/0061: {characterized by the use of several polymeric components} - C08J 2201/03: Extrusion of the foamable blend - C08J 2323/02: not modified by chemical after treatment - C08J 2401/00: Characterised by the use of cellulose, modified cellulose or cellulose derivatives - Y02W 10/10: Biological treatment of water, waste water, or sewage - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - C02F: TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE (separation in general B01D; special arrangements on waterborne vessels of installations for treating water, waste water or sewage, e.g. for producing fresh water, B63J; adding materials to water to prevent corrosion C23F; treating radioactively-contaminated liquids G21F9/04; regeneration of reactants for recirculation into processes, see the relevant places for the processes) - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) - Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT ## Abstract A foam containing 30 to 95% by weight of a polyolefin-based resin and 5 to 70% by weight of a hydrophilizing agent composed of a cellulose-based powder, the surface of the foam being in a melt fractured state. ## Claims ### Claim 1 A carrier for fluid treatment comprising: a foam containing 30 to 95% by weight of a polyolefin-based resin, and 5 to 70% by weight of a cellulose-based powdery hydrophilizing agent, the surface of the foam being in a melt fractured state having a specific surface area ratio represented by the following formula (1): B/A=1.5 to 4.0 (1), where A represents the apparent specific surface area of the foam, and B represents the specific surface area of the foam, wherein the hydrophilizing agent is exposed at or projecting from the surface of the foam, and; the polyolefin-based resin is a composition having a melt flow index of 5 to 25 g/10 min. ### Claim 2 A carrier for fluid treatment comprising: a foam containing 30 to 95% by weight of a polyolefin-based resin, 4 to 69% by weight of a cellulose-based powdery hydrophilizing agent, and 1 to 30% by weight of an inorganic powder, the surface of the foam being in a melt fractured state having a specific surface area ratio represented by the following formula (1): B/A=1.5 to 4.0 (1), where A represents the apparent specific surface area of the foam, and B represents the specific surface area of the foam, wherein the hydrophilizing agent is exposed at or projecting from the surface of the foam, and; the polyolefin-based resin is a composition having a melt flow index of 5 to 25 g/10 min. ### Claim 3 (depends on 1) The carrier for fluid treatment according to claim 1, wherein the polyolefin-based resin is polyethylene, a mixture of polyethylene and polypropylene, a mixture of polyethylene and ethylene-vinyl acetate copolymer, a mixture of polyethylene, polypropylene, and ethylene-vinyl acetate copolymer, a mixture of polyethylene, polypropylene, and polystyrene, or a mixture of polyethylene, polypropylene, polystyrene, and ethylene-vinyl acetate copolymer. ### Claim 4 (depends on 1) The carrier for fluid treatment according to claim 1, wherein the foam has an expansion ratio of 2 to 10, and an apparent specific gravity of 0.10 to 0.80 g/ml. ### Claim 5 A method of making a carrier for fluid treatment, comprising steps of: charging a foaming agent, and charging a primary blend, which has been prepared by kneading 30 to 95% by weight of a polyolefin-based resin and 5 to 70% by weight of a hydrophilizing agent composed of a cellulose-based powder, in a melt stirrer at a temperature not lower than the melting point of the polyolefin-based resin, followed by pulverization, or in a multiscrew extruder at a temperature not lower than the melting point of the polyolefin-based resin, followed by pelletization, into a single screw or multiscrew extruder, kneading them, extrusion-foaming the kneaded mass in water, and then cutting the foamed mass with an underwater pelletizer, or extrusion-foaming the kneaded mass in a vapor phase, and then hot cutting the foamed mass, to obtain a foam, the surface of the foam being in a melt fractured state having a specific surface area ratio represented by the following formula (1): B/A=1.5 to 4.0 (1), where A represents the apparent specific surface area of the foam, and B represents the specific surface area of the foam, wherein the hydrophilizing agent is exposed at or projecting from the surface of the foam, and; the polyolefin-based resin is a composition having a melt flow index of 5 to 25 g/10 min. ### Claim 6 A method of making a carrier for fluid treatment, comprising steps of: charging a foaming agent, and charging a primary blend, which has been prepared by kneading 30 to 95% by weight of a polyolefin-based resin, 4 to 69% by weight of a hydrophilizing agent composed of a cellulose-based powder, and 1 to 30% by weight of an inorganic powder in a melt stirrer at a temperature not lower than the melting point of the polyolefin-based resin, followed by pulverization, or in a multiscrew extruder at a temperature not lower than the melting point of the polyolefin-based resin, followed by pelletization, into a single screw or multiscrew extruder, kneading them, extrusion-foaming the kneaded mass in water, and then cutting the foamed mass with an underwater-pelletizer, or extrusion-foaming the kneaded mass in a vapor phase, and then hot cutting the foamed mass, to obtain a foam, the surface of the foam being in a melt fractured state having a specific surface area ratio represented by the following formula (1): B/A=1.5 to 4.0 (1), where A represents the apparent specific surface area of the foam, and B represents the specific surface area of the foam, wherein the hydrophilizing agent is exposed at or projecting from the surface of the foam, and; the polyolefin-based resin is a composition having a melt flow index of 5 to 25 g/10 min. ### Claim 7 A method of making a carrier for fluid treatment, comprising steps of: charging 30 to 95% by weight of a polyolefin-based resin, 5 to 70% by weight of a hydrophilizing agent composed of a cellulose-based powder, and a foaming agent, or optionally charging 30 to 95% by weight of a polyolefin-based resin, 4 to 69% by weight of a hydrophilizing agent composed of a cellulose-based powder, 1 to 30% by weight of an inorganic powder and a foaming agent, into a multiscrew extruder and kneading them at a temperature not lower than the melting point of the polyolefin-based resin, extrusion-foaming the kneaded mass in water, and then cutting the foamed mass with an underwater pelletizer, or extrusion-foaming the kneaded mass in a vapor phase, and then hot cutting the foamed mass, to obtain a foam, the surface of the foam being in a melt fractured state having a specific surface area ratio represented by the following formula (1): B/A=1.5 to 4.0 (1), where A represents the apparent specific surface area of the foam, and B represents the specific surface area of the foam, wherein the hydrophilizing agent is exposed at or projecting from the surface of the foam, and; the polyolefin-based resin is a composition having a melt flow index of 5 to 25 g/10 min. ### Claim 8 (depends on 5, 6, 7) The method of making a carrier for fluid treatment according to any one of claims 5 to 7, wherein the foaming agent is a chemical foaming agent or a combination of a chemical foaming agent and a self-supporting foaming agent. ### Claim 9 (depends on 5, 6, 7) The method of making the carrier for fluid treatment of any one of claims 5 to 7, wherein the nozzle temperature of the extruder is adjusted to a temperature in the range of 10° C. higher than the decomposition temperature or vaporization temperature of the foaming component contained in the foaming agent, to 60° C. higher than the melting point of the polyolefin-based resin, thereby bringing the surface of the foam to a melt fractured state, and exposing or projecting the hydrophilizing agent from the surface of the foam. ### Claim 10 (depends on 1) The carrier for fluid treatment according to claim 1, wherein the foam is produced by charging a polyolefin-based resin, a hydrophilizing agent composed of a cellulose-based powder, and a foaming agent into a multiscrew extruder and kneading them at a temperature not lower than the melting point of the polyolefin-based resin, said foaming agent is a chemical foaming agent or a combination of a chemical foaming agent and a self-supporting foaming agent, said melt fractured state of the surface of the foam is formed by an extruder where a nozzle temperature of the extruder is adjusted to a temperature in the range of 10° C. higher than the decomposition temperature or vaporization temperature of the foaming component contained in the foaming agent, to 60° C. higher than the melting point of the polyolefin-based resin, the hydrophilizing agent is exposed or projected from the surface of the foam, the kneaded mass is extrusion-formed in water, and the foamed mass is cut with an underwater pelletizer, or the kneaded mass is extrusion-foamed in a vapor phase, and the foamed mass is hot cut to obtain the foam. ### Claim 11 (depends on 2) The carrier for fluid treatment according to claim 2, wherein the foam is produced by charging a polyolefin-based resin, a hydrophilizing agent composed of a cellulose-based powder, a foaming agent, and an inorganic powder into a multiscrew extruder and kneading them at a temperature not lower than the melting point of the polyolefin-base resin, said foaming agent is a chemical foaming agent or a combination of a chemical foaming agent and a self-supporting foaming agent, said melt fractured state of the surface of the foam is formed by an extruder where a nozzle temperature of the extruder is adjusted to a temperature in the range of 10° C. higher than the decomposition temperature or vaporization temperature of the foaming component contained in the foaming agent, to 60° C. higher than the melting point of the polyolefin-based resin, the hydrophilizing agent is exposed or projected from the surface of the foam, the kneaded mass is extrusion-formed in water, and the foamed mass is cut with an underwater pelletizer, or the kneaded mass is extrusion-foamed in a vapor phase; and the foamed mass is hot cut to obtain the foam. ### Claim 12 (depends on 2) The carrier for fluid treatment according to claim 2, wherein the polyolefin-based resin is polyethylene, a mixture of polyethylene and polypropylene, a mixture of polyethylene and ethylene-vinyl acetate copolymer, a mixture of polyethylene, polypropylene, and ethylene-vinyl acetate copolymer, a mixture of polyethylene, polypropylene, and polystyrene, or a mixture of polyethylene, polypropylene, polystyrene, and ethylene-vinyl acetate copolymer. ### Claim 13 (depends on 2) The carrier for fluid treatment according to claim 2, wherein the foam has an expansion ratio of 2 to 10, and an apparent specific gravity of 0.10 to 0.80 g/ml. ### Claim 14 (depends on 1) The carrier for fluid treatment according to claim 1, wherein the foam is produced by charging a foaming agent, the foaming agent being a chemical foaming agent or a combination of a chemical foaming agent and a self-supporting foaming agent, and a primary blend, which has been prepared by kneading the polyolefin-based resin and the hydrophilizing agent composed of a cellulose-based powder in a melt stirrer at a temperature not lower than the melting point of the polyolefin-based resin, followed by pulverization, or by kneading the polyolefin-based resin and the hydrophilizing agent composed of a cellulose-based powder in a multiscrew extruder at a temperature not lower than the melting point of the polyolefin-based resin, followed by pelletization, into a single screw or multiscrew extruder, kneading them, extrusion-foaming the kneaded mass in water, and then cutting the foamed mass with an underwater pelletizer, or extrusion-foaming the kneaded mass in a vapor phase, and then hot cutting the foamed mass. ### Claim 15 (depends on 14) The carrier for fluid treatment according to claim 14, wherein the nozzle temperature of the extruder is adjusted to a temperature in the range of 10° C. higher than the decomposition temperature or vaporization temperature of the foaming component contained in the foaming agent, to 60° C. higher than the melting point of the polyolefin-based resin thereby bringing the surface of the foam to a melt fractured state, and exposing or projecting the hydrophilizing agent from the surface of the foam. ### Claim 16 (depends on 2) The carrier for fluid treatment according to claim 2, wherein the foam is produced by charging a foaming agent, the foaming agent being a chemical foaming agent or a combination of a chemical foaming agent and a self-supporting foaming agent, and a primary blend, which has been prepared by kneading the polyolefin-based resin, the hydrophilizing agent composed of a cellulose-based powder, and the inorganic powder in a melt stirrer at a temperature not lower than the melting point of the polyolefin-based resin, followed by pulverization, or by kneading the polyolefin-based resin, the hydrophilizing agent composed of a cellulose-based powder, and the inorganic powder in a multiscrew extruder at a temperature not lower than the melting point of the polyolefin-based resin, followed by pelletization, into a single screw or multiscrew extruder, kneading them, extrusion-foaming the kneaded mass in water, and then cutting the foamed mass with an underwater pelletizer, or extrusion-foaming the kneaded mass in a vapor phase, and then hot cutting the foamed mass. ### Claim 17 (depends on 16) The carrier for fluid treatment according to claim 16, wherein the nozzle temperature of the extruder is adjusted to a temperature in the range of 10° C. higher than the decomposition temperature or vaporization temperature of the foaming component contained in the foaming agent, to 60° C. higher than the melting point of the polyolefin-based resin thereby bringing the surface of the foam to a melt fractured state, and exposing or projecting the hydrophilizing agent from the surface of the foam. ### Claim 18 (depends on 10) The carrier for fluid treatment according to claim 10, wherein the nozzle temperature of the extruder is adjusted to a temperature between 160° C. and 200° C. ### Claim 19 (depends on 11) The carrier for fluid treatment according to claim 11, wherein the nozzle temperature of the extruder is adjusted to a temperature between 160° C. and 200° C. ### Claim 20 (depends on 14) The carrier for fluid treatment according to claim 14, wherein the nozzle temperature of the extruder is adjusted to a temperature between 160° C. and 200° C., thereby bringing the surface of the foam to a melt fractured state, and exposing or projecting the hydrophilizing agent from the surface of the foam. ### Claim 21 (depends on 16) The carrier for fluid treatment according to claim 16, wherein the nozzle temperature of the extruder is adjusted to a temperature between 160° C. and 200° C., thereby bringing the surface of the foam to a melt fractured state, and exposing or projecting the hydrophilizing agent from the surface of the foam.