A PROCESS OF FORMING A GAS ADSORBANT MACROPOROUS MATERIAL

Abstract

Compositing a gas adsorbant, macroporous object includes the immersion of a macroporous substrate into a charge stabilized suspension of nanoparticles that has been adapted for electrostatic repulsion. In this regard, the macroporous substrate includes a multiplicity of pores and demonstrates a compatibility with an adsorbant additive while lacking a repellant reaction to the charge stabilized solution. The nanoparticles are then positioned onto different walls of the pores resulting in the decoration of the macroporous structure with high surface volume materials. Finally, the macroporous substrate is removed from the suspension and dried. Thereafter, a gas adsorbant additive is introduced onto both surface portions of the macroporous substrate and also to the different walls of the pores of the macroporous substrate.

Claims

1. A method of compositing a gas adsorbant, macroporous object comprising: immersing into a charge stabilized suspension of nanoparticles and adapted for electrostatic repulsion, a macroporous substrate comprising a multiplicity of pores and demonstrating a compatibility with an adsorbant additive and lacking a repellant reaction to the charge stabilized solution; positioning the nanoparticles onto to different walls of the pores so as to decorate the macroporous structure with high surface volume materials; removing the macroporous substrate from the suspension; drying the macroporous substrate; and introducing a gas adsorbant additive onto both surface portions of the macroporous substrate and also to the different walls of the pores of the macroporous substrate.

2. The method of claim 1, wherein the positioning includes introducing a de-stabilizer to the solution, the de-stabilizer promoting swelling of the macroporous substrate while repelling the nanoparticles onto to different walls of the pores so as to decorate the macroporous structure with high surface volume materials.

3. The method of claim 1, wherein the positioning includes freeze-drying the macroporous structure including the suspension causing a vaporization of the suspension leaving only the nanoparticles to fix to the different walls of the pores.

4. The method of claim 1, wherein the gas adsorbant additive is one of an amine monomer and an amine polymer.

5. The method of claim 1, wherein the nanoparticles comprise colloidal silica particles.

6. The method of claim 1, wherein the macroporous material comprises a silicone base.

7. The method of claim 2, wherein the additive destabilizer is a swelling solvent.

8. The method of claim 1, wherein the object is spherical in shape.

9. The method of claim 1, wherein the drying is a freeze-drying.

10. The method of claim 1, wherein the suspension has a pH greater than 7.0.

11. A method for enhancing gas adsorbant qualities of a gas adsorbant porous object comprising: precipitating a multiplicity of nanoparticles out of a suspension of the nanoparticles in a charge stabilized solution onto interior walls of pores of a gas adsorbant object; and, subsequently adding to the walls of the gas adsorbant object, a gas adsorbant solution.

12. The method of claim 11, wherein the nanoparticles comprise colloidal silica particles.

13. The method of claim 11, wherein the gas adsorbant solution is one of an amine monomer solution and an amine polymer solution.

14. The method of claim 11, wherein the object is spherical in shape.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0020] The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention. The embodiments illustrated herein are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:

[0021] FIG. 1 is a pictorial illustration of a process for compositing a gas adsorbant, macroporous object;

[0022] FIG. 2 is a schematic illustration of a macroporous structure decorated with nanoparticles and a gas adsorbant additive as a result of the compositing process of FIG. 1; and,

[0023] FIG. 3 is a flow chart illustrating a process for compositing a gas adsorbant, macroporous object.

DETAILED DESCRIPTION OF THE INVENTION

[0024] Embodiments of the invention provide for the composition of a gas adsorbant, macroporous object useful in adsorbing a gas adsorbant in a large-scale physisorption system. In accordance with an embodiment of the invention a macroporous object, such as a silicone sphere, which defines multiple different pores, can be pre-treated with an electrostatically neutral suspension of nanoparticles, such as silica. During pre-treatment, the nanoparticles are repelled onto the walls of each of the pores so as to enhance the surface area of the pores. In this regard, the nanoparticles may be repelled onto the walls of each of the pores by introducing an electrically charged destabilizer into the pores of the object, or by freeze drying the suspension leaving the nanoparticles to fall out onto the walls of the pores. Finally, a gas adsorbant additive such as an amine monomer or an amine polymer, fixes to the surface of the object including the nanoparticles of the pores in order to create a highly optimized gas adsorbant macroporous object suitable for use in a large-scale commercial gas adsorption system. In this regard, the fixing to the surface can include a chemical bonding of the additive to the surface, a physical impregnation of the surface with the additive, a grafting of the additive to the surface, or a chemical linking of the additive to the surface.

[0025] In further illustration, FIG. 1 pictorially shows an exemplary albeit non-limiting process for compositing a gas adsorbant, macroporous object. As shown in FIG. 1, a macroporous object 100 includes a surface 170 with a set of micrometer scale pores 110. As shown in the cut-away, detailed portion of FIG. 1, each of the pores 110 can be defined by pore walls 110A and a pore opening 110B. In a first step (A), a charge suspension of nanoparticles 130 in a charge stabilized suspension 120 can be introduced to the macroporous object 100, for example by immersing the macroporous object 100 into a container of the charge stabilized suspension 120. In doing so, the suspension 120 invades each interior portion of the pores 110 including the nanoparticles 130 suspended therein.

[0026] Subsequently, in step (B) a destabilizer 140 is added to the macroporous object 100 causing a repulsion of the nanoparticles 130 onto the walls 110A of the pores 110A. The repulsion shown in the cut-away detailed portion of FIG. 1 can be characterized as a precipitation of the nanoparticles 130 from the suspension 120 onto the pore walls 110A. As an alternative to the addition of the destabilizer, the macroporous object 100 can be subjected to freeze-drying so as to separate the nanoparticles 130 from surrounding solution in the suspension 120 so as to cause the nanoparticles 130 to fix to the pore walls 110A. Thereafter, in step (C) the macroporous object 100, now decorated with the nanoparticles 130particularly with respect to the pore walls 110A, is exposed to a gas adsorbant additive 150. Finally, in step (D) the macroporous object 100, is removed from the presence of the additive 150 and subjected to a drying process 160.

[0027] In further illustration of the structure of the composition created in the process of FIG. 1, FIG. 2 is a schematic illustration of a macroporous structure decorated with nanoparticles and a gas adsorbant additive. As shown in FIG. 2, a macroporous structure 210 is decorated with nanoparticles 230 in order to enhance a surface area of the structure 210 onto which a gas adsorbant additive 220 is affixed. Consequently, the total surface area of the macroporous structure 210 is enlarged to accommodate a greater volume of adsorbed gaseous molecules so as to optimize an adsorption capacity of the. macroporous structure 210.

[0028] In even yet further illustration of the process of FIG. 1 producing the object of FIG. 2, FIG. 3 is a flow chart illustrating a process for compositing a gas adsorbant, macroporous object. Beginning in block 310, a macroporous structure of a silicone base is immersed into a charge stabilized suspension adapted for electrostatic repulsion and including nanoparticles, for instance, colloidal silica particles. The macroporous structure necessarily must lack a repellant reaction to the charge stabilized solution. As well, preferably, the charged stabilized suspension has a pH greater than 7.0.

[0029] In block 320, a destablizer is added to the macroporous structure and can include, a swelling solvent, so as to cause swelling of the macroporous structure, while repelling the nanoparticles onto to different walls of the pores resulting in the decoration of the macroporous structure with high surface volume material. Thereafter, in block 330 the macroporous structure is removed from the presence of the suspension and allowed to dry. Then, in block 340 the macroporous structure is immersed into an adsorbant additive. In this regard, the adsorbant additive can include an amine monomer or an amine polymer. Finally, in block 350, the macroporous structure is removed from the presence of the adsorbant additive and dried, for instance by operation of freeze-drying. The result is a gas adsorbant, macroporous object optimized for physisorption in a large-scale adsorption system.

[0030] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms include, includes, and/or including, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

[0031] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.

[0032] Having thus described the invention of the present application in detail and by reference to embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims as follows: