Three-dimensional air-adsorbing structure

Patent metadata

Field	Value
Publication number	US-9357289-B2
Application number	US-201514953321-A
Country	US
Kind code	B2
Filing date	Nov 28, 2015
Priority date	Mar 15, 2013
Publication date	May 31, 2016
Grant date	May 31, 2016

Abstract

A three-dimensional air-adsorbing structure. The structure has a three-dimensional, unitary, skeletal, porous scaffold, air-adsorbing material particles, and one or more hydrophobic binders that couple air-adsorbing material particles to each other to form agglomerates and couples particles and agglomerates to the scaffold. The structure has structure openings in the agglomerates and structure openings between agglomerates, such structure openings being open to the outside environment. The air-adsorbing material and the agglomerates are coupled to the scaffold by creating a water-based emulsion of air-adsorbing material, agglomerates of the material, and binder, and then impregnating the scaffold with this emulsion. The emulsion is dried at least in part at a temperature below the freezing point of the emulsion.

First claim

What is claimed is:

1. A three-dimensional air-adsorbing structure that has a volume, comprising:
(i) a three-dimensional, unitary, skeletal, porous scaffold;
(ii) air-adsorbing material particles; and
(iii) one or more hydrophobic binders that couple air-adsorbing material particles to each other to form agglomerates and couples particles and agglomerates to the scaffold;
wherein the structure has structure openings in the agglomerates and structure openings between agglomerates, such structure openings being open to the outside environment;
wherein the cumulative volume of the structure openings that have an apparent diameter larger than about 5 microns as measured by mercury porosimetry is greater than 0.2 ml/g of the air-adsorbing structure.

2. The three-dimensional air-adsorbing structure of claim 1 wherein the air-adsorbing material and the agglomerates are coupled to the scaffold by creating a water-based emulsion of air-adsorbing material, agglomerates of the material, and binder, and then impregnating the scaffold with this emulsion.

3. The three-dimensional air-adsorbing structure of claim 1 wherein the cumulative volume of the structure openings that have an apparent diameter larger than about 0.01 microns as measured by mercury porosimetry is greater than 0.6 ml/g of the air-adsorbing structure.

4. The three-dimensional air-adsorbing structure of claim 1 wherein the scaffold comprises an open-cell foam or an electrospun fibrous material.

5. The three-dimensional air-adsorbing structure of claim 4 wherein the open-cell foam has more than about 50 cells per inch and less than about 500 cells per inch.

6. The three-dimensional air-adsorbing structure of claim 1 wherein the scaffold openings make up at least about 90% of the volume of the scaffold.

7. The three-dimensional air-adsorbing structure of claim 1 wherein the scaffold comprises melamine foam or polyurethane foam.

8. The three-dimensional air-adsorbing structure of claim 1 wherein the air-adsorbing material comprises a silicon-based zeolite material.

9. The three-dimensional air-adsorbing structure of claim 1 where the acidity of the air-adsorbing structure, as determined by mixing one part by weight of the structure with five parts by weight of water and measuring the resulting pH, is such that the pH is greater than 4.

10. A three-dimensional air-adsorbing structure that has a volume, comprising:
(i) a three-dimensional, unitary, skeletal, porous scaffold having scaffold openings distributed within its volume, where the scaffold openings make up at least about 90% of the volume of the scaffold;
(ii) air-adsorbing material particles; and
(iii) one or more hydrophobic binders that couple air-adsorbing material particles to each other to form agglomerates and couples particles and agglomerates to the scaffold;
wherein the structure has structure openings in the agglomerates and structure openings between agglomerates, such structure openings being open to the outside environment;
wherein the structure further comprises closed volumes that are not open to the outside environment, and wherein the surface area of the structure openings plus the surface area of closed volumes, as measured by CT scanning with a resolution of at least 5 microns, is at least about 3 mm 2 /mm 3 of air-adsorbing structure.

11. The three-dimensional air-adsorbing structure of claim 10 wherein the cumulative volume of the structure openings that have an apparent diameter larger than about 5 microns as measured by mercury porosimetry is greater than 0.2 ml/g of the air-adsorbing structure.

12. The three-dimensional air-adsorbing structure of claim 11 wherein the cumulative volume of the structure openings that have an apparent diameter larger than about 0.01 microns as measured by mercury porosimetry is greater than 0.6 ml/g of the air-adsorbing structure.

13. The three-dimensional air-adsorbing structure of claim 10 wherein the volume of the structure openings is greater than the volume of the closed volumes.

14. The three-dimensional air-adsorbing structure of claim 10 wherein the scaffold comprises an open-cell foam or an electrospun fibrous material.

15. The three-dimensional air-adsorbing structure of claim 14 wherein the open-cell foam has more than about 50 cells per inch and less than about 500 cells per inch.

16. The three-dimensional air-adsorbing structure of claim 10 wherein the scaffold openings make up at least about 90% of the volume of the scaffold.

17. The three-dimensional air-adsorbing structure of claim 10 wherein the scaffold comprises melamine foam or polyurethane foam.

18. The three-dimensional air-adsorbing structure of claim 10 wherein the air-adsorbing material and the agglomerates are coupled to the scaffold by creating a water-based emulsion of air-adsorbing material, agglomerates of the material, and binder, and then impregnating the scaffold with this emulsion.

19. The three-dimensional air-adsorbing structure of claim 18 wherein the binder comprises an acrylic material or a polyurethane material or a polyacrylate material.

20. The three-dimensional air-adsorbing structure of claim 10 wherein the air-adsorbing material comprises a silicon-based zeolite material.

21. The three-dimensional air-adsorbing structure of claim 10 where the acidity of the air-adsorbing structure, as determined by mixing one part by weight of the structure with five parts by weight of water and measuring the resulting pH, is such that the pH is greater than 4.

Assignees

• Bose Corp

Inventors

• Lin Lifun

Classifications

• H04R1/288

  for loudspeaker transducers · CPC title

• H04R1/2826

  for loudspeaker transducers · CPC title

• C08J2375/04

  Polyurethanes · CPC title

• C08J2205/05

  Open cells, i.e. more than 50% of the pores are open · CPC title

• C08J2475/04

  Polyurethanes · CPC title