An adsorbent material, and method for making same, is disclosed wherein an application is made on the adsorbent material of a polymer coating with surface porosity. The product adsorbent material retains it adsorptive properties, while the coating provides advantages such as reduced dusting. For par
An adsorbent material, and method for making same, is disclosed wherein an application is made on the adsorbent material of a polymer coating with surface porosity. The product adsorbent material retains it adsorptive properties, while the coating provides advantages such as reduced dusting. For particulate or pellet forms of adsorbents, a reduction in attrited dust is useful for improved performance in emission control systems. The coating may also be used to color the product.
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What is claimed is: 1. A coated adsorbent material having a polymer coating, said coating having a surface opening area of at least about 2 μm2 open area at the external surface per mm2 of coated surface. 2. The coated adsorbent material of claim 1, wherein said open area is in the form of
What is claimed is: 1. A coated adsorbent material having a polymer coating, said coating having a surface opening area of at least about 2 μm2 open area at the external surface per mm2 of coated surface. 2. The coated adsorbent material of claim 1, wherein said open area is in the form of microfissures, cracks, crevices, holes, or craters in said coating. 3. The coated adsorbent material of claim 1 wherein said adsorbent material is of a form selected from the group consisting of particulates, beads, granules, pellets, fibers, blocks, monoliths, honeycombs, fabrics, and sheets, and combinations thereof. 4. The coated adsorbent material of claim 1 wherein said polymer is selected from the group consisting of polyolefins, polyethylene, polypropylene, polyisobutylene, polystyrene, polyisoprene, polychloroprene, poly-4-methyl-1-pentene, polybutadiene, polybutene; polyacrylics, polyacrylates, polymethyl methacrylate, polybutylmethacrylate, polymethacrylates, polyacrylic acid, halogen-substituted alkanes, polytetrafluoroethylene, trifluoroethylene, vinyl fluoride, fluorvinylidene, fluorobutylene, and fluoropropylene, polyurethane, polyethylene terephthalate, styrene butadiene, modified polybutadiene, epoxies, modified alkyds, polyesters, starches, methyl cellulose, ethyl cellulose, carboxymethyl cellulose, polyvinyl acetate, cellulose acetate, cellulose nitrate, cellulose triacetate, cellulose acetate butyrate, cellulose acetate phthalate, cellulose propionate morpholinobutyrate, hydroxypropylmethyl cellulose, ethylene vinyl acetate, acrylic copolymers, polysulfones, polyether sulfones, polyethers, polyalkylene glycols, polyimines, polybutylene, polyvinyl ethers, polyvinyl esters, polyalkylsulfides, polyarylsulfides, lignosulfonates, polyacrylamide, cyanoacrylate, polyamides, polyimides, polysiloxanes, polymethacrylonitrile, polyacrylonitrile, polyvinylpyridine, polyvinyl acetate, polyvinylpyrrolidone, polyvinyl butyral, polyvinyl alcohol, polyvinyl chloride, polyvinyl formal, polyformaldehyde, polycarbonates, and polyvinylidene chloride. 5. The coated adsorbent material of claim 4 wherein said polymer is selected from the group consisting of polysiloxane, acrylic copolymer and polyethylene. 6. The coated adsorbent material of claim 1 wherein said adsorbent material is derived from a member of the group of carbon precursors consisting of coal, lignocellulosic materials, petroleum, resin, polymer, bone, and blood. 7. The coated adsorbent material of claim 6 wherein said lignocellulosic materials are selected from the group consisting of pulp, paper, residues from pulp production, wood chips, sawdust, wood flour, nut shell, kernel, and fruit pits. 8. The coated adsorbent material of claim 1 wherein said coating comprises an insoluble colorant selected from the group consisting of organic and inorganic compounds. 9. The coated adsorbent material of claim 8 wherein said insoluble colorant is selected from the group consisting of powders, dispersions, chromophores grafted to an insoluble solid additive, colorants immobilized in the polymer, and chromophores grafted to the polymer. 10. The coated adsorbent material of claim 9 wherein said insoluble colorant is an indicator compound. 11. The coated adsorbent material of claim 10 wherein said indicator compound is selected from the group consisting of compounds that gain color, change color, and lose color. 12. The coated adsorbent material of claim 1 where the form of said adsorbent material is selected from the group consisting of particulates, beads, pellets, fibers, blocks, monoliths, honeycombs, fabrics, and sheets, and combinations thereof. 13. The coated adsorbent material of claim 1 wherein said coating has been chosen that will form surface openings upon drying or heat treatment. 14. The coated adsorbent material of claim 1 wherein the elasticity of said coating was reduced in order to cause surface openings to form upon drying or heat treatment. 15. The coated adsorbent material of claim 1, wherein the glass transition temperature of said coating was increased in order to cause surface openings to form upon drying or heat treatment. 16. The coated adsorbent material of claim 1, wherein solubilizing, volatilizing, or sublimation additives were added to said coating to create surface openings upon washing, drying, or heat treatment. 17. The coated adsorbent material of claim 1, wherein solids were added to said coating which created surface openings at the coating-solid boundary. 18. A filter for removing contaminants, said filter comprising the coated adsorbent material of claim 1. 19. An emission control device comprising the coated adsorbent material of claim 1. 20. A method for creating an adsorbent material by coating adsorbent material with at least one film layer of polymer emulsion, wherein drying or heat treatment causes surface openings in the polymer coating of at least about 2 μm2 open area at the external surface per mm2 of coated surface. 21. The method of claim 20, wherein said surface openings are in the form of microfissures, cracks, crevices, holes, or craters in said coating. 22. The method of claim 20 wherein said adsorbent material is prepared by the steps of: (a) spraying polymer emulsion onto exposed surfaces of said adsorbent material, and (b) drying the coated adsorbent material. 23. The method of claim 22 comprising a further step of: (c) de-dusting the dry, coated adsorbent material by removing any residual dust therefrom. 24. The method of claim 20 wherein said polymer is selected from the group consisting of polyolefins, polyethylene, polypropylene, polyisobutylene, polystyrene, polyisoprene, polychloroprene, poly-4-methyl-1-pentene, polybutadiene, polybutene; polyacrylics, polyacrylates, polymethyl methacrylate, polybutylmethacrylate, polymethacrylates, polyacrylic acid, halogen-substituted alkanes, polytetrafluoroethylene, trifluoroethylene, vinyl fluoride, fluorvinylidene, fluorobutylene, and fluoropropylene, polyurethane, polyethylene terephthalate, styrene butadiene, modified polybutadiene, epoxies, modified alkyds, polyesters, starches, methyl cellulose, ethyl cellulose, carboxymethyl cellulose, polyvinyl acetate, cellulose acetate, cellulose nitrate, cellulose triacetate, cellulose acetate butyrate, cellulose acetate phthalate, cellulose propionate morpholinobutyrate, hydroxypropylmethyl cellulose, ethylene vinyl acetate, acrylic copolymers, polysulfones, polyether sulfones, polyethers, polyalkylene glycols, polyimines, polybutylene, polyvinyl ethers, polyvinyl esters, polyalkylsulfides, polyarylsulfides, lignosulfonates, polyacrylamide, cyanoacrylate, polyamides, polyimides, polysiloxanes, polymethacrylonitrile, polyacrylonitrile, polyvinylpyridine, polyvinyl acetate, polyvinylpyrrolidone, polyvinyl butyral, polyvinyl alcohol, polyvinyl chloride, polyvinyl formal, polyformaldehyde, polycarbonates, and polyvinylidene chloride. 25. The method of claim 24 wherein said polymer is selected from the group consisting of polysiloxane, acrylic copolymer and polyethylene. 26. The method of claim 20 wherein said adsorbent material is an active carbon material derived from a member of the group consisting of coal, lignocellulosic materials, petroleum, resin, polymer, bone, and blood. 27. The method of claim 26 wherein said lignocellulosic materials are selected from the group consisting of including pulp, paper, residues from pulp production, wood chips, sawdust, wood flour, nut shell, kernel, and fruit pits. 28. The method of claim 20 wherein said coating comprises an insoluble colorant selected from the group consisting of organic and inorganic compounds. 29. The method of claim 28 wherein said insoluble colorant is selected from the group consisting of powders, dispersions, chromophores grafted to an insoluble solid additive, colorants immobilized in the polymer, and chromophores grafted to the polymer. 30. The method of claim 29 wherein said insoluble colorant is an indicator compound. 31. The method of claim 30 wherein said indicator compound is selected from the group consisting of indicator compounds that gain color, change color, and lose color. 32. The method of claim 20 where the form of said adsorbent material is selected from the group consisting of particulates, beads, pellets, fibers, blocks, monoliths, honeycombs, fabrics, and sheets, and combinations thereof. 33. The method of claim 20 wherein said coating is chosen that will form said surface openings upon drying or heat treatment. 34. The method of claim 20, wherein said surface openings are created by rapidly drying said adsorbent material after coating. 35. The method of claim 20 wherein the elasticity of said coating is reduced in order to cause said surface openings to form upon drying or heat treatment. 36. The method of claim 20, wherein the glass transition temperature of said coating is increased in order to cause said surface openings to form upon drying or heat treatment. 37. The method of claim 20, wherein solubilizing, volatilizing, or sublimation additives are added to said coating to create said surface openings upon washing, drying, or heat treatment. 38. The method of claim 20, wherein volatilizing or sublimation additives are added to said adsorbent material prior to coating, and after coating said additives are flashed out of out of said adsorbent material to create said surface openings in said coating. 39. The method of claim 20, wherein solids are added to said coating which create said surface openings at the coating-solid interface. 40. The method of claim 20, wherein said surface openings are created by physical means that disrupt the coating. 41. The method of claim 20, wherein said surface openings are created by laser ablation, tumbling, or vibration. 42. The method of claim 20, wherein said adsorbent material is in a particulate or pellet form and is coated according to the steps of: (a) spraying an emulsion of the polymer onto exposed surfaces of said adsorbent material while it is in a state of turbulence at a processing temperature above ambient temperature; and (b) drying the coated adsorbent material at above ambient temperature. 43. The method of claim 42 further comprising an initial step of heating said adsorbent material at above ambient temperature. 44. The method of claim 42 wherein the processing temperature is maintained from 50째 F. (10째 C.) to 280째 F. (138째 C.) for from about 1 minute to about 12 hours. 45. The method of claim 44 wherein the processing temperature is maintained from about 70째 F. (21째 C.) to about 250째 C. (121째 C.) for from about 5 minutes to about 6 hours. 46. A method for capturing vapor from a fluid stream containing same by routing said stream through an adsorbent material having its surface coated with a continuous film of a polymer, said polymer film having surface openings of at least about 2 μm2 open area at the external surface per mm2 of coated surface. 47. A method for capturing gasoline vapor and combustion emission from a fluid stream containing same by routing said stream through a polymer-coated adsorbent material having surface openings of at least about 2 μm2 open area at the external surface per mm2 of coated surface.
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