PTFE and active particle compositions

Abstract

Tapes, expanded tapes, and methods of making the same. The tapes and expanded tapes include long strand PTFE fibrils, short strand PTFE fibrils, and an oriented network. The oriented network includes nodes. The nodes include active particles and short strand PTFE fibrils distributed among the active particles.

Description

Cross-references to related applications

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 599,181, filed November 15, 2023, which is incorporated herein by reference in its entirety. Background Technology

[0002] Catalysts and adsorbents (adsorbents and absorbents) can be used to remove unwanted chemicals from fluids (e.g., gases or liquids). For example, catalysts can be used to destroy ozone. Adsorbents can be used to separate or remove acidic molecules, basic molecules, ozone, or various other organic or inorganic compounds from fluids. When catalysts and adsorbents are in powder or particulate form, they can be difficult to handle. Therefore, catalysts and adsorbents are typically immobilized onto or within a support. Immobilizing a catalyst or absorbent onto a support makes it easier to handle; however, immobilizing a catalyst or absorbent onto a support may reduce the surface area on which the catalyst or absorbent can be used to remove unwanted chemicals from the fluid. Additionally, the physical and chemical properties of the support may affect the function of the catalyst or adsorbent (e.g., catalytic efficiency). Furthermore, the physical and chemical properties of the support may affect the final construction of products (e.g., filters) that incorporate catalyst or absorbent-functionalized supports. Ideally, the functionalized support for the catalyst or adsorbent has one or more of the following characteristics: ease of shape design; fixation of the catalyst or adsorbent in a certain structure to present a large surface area of ​​the catalyst or adsorbent; and resistance to mechanical and chemical degradation. Summary of the Invention

[0003] In one aspect, this disclosure describes a strip. The strip includes a machined matrix. The machined matrix has a machining direction. The machined matrix includes long strands of PTFE fibrils and nodes. The long strands of PTFE fibrils form an orientation network. The orientation network includes long strands of PTFE fibrils. The long strands of PTFE fibrils define a longitudinal direction. Nodes are distributed in the orientation network. Nodes include active particles and short strands of PTFE fibrils distributed within the active particles.

[0004] In another aspect, this disclosure describes an expandable tape. The expandable tape comprises an expandable matrix. The expandable matrix has an expansion direction. The expandable matrix comprises long strands of PTFE fibrils and nodes. The long strands of PTFE fibrils form an orientation network. The orientation network comprises long strands of PTFE fibrils. The long strands of PTFE fibrils define a longitudinal direction. The nodes comprise active particles and short strands of PTFE distributed within the active particles.

[0005] In another aspect, this disclosure describes a method for forming a strip. This method may include machining a fiber matrix in a machining direction to form a machined matrix. The fiber matrix comprises long strands of PTFE fibrils, short strands of PTFE fibrils, and active particles.

[0006] In another aspect, this disclosure describes a method for forming expanded strip. Expanded strip can be formed by expanding a machining substrate.

[0007] The foregoing summary of this disclosure is not intended to describe every embodiment or implementation of each disclosure. The following description provides more specific examples of illustrative embodiments. Throughout this disclosure, guidance is provided by a list of examples that can be used in various combinations. In each case, the enumerated list is intended only as a representative group and should not be construed as an exclusive or exhaustive list. Therefore, the scope of this disclosure should not be limited to the specific illustrative structures described herein, but extends at least to the structures described in the language of the claims and their equivalents. Any element actively enumerated as an option in this specification may be expressly included in the claims or excluded from the claims in any desired combination. Although various theories and possible mechanisms may have been discussed herein, such discussion should in no way be used to limit the claimed subject matter. definition

[0008] Unless otherwise specified, all scientific and technical terms used herein have their common meaning in the art. The definitions provided herein are intended to aid in understanding certain terms that are frequently used herein and are not intended to limit the scope of this disclosure.

[0009] Terms such as “a / an” and “the” are not intended to refer to singular entities only, but rather to include general categories that can be described using specific examples.

[0010] The terms “one” and “the” are used interchangeably with the term “at least one”. The phrases “at least one of…” and “including at least one of…” preceding the list refer to any one item in the list and any combination of two or more items in the list.

[0011] As used herein, the term “or” is generally used in its usual sense, including “and / or”, unless the context clearly indicates otherwise. The term “and / or” means one or all of the listed elements or a combination of any two or more of the listed elements.

[0012] The terms “have / having,” “include / including,” and “comprise / comprising,” etc., are used in their open-ended sense and generally mean “including, but not limited to.” The phrase “consisting of” means including and limited to anything that follows the phrase “consisting of.” Therefore, the phrase “consisting of” indicates that the listed element is necessary or mandatory, and other elements may not be present. The phrase “substantially constitutes” means including any element listed after this phrase and is limited to other elements that do not interfere with or contribute to the activity or function specified for the listed element in this disclosure. Therefore, the phrase “substantially constitutes” indicates that the listed element is necessary or mandatory, but other elements are optional and may be present or may not be present, depending on whether they substantially affect the activity or function of the listed element. Any element or combination of elements listed in this specification in open-ended language (e.g., including and its derivatives) is considered to be additionally listed in closed language (e.g., consisting of and its derivatives) and partially closed language (e.g., substantially consisting of and its derivatives).

[0013] The terms "preferred" and "ideally" refer to embodiments of this disclosure that may provide certain benefits in certain circumstances. However, other embodiments may also be preferred in the same or other circumstances. Furthermore, the listing of one or more preferred embodiments does not imply that other embodiments are unavailable and is not intended to exclude other embodiments from the scope of this disclosure.

[0014] Furthermore, it is assumed herein that all figures are modified by the term "about" and, in some embodiments, preferably by the term "precisely." As used herein in conjunction with the quantity being measured, the term "about" refers to a variation in the measured quantity as would be expected by a person skilled in the art to perform the measurement and to operate with a level of care commensurate with the purpose of the measurement and the accuracy of the measuring equipment used. At least, and not in an attempt to limit the scope of the claims, each numerical parameter should be interpreted based on at least the number of significant digits reported and by applying general rounding methods.

[0015] A range of values ​​described by its endpoints includes all numbers falling within that range (for example, 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc., or 10 or less includes 10, 9.4, 7.6, 5, 4.3, 2.9, 1.62, 0.3, etc.). If the range of values ​​is "up to" or "at least" a specific value, then that value is included within that range.

[0016] While the numerical ranges and parameters illustrating the broad scope of the invention are approximate, the values ​​described in specific examples are reported as precisely as possible. However, all values ​​inherently contain ranges that are necessarily generated by the standard deviations found in their respective test measurements.

[0017] As used in this article, the term “room temperature” or “ambient temperature” refers to a temperature between 20 and 25 degrees Celsius.

[0018] The terms “in the range” or “within the scope” (and similar statements) include the endpoints of the stated range.

[0019] Throughout this specification, the terms "one aspect," "an aspect," "aspects," "one embodiment," "an embodiment," "some embodiments," "one or more embodiments," or "some embodiments," etc., refer to a specific feature, construction, composition, or characteristic described in connection with that embodiment or aspect, which is included in at least one embodiment or aspect of this disclosure. Therefore, the appearance of such phrases throughout this specification does not necessarily refer to the same embodiment or aspect of this disclosure. Furthermore, in one or more embodiments or aspects, specific features, constructions, compositions, or characteristics can be combined in any suitable manner.

[0020] When used in the context of a composition or hydrated solid being disposed on a surface or substrate, the term "on" includes both the composition or hydrated solid being disposed (e.g., applied to) the surface or substrate directly or indirectly (e.g., on a primer layer). Thus, for example, a composition or hydrated solid disposed on a pretreatment layer or primer layer covering a substrate constitutes a composition or hydrated solid disposed on a substrate.

[0021] For any method disclosed herein that includes discrete steps, these steps can be performed in any feasible order. Furthermore, any combination of two or more steps can be performed simultaneously, where appropriate.

[0022] All disclosures of patents, patent applications, publications, and materials available electronically in connection with this document are incorporated herein by reference in their entirety. In the event of any inconsistency between this disclosure and the disclosures of any document incorporated herein by reference, this disclosure shall prevail. The foregoing detailed descriptions and examples are provided for clarity only and should not be construed as unnecessarily limiting. The invention is not limited to the precise details shown and described, and variations that will be apparent to those skilled in the art will be included within the scope of the invention as defined by the claims.

[0023] All headings are for the reader's convenience and should not be used to limit the meaning of the text that follows the heading, unless otherwise specified. Attached Figure Description

[0024] Figure 1 These are schematic diagrams of illustrative strips at two magnifications, consistent with the embodiments disclosed herein.

[0025] Figure 2 This is a schematic diagram illustrating the relationship between the longitudinal direction defined by long strands of PTFE fibrils and the machining direction.

[0026] Figures 3A-3B This indicates that when the angle defined by the longitudinal direction and the machining direction is 0 degrees ( Figure 3A ) and greater than 0 degrees ( Figure 3B A schematic diagram showing the relationship between the longitudinal direction defined by the long strand of PTFE fibrils and the machining direction.

[0027] Figures 4A-4B This illustrates the embedded structure ( Figure 4A ) and aggregation structure ( Figure 4B A schematic diagram of ( ).

[0028] Figure 5 This is a schematic diagram of an illustrative expanded strip at two magnifications, consistent with the embodiments disclosed herein.

[0029] Figure 6 This is a schematic diagram illustrating the relationship between the longitudinal direction and the expansion direction defined by long strands of PTFE fibrils.

[0030] Figures 7A-7B This indicates that when the angle defined by the longitudinal direction and the expansion direction is 0 degrees ( Figure 7A ) and greater than 0 degrees ( Figure 7B A schematic diagram showing the relationship between the longitudinal direction, the machining direction, and the expansion direction when ( ).

[0031] Figures 8A-8B This outlines a first method for manufacturing strip consistent with embodiments disclosed herein. Figure 8A ) and the second method ( Figure 8B ) flowchart.

[0032] Figure 9 This is a flowchart outlining a method for manufacturing a fiber matrix consistent with embodiments disclosed herein.

[0033] Figure 10 This is a schematic diagram of an illustrative fiber matrix at two magnifications, consistent with the embodiments disclosed herein.

[0034] Figures 11A-11BThis outlines a first method for manufacturing expanded strip consistent with embodiments disclosed herein. Figure 11A ) and the second method ( Figure 11B ) flowchart.

[0035] Figure 12 It is a schematic diagram showing the dimensions of the machined substrate and the dimensions of the expanded substrate formed by expanding the machined substrate, as well as the relationship between these dimensions.

[0036] Figure 13 This is a scanning electron micrograph of an expanded tape containing 72.7 wt% CARULITE. The longitudinal direction 60°, machining direction 50°, and expansion direction 90° are shown.

[0037] Figure 14 This is a scanning electron micrograph of conventional expanded PTFE without active particles.

[0038] Figure 15 This is an image of a failed fiber matrix extrusion performed using a channel-type honeycomb mold.

[0039] Figure 16 This is an image of a strip formed by manually rolling a fiber matrix.

[0040] Figures 17A-17D It has 54.7 wt% active particles ( Figure 17A ), 65.5 wt-% active particles ( Figure 17B ), 72.7 wt-% active particles ( Figure 17C ) and 93.7 wt-% active particles ( Figure 17D Scanning electron micrograph of the fiber matrix.

[0041] Figure 18 This is a graph showing the ozone destruction rate of catalyst-coated flat plates and self-standing catalyst strips at 150,000 ppb ozone and a flow rate of 1.3 L / min.

[0042] Figure 19 This is a schematic diagram illustrating how the machined substrate is cut into segments at various angles for expansion in an example. The relationship between the machining direction and the expansion direction is also shown.

[0043] Figures 20A-20B The machining substrate is at various rates at 175 degrees Celsius ( Figure 20A ) and 200 degrees Celsius ( Figure 20B The stress / strain curve of expansion at the expansion temperature, where the cutting is parallel to the machining direction.

[0044] Figures 21A-21CThis causes the machining substrate to expand in the same direction as the machining direction at a rate of 10 mm / s. Figure 21A ), 1 mm / s ( Figure 21B ) and 0.1 mm / s ( Figure 21C Scanning electron micrograph of the expanded matrix formed by the expansion rate of the matrix.

[0045] Figure 22 It is a scanning electron micrograph of an expanded matrix formed by expanding a machining matrix in the same direction as the machining direction at an expansion rate of 0.1 mm / s and an expansion temperature of 175 degrees Celsius.

[0046] Figure 23 It is a stress / strain curve of the machining matrix expanding in an expansion direction intersecting the machining direction. The machining matrix expands at different rates and an expansion temperature of 200 degrees Celsius.

[0047] Figures 24A-24C It causes the machining substrate to expand at a rate of 10 mm / s in a direction intersecting the machining direction. Figure 24A ), 1 mm / s ( Figure 24B ) and 0.1 mm / s ( Figure 24C Scanning electron micrograph of the expanded matrix formed by the expansion rate of the matrix.

[0048] Figures 25A-25C It is a chain-like structure of the expanded matrix ( Figure 25A ), first aggregation structure ( Figure 25B ) and second aggregate structure ( Figure 25C Several scanning electron micrographs of the matrix. The expanded matrix contained 72.7 wt% CARULITE and expanded at 0.1 mm / s at 175°C.

[0049] Figure 26 It is a scanning electron micrograph of the machined matrix, in which the longitudinal direction of the long strands of PTFE fibrils is circled.

[0050] Figures 27A-27B It is a machining substrate (27A) and by making Figure 27A The expanded matrix formed by the expansion of the machining matrix ( Figure 27B Scanning electron micrographs of .

[0051] Figure 28 It is relative to the x-axis. Figure 14 and Figure 22 The angular distribution of the 38 fibrils was measured. Detailed Implementation

[0052] This disclosure describes tapes, expanded tapes, and methods for manufacturing tapes and expanded tapes. The tapes and expanded tapes contain active particles that can be used as adsorbents and / or catalysts. One or more of the tapes and / or expanded tapes can be configured into higher-level structures, such as honeycomb structures, cinnamon roll structures, pleated structures, or packed bed structures. The tapes, expanded tapes, and higher-level structures containing them can be used in fluid (e.g., gas and / or liquid) filters.

[0053] Figure 1 and Figure 5 Strip 10 is shown that is consistent with the embodiments disclosed herein. Figure 1 ) and expansion strip 100 ( Figure 5 A schematic diagram of a strip. Strip is a sheet of material with two opposing principal surfaces, each defining two principal dimensions (e.g., length and width). Strip also has a thickness that can be several orders of magnitude smaller than the largest principal dimension. The thickness of the strip can be substantially uniform. Expanded strip ( Figure 5 The 100 in this disclosure is generated by exposing the strip to one or more forces (e.g., pushing, pulling, stretching, etc.) (which increase one or two major dimensions without the addition of material). The expanded strip 100 disclosed herein... Figure 5 This includes expanded strips or machined matrices, or strips formed therefrom. The strips and expanded strips disclosed herein comprise PTFE fibrils and active particles 42. In some embodiments, the strips and expanded strips comprise short-strand PTFE fibrils 24 and long-strand PTFE fibrils 22.

[0054] Short-ply PTFE fibrils and long-ply PTFE fibrils are used relative to each other. As measured by dimensional analysis methods, short-ply PTFE fibrils have a shorter length than long-ply PTFE fibrils. As measured by dimensional analysis methods, multiple short-ply PTFE fibrils have an average length that is shorter than the average length of multiple long-ply PTFE fibrils. The length of the fibril is its maximum dimension.

[0055] PTFE fibrils (short and long strands) are formed from PTFE resin. PTFE resin may include PTFE polymers, oligomers, monomers, or any combination thereof. PTFE resin may be solid or liquid. PTFE resin comprises particles that contain PTFE polymers, oligomers, monomers, or any combination thereof. Each particle of PTFE resin has a resin particle size. The resin particle size is the maximum cross-sectional distance across the resin particle.

[0056] Short-strand PTFE fibrils are formed from short-strand PTFE resin. Short-strand PTFE resin can be obtained or formed as an emulsion having a dispersant (e.g., water and / or an organic solvent) and / or a surfactant. As used herein, using short-strand PTFE resin includes using the resin and / or using a short-strand PTFE emulsion having a dispersant and / or a surfactant. In some embodiments, the short-strand PTFE resin has an average resin particle size of 1 micrometer (µm) to 9 micrometers, such as 3 micrometers to 5 micrometers, as measured according to dimensional analysis testing methods. When short-strand PTFE resin is incorporated into the matrix, tape, and expanded tape of this disclosure (e.g., using the methods disclosed herein), the resin particles of the short-strand PTFE resin are elongated (e.g., fibrilized) to form short-strand PTFE fibrils.

[0057] Each short-strand PTFE fibril has a diameter and a length. The diameter, length, or both of each short-strand PTFE fibril can be varied throughout the manufacturing process of the strip or expanded strip. For example, the diameter, length, or both of the short-strand PTFE fibrils in the strip can differ from the diameter, length, or both of the short-strand PTFE fibrils in the expanded strip. For example, the length of the short-strand PTFE fibrils in the expanded matrix can be 101% to 200% of the length of the same fibril in the pre-expansion machined matrix. As described herein, the diameter, length, or both of the short-strand PTFE fibrils can be varied during the processing of the fiber matrix (described herein) into a machined matrix (in the strip disclosed herein) or into an expanded matrix (in the expanded strip disclosed herein). In embodiments, the short-strand PTFE fibrils in the strip and / or expanded strip have an average length of 30 micrometers or less (down to 1 micrometer), preferably 20 micrometers or less (down to 1 micrometer), 10 micrometers or less (down to 1 micrometer), or 5 micrometers or less (down to 1 micrometer), as measured by dimensional analysis testing methods. In some embodiments, the short-strand PTFE fibrils in the strip and / or expanded strip have an average length of 1 micrometer or greater, 5 micrometers or greater, 10 micrometers or greater, or 20 micrometers or greater, as measured by dimensional analysis testing methods. In some embodiments, the short-strand PTFE fibrils in the strip and / or expanded strip have an average diameter of 0.01 micrometers or greater, 0.05 micrometers or greater, 0.3 micrometers or greater, or 0.5 micrometers or greater, as measured by dimensional analysis testing methods. In some embodiments, the short-strand PTFE fibrils in the strip and / or expanded strip have an average diameter of 1 micrometer or less, 0.5 micrometers or less, or 0.3 micrometers or less, as measured by dimensional analysis testing methods.

[0058] Long-strand PTFE fibrils are formed from long-strand PTFE resin. In some embodiments, the long-strand PTFE resin has an average resin particle size of 10 micrometers or larger, 25 micrometers or larger, 50 micrometers or larger, 100 micrometers or larger, 200 micrometers or larger, 200 micrometers or larger, and up to 1000 micrometers, as measured by size analysis testing methods. When long-strand PTFE resin is incorporated into the matrix disclosed herein (e.g., using the methods disclosed herein), the particles of the long-strand PTFE resin are elongated (e.g., fibrillated) to form long-strand PTFE fibrils.

[0059] Each long-strand PTFE fibril has a diameter and a length. The diameter, length, or both of the long-strand PTFE fibrils can be varied throughout the manufacturing process of the strip and / or expanded strip. For example, the diameter, length, or both of the long-strand PTFE fibrils in the strip can differ from the diameter, length, or both of the long-strand PTFE fibrils in the expanded strip. As described herein, the diameter, length, or both of the long-strand PTFE fibrils can be varied during the processing of the fiber matrix (described herein) into a machined matrix (in the strip disclosed herein) or into an expanded matrix (in the expanded strip disclosed herein). For example, the length of the long-strand PTFE fibrils in the expanded matrix can be 101% to 200% of the length of the same fiber in the machined matrix before expansion. In embodiments, the long strands of PTFE fibrils in the strip and / or expanded strip have an average length of 40 micrometers (µm) or greater, 60 micrometers or greater, 80 micrometers or greater, 100 micrometers or greater, 200 micrometers or greater, 300 micrometers or greater, 400 micrometers or greater, 500 micrometers or greater, 1000 micrometers or greater, 2000 micrometers or greater, or 5000 micrometers or greater, as measured by dimensional analysis testing methods. In embodiments, the long strands of PTFE fibrils in the strip and / or expanded strip have an average length of 10000 micrometers or less, 5000 micrometers or less, 2000 micrometers or less, 1000 micrometers or less, 500 micrometers or less, 400 micrometers or less, 300 micrometers or less, 200 micrometers or less, 100 micrometers or less, 80 micrometers or less, or 60 micrometers or less, as measured by dimensional analysis testing methods. Not wanting to be bound by theory, they believed that long-stranded PTFE fibrils could impart a certain degree of mechanical robustness to the expanded matrix, thereby producing a membrane-like expanded matrix.

[0060] To avoid being bound by theory, it is assumed that short-strand PTFE resin particles and long-strand PTFE resin particles will not merge to form PTFE fibrils; that is, it is assumed that long-strand PTFE resin particles form long-strand PTFE fibrils, and short-strand PTFE resin particles form short-strand PTFE fibrils. Short-strand PTFE fibrils may be located within long-strand PTFE fibrils; however, they are considered as separate entities.

[0061] In some embodiments, according to the compositional analysis test method, the tape and / or expanded tape disclosed herein contain 0.01 wt% or more, 1 wt% or more, 5 wt% or more, 10 wt% or more, 15 wt% or more, 25 wt% or more, 45 wt% or more, 55 wt% or more, or 65 wt% or more PTFE fibrils (the sum of short-strand PTFE fibrils and long-strand PTFE fibrils) based on the total weight of the tape or expanded tape. In some embodiments, according to the compositional analysis test method, the tape and / or expanded tape disclosed herein contain 80 wt% or less, 65 wt% or less, 55 wt% or less, 45 wt% or less, 25 wt% or less, or 15 wt% or less, 10 wt% or less, 5 wt% or less, or 1 wt% or less PTFE fibrils based on the total weight of the tape or expanded tape.

[0062] The weight ratio of short-strand PTFE fibrils to long-strand PTFE fibrils in the tape and / or expanded tape can vary depending on the desired end application of the tape and / or expanded tape. The ratio and weight percentage of short-strand PTFE fibrils to long-strand PTFE fibrils in the tape and / or expanded tape are calculated based on the mass of the short-strand PTFE resin and the mass of the long-strand PTFE resin used to manufacture the fiber matrix forming the tape and expanded tape. In some embodiments, the weight ratio of short-strand PTFE fibrils to long-strand PTFE fibrils may be 50 to 10 parts short-strand PTFE fibrils per 1 part long-strand PTFE fibrils, for example, 30 to 10 parts short-strand PTFE fibrils per 1 part long-strand PTFE fibrils.

[0063] In other words, the total amount of PTFE in the tape and / or expanded tape (i.e., the sum of short-strand PTFE fibrils and long-strand PTFE fibrils) may contain different weight percentages of short-strand PTFE fibrils and long-strand PTFE fibrils. In some embodiments, according to the compositional analysis test method, the tape and / or expanded tape contains 0.1 wt% (wt-%) or more, 5 wt-% or more, 15 wt-% or more, 25 wt-% or more, 45 wt-% or more, 55 wt-% or more, or 65 wt-% or more of short-strand PTFE fibrils based on the total weight of the tape and / or expanded tape. In some embodiments, according to the compositional analysis test method, the tape and / or expanded tape comprises short-strand PTFE fibrils at 80 wt% or less, 65 wt% or less, 55 wt% or less, 45 wt% or less, 25 wt% or less, 15 wt% or less, or 5 wt% or less based on the total weight of the tape and / or expanded tape. In some embodiments, according to the compositional analysis test method, the tape and / or expanded tape comprises long-strand PTFE fibrils at 0.01 wt% or more, 1 wt% or more, 5 wt% or more, or 10 wt% or more based on the total weight of the tape and / or expanded tape. In some embodiments, according to the compositional analysis test method, the tape and / or expanded tape comprises long-strand PTFE fibrils at 15 wt% or less, 10 wt% or less, 5 wt% or less, or 1 wt% or less based on the total weight of the tape and / or expanded tape.

[0064] The average diameter, average length, and average resin particle size of PTFE fibrils can be determined using various methods, including microscopy, such as scanning electron microscopy (SEM; see Size Analysis Test Methods) or transmission electron microscopy (TEM).

[0065] Short-strand PTFE fibrils and long-strand PTFE fibrils can contain various forms of PTFE, such as C3-PTFE, C2-PTFE, C1-PTFE, or combinations thereof. C1-PTFE is a polytetrafluoroethylene polymer containing the repeating group –(CF2-C(F)(CF3))-. C2-PTFE is a polytetrafluoroethylene polymer containing the repeating group –(CF2-C(F)(CF2-CF3))-. C3-PTFE is a polytetrafluoroethylene polymer containing the repeating group –(CF2-C(F)(CF2-CF2-CF3))-. In some cases, it may be desirable to reduce the amount of fluorine in the final composition and / or reduce the amount of fluorine-carbon bonds used in the production of PTFE. In some embodiments, the PTFE resin used to form the PTFE fibrils, and therefore the PTFE fibrils in the matrix, can contain any combination of C1-short-strand PTFE, C2-short-strand PTFE, C3-short-strand PTFE, C1-long-strand PTFE, C2-long-strand PTFE, or C3-long-strand PTFE.

[0066] The tapes and expanded tapes disclosed herein contain active particles. Active particles are particles containing at least one component capable of participating in a chemical reaction (e.g., as a catalyst) and / or capable of acting as an adsorbent.

[0067] The physical and / or chemical functions of the particles constituting the active particles can vary based on the intended use of a given tape or expanded tape. Multiple active particles may comprise catalysts, adsorbents (such as adsorbents and / or absorbents), growth seeds, metal-organic frameworks, electroactive materials, or any combination thereof.

[0068] In some embodiments, the active particles comprise a catalyst. A "catalyst" is a chemical substance that alters the rate of one or more reactions without being consumed. The expanded matrix may contain any suitable catalyst, or a combination of catalysts, to facilitate any desired reaction. In some embodiments, the desired reaction may include nitrobenzene reduction, NO... x Reduction, hydrogenation, and any combination thereof. Catalysts capable of removing, preventing, and / or reducing the emission of harmful gases into the atmosphere may be of particular interest. For example, multiple active particles may contain components capable of removing one or more nitrogen oxides (NOx). x Catalysts that reduce and / or convert diatomic nitrogen compounds (e.g., nitric oxide, nitrogen dioxide, dinitrogen trioxide, and / or nitrates). The catalyst may be grafted onto a support such as an adsorbent (described elsewhere herein).

[0069] In some embodiments, the catalyst is capable of destroying ozone (O3); that is, the catalyst is capable of converting ozone (O3) into oxygen (O2) through bond rearrangement. Examples of catalysts capable of destroying ozone include silicates, such as iron silicates, iron-manganese silicates, zinc-iron silicates, and combinations thereof; transition metal oxides, such as zinc oxide, manganese oxide, copper oxide, cerium dioxide, and combinations thereof; reducing metals (i.e., zero-valent metals), including titanium, lead, iron, copper, zinc, chromium, cobalt, nickel, manganese, gold, silver, platinum, palladium, rhodium, tungsten, molybdenum, vanadium, zirconium, silicon, ruthenium, and combinations thereof; carbonates, such as barium carbonate, magnesium carbonate, calcium carbonate, strontium carbonate, and combinations thereof; zeolites; and any combination thereof. As used herein, the term "zeolite" refers to an aluminosilicate compound composed of aluminum, oxygen, silicon, and one or more counterions.

[0070] In some embodiments, the active particles comprise an ozone-destroying catalyst comprising manganese oxide (e.g., amorphous manganese oxide), copper oxide, or both. Amorphous materials have little to no crystallinity, as opposed to polycrystalline materials. Examples of ozone-destroying catalysts comprising amorphous manganese oxide are available from Carus LLC (Illinois) under the trade name CARULITE 400. In some embodiments, multiple active particles comprise an ozone-destroying catalyst comprising cerium dioxide. In some embodiments, the active particles comprise an ozone-destroying catalyst comprising manganese oxide, copper oxide, cerium dioxide, or any combination thereof.

[0071] In some embodiments, the active particles comprise an adsorbent. In some embodiments, the adsorbent is an adsorbent, absorbent, or both. Examples of adsorbents include cellulose, fumed silica, cotton, natural or synthetic sponges, clay, sodium polyacrylate, sodium alginate, gelatin, and wool.

[0072] In some embodiments, the active particles comprise an adsorbent, such as a physisorbent, a chemisorbent, a physisorbent-chemisorbent hybrid, or any combination thereof. In some embodiments, the adsorbent is a chemisorbent-physisorbent hybrid. Chemisorbent-physisorbent hybrids include grafted hybrids and impregnated hybrids. A grafted hybrid is a chemisorbent grafted onto a physisorbent or a physisorbent grafted onto a chemisorbent. An impregnated hybrid is a physisorbent impregnated with a chemisorbent or a chemisorbent impregnated with a physisorbent. A grafted hybrid is characterized by a covalently bonded chemisorbent to a physisorbent. An impregnated hybrid is characterized by the chemisorbent residing within the pores of the physisorbent. In an impregnated hybrid, the chemisorbent is retained within the pores by non-covalent interactions (e.g., van der Waals forces). In some embodiments, the grafted hybrid or impregnated hybrid comprises one or more of the following physisorbents: activated carbon, zeolite, silicate, metal-organic framework (MOF), or mesoporous transition metal oxide.

[0073] An adsorbent is a material capable of adsorbing chemicals; that is, the material can separate chemicals over at least a portion of its surface area. Physical adsorbents separate chemicals by forming weak interactions (e.g., van der Waals and / or electrostatic forces) between the physical adsorbent and the adsorbed chemical. Chemisorbents separate chemicals by forming ionic or covalent bonds between the chemisorbent and the adsorbed chemical.

[0074] The type of adsorbent depends on the intended use of the composition. It may contain adsorbents capable of adsorbing alkaline gases, acidic gases, gaseous organic compounds, gaseous inorganic compounds, or combinations thereof. Such adsorbents can be physical adsorbents, chemisorbents, or hybrids of physical and chemisorbents.

[0075] In some embodiments, the adsorbent is capable of adsorbing gaseous organic compounds. As used herein, the term "gaseous organic compound" refers to a compound that contains at least one carbon-hydrogen covalent bond and is in the gas phase, vapor phase, or both. Examples of gaseous organic compounds that adsorbents can adsorb include aromatic hydrocarbons such as toluene, benzene, xylene, and ethylbenzene; polycyclic aromatic hydrocarbons such as the 16 polycyclic aromatic hydrocarbons (PAHs) classified as priority pollutants by the U.S. Environmental Protection Agency in 2005 (i.e., naphthalene, acenaphthene, fluorene, phenanthrene, anthracene, fluoranthene, pyrene, benzo(a)anthene, chrysene, benzo(b)fluoranthene, benzo(k)fluoranthene, benzo(a)fluoranthene, dibenzo(a,h)anthene, benzo(ghi)perylene, and indo(1,2,3-cd)pyrene); n-alkanes such as methane, ethane, and n-propane, n-butane, n-pentane, and n-hexane; n-olefins such as methylene, ethylene, and propylene; various alcohols; aldehydes such as formaldehyde; siloxanes; and any combination thereof. Examples of adsorbents capable of adsorbing gaseous organic compounds include activated carbon, zeolites (e.g., zeolite X, zeolite A, zeolite Y, zeolite β and zeolite ZSM-5), silicates, metal-organic frameworks (MOFs), mesoporous transition metal oxides, and any combination thereof.

[0076] In some embodiments, the activated particles comprise an adsorbent capable of adsorbing gaseous inorganic compounds. As used herein, the term "gaseous inorganic compound" refers to a compound that does not have at least one carbon-hydrogen bond and is in the gas phase, vapor phase, or both. Examples of inorganic compounds that an adsorbent can adsorb include carbon dioxide; carbon monoxide; water; perfluorinated carbons such as tetrafluoromethane and hexafluoroethane; sulfur hexafluoride; ozone; and any combination thereof. Examples of adsorbents capable of adsorbing one or more inorganic compounds include activated carbon, zeolites (e.g., zeolite X, zeolite A, zeolite Y, zeolite β, and zeolite ZsM-5), silicates, metal-organic frameworks (MOFs), mesoporous transition metal oxides, and any combination thereof. Zeolite physical adsorbents are examples of adsorbents capable of adsorbing ozone.

[0077] In some embodiments, the active particles comprise an adsorbent capable of adsorbing acidic gases. An acidic gas is a gas that, when mixed with water at pH 7, acidifies the water, resulting in a solution with a pH below 7. The acidic gas can be a gaseous inorganic compound or a gaseous organic compound. Examples of acidic gases that the adsorbent can adsorb include sulfur dioxide, nitrogen dioxide, hydrogen sulfide, sulfur trioxide, nitric oxide, and any combination thereof. Examples of adsorbents capable of adsorbing acidic gases include chemisorbents comprising: Group I metal (Li, Na, K, Rb, Cs, Fr) carbonates; metal oxides; Group I metal (Li, Na, K, Rb, Cs, Fr) hydroxides; Group II metal (Be, Mg, Ca, Sr, Ba, Ra) hydroxides; Group II metal (Be, Mg, Ca, Sr, Ba, Ra) oxides; nitrogen-containing compounds such as amines (e.g., tetraethylenepentamine, ethylenediamine, and 3-aminopropyltriethoxysilane), imines (e.g., polyethyleneimine), and ammonium salts (e.g., ammonium persulfate); and any combination thereof. In some embodiments, the selected chemisorbent may be grafted onto or impregnated within a physical adsorbent, such as activated carbon; zeolite; silicate; or combinations thereof.

[0078] In some embodiments, the active particles comprise an adsorbent capable of adsorbing alkaline gases. An alkaline gas is a gas that, when mixed with water at pH 7, alkalizes the water, resulting in a solution with a pH higher than 7. Alkaline gases can be gaseous inorganic compounds or gaseous organic compounds. Examples of alkaline gases that the adsorbent can adsorb include ammonia and nitrogen trifluoride. Examples of adsorbents capable of adsorbing alkaline gases include physical adsorbents such as activated carbon, zeolites, silicates, and any combinations thereof. Further examples of adsorbents capable of adsorbing alkaline gases include chemisorbents having a carboxylic acid (COOH) functional group. Examples of chemisorbent compounds having a carboxylic acid functional group include citric acid, terephthalic acid, trimesic acid, tartaric acid, maleic acid, benzoic acid, oxalic acid, and any combinations thereof. Chemisorbents capable of adsorbing alkaline gases include inorganic acids such as boric acid, nitric acid, sulfuric acid, hydrochloric acid, and any combinations thereof. Such chemical adsorbents can be grafted onto or impregnated within physical adsorbents, such as activated carbon, zeolite, silicates, or combinations thereof.

[0079] In some embodiments, the active particles comprise a metal-organic framework (MOF). As used herein, the term "metal-organic framework (MOF)" refers to a compound comprising clusters of metal ions coordinated to an organic ligand, these metal ion clusters forming a two-dimensional or three-dimensional structure. MOFs can be adsorbents (e.g., physisorbents, chemisorbents, or both), catalysts, or both. Examples of MOF adsorbents include copper benzene-1,3,5-tricarboxylate (C... 18 H6Cu3O 12Also known as HKUST-1, Cu-BTC MOF or MOF-199; available from NOVOMOF in Zofinen, Aargau, Switzerland; 1,4-dicarboxylated zirconium MOF (Zr6O4(OH)4(dicarboxylate)6, also known as UiO-66; available from NOVOMOF in Switzerland); 4,4'-biphenyl dicarboxylate MOF (Zr6O4(OH)4(4,4'-biphenyldicarboxylic acid)6, also known as UiO-67; available from NOVOMOF in Switzerland); and any combination thereof.

[0080] In some embodiments, the active particles comprise seed crystals. The seed crystals can serve as nucleation sites for the synthesis of metal-organic frameworks (MOFs). In some such embodiments, the seed crystals comprise copper nitrate as seed crystals for copper-based MOFs such as copper phenyl-1,3,5-tricarboxylate. In some embodiments, the seed crystals comprise trimesic acid as seed crystals for copper-based MOFs such as copper phenyl-1,3,5-tricarboxylate. The seed crystals can react with one or more additional reagents before, during, or after matrix formation to form the MOF.

[0081] In some embodiments, the active particles comprise an electroactive material. In some embodiments, the electroactive material comprises lithium. In some embodiments, the electroactive material comprises lithium and one or more metals. Examples of cathode active electroactive materials include LiCoO2, LiFePO4, LiMn2O4, LiNiO2, and Li(Ni) x Mn y Co z )O2, and Li(Ni x Al y Co z O2, where x + y + z = 1. In some embodiments, the cathode electroactive material is LiCoO2. In some embodiments, the cathode active electroactive material is LiNiO2.

[0082] In some embodiments, the electroactive material is an anolyl active compound. Examples of anolyl electroactive materials include Co3O4, Cu2O, and Li4Ti5O. 12Lithium titanate, SiO2, Fe2O3, Al3Ni, CuCo2O4, PdNiBi, TiO, Sn4P3, NiO, their carbides, and any combination thereof. Examples of metallic anode materials include Li metal and alkaline earth metals such as Mg or Ca, as well as Si-based compounds. Si-based compounds can be in the form of Si fibers. Other examples of anolyl active materials include LiAl alloys, LiSi alloys, LiBi alloys, LiCd alloys, AlMg alloys, LiMg alloys, LiSn alloys, LiSb alloys, FeSn alloys, SnSb alloys, SnCu alloys, LiGe alloys, LiPb alloys, their oxides, their sulfides, their phosphides, their carbides, their nitrides, and any combination thereof. The molecular formula of an anolyl active material may not reflect an empirical formula. Other examples of anolyte materials include nitrides, oxides, and carbides of metallic or semi-metallic elements, including Li, Co, Pd, Pt, W, Mo, Zr, Fe, Al, Ni, Ti, Sn, and any combination thereof. In some embodiments, the anolyte material is silicon. In some embodiments, the active material is silicon, and the silicon has a silicon fiber structure. In some embodiments, the anolyte material is Li₄Ti₅O. 12 .

[0083] Each active particle has a particle size. Particle size is defined as the maximum cross-sectional distance across the particle. The average particle size of multiple active particles can vary based on the intended use of the strip or expanded strip and / or the chemical or physical properties of the active particles. Active particles can have an average particle size of 0.001 micrometers (µm) or larger, 0.01 micrometers or larger, 0.1 micrometers or larger, 1 micrometer or larger, 5 micrometers or larger, 10 micrometers or larger, or 100 micrometers or larger, as measured by dimensional analysis testing methods. Multiple active particles can have an average particle size of 500 micrometers or smaller, 100 micrometers or smaller, 10 micrometers or smaller, or 1 micrometer or smaller, as measured by dimensional analysis testing methods.

[0084] Generally, for particles containing catalysts, smaller particle sizes are often preferred because they increase surface area and the density of active sites available for catalytic reactions. Thus, in some embodiments where multiple active particles contain catalysts, the average particle size of the multiple active particles, as measured by size analysis methods, is 0.001 μm to 5 μm, 0.001 μm to 1 μm, or 0.001 μm to 0.1 μm. Generally, active particles containing adsorbents with small particle sizes are often preferred because smaller particle sizes allow for larger surface areas and greater diffusion. In some embodiments where multiple active particles contain adsorbents, the average particle size of the particles in the multiple active particles, as measured by size analysis methods, is 0.001 μm to 100 μm, 1 μm to 100 μm, or 0.001 μm to 0.1 μm.

[0085] The strips and expanded strips disclosed herein may have various amounts of active particles. The weight-% of active particles (or any individual component of active particles) in the strip or expanded strip can be calculated according to compositional analysis testing methods. The sum of the wt-% of each component of the active particles is considered as the wt-% of the active particles in the strip or expanded strip containing the active particle component. For example, if the active particles contain activated carbon, the amount of activated carbon is the wt-% of the active particles containing activated carbon. If the solid particles contain manganese oxide and copper oxide, the wt-% of the active particles containing manganese oxide and copper oxide is the sum of the wt-% of manganese oxide and the wt-% of copper oxide.

[0086] The total active particle content is the sum of the wt% of one or more components constituting a plurality of active particles in a strip or expanded strip. For example, in embodiments where the active particles comprise manganese oxide and copper oxide, the total active particle wt% in the strip or expanded strip is the sum of the wt% of manganese oxide and the wt% of copper oxide. In some embodiments, according to compositional analysis testing methods, the total active particle wt% in the strip or expanded strip disclosed herein is 50 wt% or more, 70 wt% or more, 80 wt% or more, or 90 wt% or more based on the weight of the strip or expanded strip. In some embodiments, according to compositional analysis testing methods, the total active particle wt% in the strip or expanded strip disclosed herein is 95 wt% or less, 90 wt% or less, 80 wt% or less, or 70 wt% or less based on the weight of the strip or expanded strip.

[0087] For some end uses of the tapes or expanded tapes disclosed herein (such as nanofiltration membranes), having low-activity particles or no active particles in the tapes or expanded tapes may be advantageous. In some embodiments, the total active particle wt% in the tapes or expanded tapes disclosed herein is 0 wt% or more, 0.001 wt% or more, 0.01 wt% or more, 0.1 wt% or more, 1 wt% or more, 2 wt% or more, 3 wt% or more, 4 wt% or more, 5 wt% or more, 10 wt% or more, or 15 wt% or more. In some embodiments, the total active particles in the strip or expanded strip disclosed herein are 20 wt% or less, 15 wt% or less, 10 wt% or less, 5 wt% or less, 4 wt% or less, 3 wt% or less, 2 wt% or less, 1 wt% or less, 0.1 wt% or less, 0.01 wt% or less, or 0.001 wt% or less.

[0088] In some embodiments, the strips and expanded strips disclosed herein comprise one or more additives. One or more additives may be part of a machined matrix or an expanded matrix. A machined matrix may comprise one or more additives. An expanded matrix may comprise one or more additives. Additives may function to enhance the retention of the particulate phase within the strip or expanded strip. Additives may function to improve the processability of the fibrous matrix. For example, additives may function to: improve the mechanical strength of the fibrous matrix before and / or after processing; increase the retention of solvent mixtures during processing of the fibrous matrix; improve the rheological properties and shape retention of the fibrous matrix during processing; or combinations thereof. Examples of additives include binders, such as ceramic binders and polymer binders. Examples of binders include ceramic binders, such as kaolinite, bentonite, silicon carbide, fumed silica, zeolite, and any combination thereof. In some embodiments, the binder is a polymer binder. Examples of polymer binders include polyamides (nylon); polyamide-imide (Torlon); polyacrylates; polyurethanes; styrene-butadiene rubber (SBR rubber); polyvinyl alcohol (PVA); polyvinyl chloride (PVC); silicones; polypropylene; polyethylene; aramid (Kevlar); polystyrene; polyethylene terephthalate (PET); polyvinylidene fluoride (PVDF); polyvinyl acetate; polyacrylonitrile; pre-formed PTFE fibers; or any combination thereof. Other examples of polymer binders include biopolymer binders such as gelatin, methylcellulose, ethylcellulose, pectin, polyethylene glycol, sodium alginate, agar, xanthan gum, and any combination thereof. Another type of additive that can be included in tapes or expanded tapes is inorganic fibers. Including inorganic fibers can enhance the chemical, electrical, thermal, or any combination thereof properties of tapes or expanded tapes. Examples of inorganic fibers include carbon fibers, activated carbon fibers, metal fibers (e.g., steel fibers, copper fibers, nickel fibers, etc.), ceramic fibers such as glass fibers, or any combination thereof.

[0089] In some embodiments, the strip or expanded strip contains 0.1 wt% or more, 1 wt% or more, 5 wt% or more, 10 wt% or more, or 15 wt% or more, 20 wt% or more, 25 wt% or more, 30 wt% or more, 35 wt% or more, 40 wt% or more, or 45 wt% or more total additives based on the total weight of the strip or expanded strip. In some embodiments, the strip or expanded strip contains 50 wt% or less, 45 wt% or less, 40 wt% or less, 35 wt% or less, 30 wt% or less, 25 wt% or less, 20 wt% or less, 15 wt% or less, 10 wt% or less, 5 wt% or less, or 1 wt% or less total additives based on the total weight of the strip or expanded strip. In some embodiments, the strip or expanded strip comprises 0.1 wt% to 10 wt%, 1 wt% to 10 wt%, or 5 wt% to 10 wt% of total additives based on the total weight of the strip or expanded strip. For example, in some embodiments where the strip or expanded strip comprises polymer binder additives, the strip or expanded strip may comprise 0.1 wt% to 10 wt%, 1 wt% to 10 wt%, or 5 wt% to 10 wt% of total additives based on the total weight of the strip or expanded strip. In some embodiments, the strip or expanded strip comprises 1 wt% to 50 wt%, 5 wt% to 50 wt%, 10 wt% to 50 wt%, 10 wt% to 40 wt%, 10 wt% to 30 wt%, 10 wt% to 20 wt%, or 20 wt% to 50 wt% of total additives based on the total weight of the strip or expanded strip. For example, in some embodiments where the strip or expanded strip contains inorganic fiber additives, the strip or expanded strip may contain 1 wt% to 50 wt%, 5 wt% to 50 wt%, 10 wt% to 50 wt%, 10 wt% to 40 wt%, 10 wt% to 30 wt%, 10 wt% to 20 wt%, or 20 wt% to 50 wt% of total additives based on the total weight of the strip or expanded strip.

[0090] In some embodiments, the machined matrix and / or expanded matrix comprises 0.1 wt% or more, 1 wt% or more, 5 wt% or more, 10 wt% or more, or 15 wt% or more, 20 wt% or more, 25 wt% or more, 30 wt% or more, 35 wt% or more, 40 wt% or more, or 45 wt% or more total additives based on the total weight of the machined matrix or expanded matrix. In some embodiments, the machined matrix and / or expanded matrix comprises 50 wt% or less, 45 wt% or less, 40 wt% or less, 35 wt% or less, 30 wt% or less, 25 wt% or less, 20 wt% or less, 15 wt% or less, 10 wt% or less, 5 wt% or less, or 1 wt% or less total additives based on the total weight of the machined matrix or expanded matrix. In some embodiments, the machined matrix and / or expanded matrix comprises 0.1 wt% to 10 wt%, 1 wt% to 10 wt%, or 5 wt% to 10 wt% of total additives based on the total weight of the machined matrix or expanded matrix. For example, in some embodiments where the machined matrix and / or expanded matrix comprises polymer binder additives, the machined matrix and / or expanded matrix may comprise 0.1 wt% to 10 wt%, 1 wt% to 10 wt%, or 5 wt% to 10 wt% of total additives based on the total weight of the machined matrix or expanded matrix. In some embodiments, the machined matrix and / or expanded matrix comprises 1 wt% to 50 wt%, 5 wt% to 50 wt%, 10 wt% to 50 wt%, 10 wt% to 40 wt%, 10 wt% to 30 wt%, 10 wt% to 20 wt%, or 20 wt% to 50 wt% of total additives based on the total weight of the machined matrix or expanded matrix. For example, in some embodiments where the machined matrix and / or expanded matrix comprises inorganic fiber additives, the machined matrix and / or expanded matrix may comprise 1 wt% to 50 wt%, 5 wt% to 50 wt%, 10 wt% to 50 wt%, 10 wt% to 40 wt%, 10 wt% to 30 wt%, 10 wt% to 20 wt%, or 20 wt% to 50 wt% of total additives based on the total weight of the machined matrix and / or expanded matrix.

[0091] return Figure 1The strip 10 comprises a machined matrix 20 or the machined matrix itself. The machined matrix has a machining direction. The machining direction is the direction in which a force is applied to the fiber matrix to generate the machined matrix. The machined matrix is ​​formed from the fiber matrix. The fiber matrix is ​​a stretchable material comprising short-strand PTFE fibrils, long-strand PTFE fibrils, and active particles. The machined matrix is ​​formed to form the strip by flattening and / or machining the fiber matrix. The machined matrix 20 comprises long-strand PTFE fibrils. The long-strand PTFE fibrils form an orientation network 30. The long-strand PTFE fibrils define a longitudinal direction 60. The orientation network 30 comprises at least a portion of the long-strand PTFE fibrils 22. Figure 26 It is a scanning electron micrograph of the machined matrix, showing the orientation of long strands of PTFE fibrils along the longitudinal direction.

[0092] Figure 1 , Figure 2 ,as well as Figures 3A-3B This illustrates the relationship between the orientation network 30, longitudinal direction 60, and machining direction 50 of the long-strand PTFE fibrils 22. The long-strand PTFE fibrils 22 define the longitudinal direction 60 ( Figure 1 The longitudinal direction 60° and the machining direction 50° define the angle α-1 (α1) (). Figures 3A-3B In some embodiments, α-1 can be 0 degrees or greater, 5 degrees or greater, 10 degrees or greater, 15 degrees or greater, 20 degrees or greater, 25 degrees or greater, 30 degrees or greater, 50 degrees or greater, or 75 degrees or greater. In some embodiments, α-1 can be 90 degrees or less, 75 degrees or less, 50 degrees or less, 30 degrees or less, 25 degrees or less, 20 degrees or less, 15 degrees or less, 10 degrees or less, or 5 degrees or less. In some embodiments, α-1 is 0 degrees. When α-1 is 0 degrees, the longitudinal direction 60 and the machining direction 50 are the same.

[0093] Figure 3A and Figure 3B A portion of the machined matrix 20 of the strip is shown (nodes not shown), where α-1 is 0 degrees ( Figure 3A ) and greater than 0 degrees ( Figure 3B The machined matrix 20 comprises an oriented network 30 of long-stranded PTFE fibrils 22. The long-stranded PTFE fibrils 22 define a longitudinal direction 60. The machined matrix has a machining direction 50. Figure 3A In this context, the longitudinal direction 60 and the machining direction 50 define α-1 at 0 degrees; that is, the longitudinal direction 60 and the machining direction 50 are identical. Figure 3B In the figure, the longitudinal direction 60 and the machining direction 50 define an α-1 greater than 0 degrees; that is, the longitudinal direction 60 and the machining direction 50 are not the same.

[0094] In some embodiments, the long-strand PTFE fibrils 22 are oriented substantially along the machining direction 50 of the machined matrix 20. In some such embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the long-strand PTFE fibrils are oriented at an α-1 degree of 20 degrees or less. In some embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the long-strand PTFE fibrils are oriented at an α-1 degree of 10 degrees or less. In some embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the long-strand PTFE fibrils are oriented at an α-1 degree of 5 degrees or less. In some embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the long-strand PTFE fibrils are oriented at an α-1 degree of 1 degree or less. The percentage of PTFE fibrils with a specific α-1 orientation can be calculated according to dimensional analysis testing methods.

[0095] return Figure 1 The machined matrix 20 includes nodes 40. Nodes 40 may be distributed within the orientation network 30. Nodes 40 may be uniformly distributed within the orientation network 30. Nodes 40 may also be non-uniformly distributed within the orientation network 30. For example, some portions of the orientation network 30 may have a higher concentration of nodes than other portions of the orientation network 30. Nodes 40 include short-stranded PTFE fibrils 24 and active particles 42. Active particles 42 may be distributed within the short-stranded PTFE fibrils 24. Some active particles 42 may be present in locations other than nodes 40 within the machined matrix 20.

[0096] Active particles 42 come into contact with and / or interact with long-stranded PTFE fibrils 22, short-stranded PTFE fibrils 24, or both. Figure 1 (See box 70). The active particles 42, which interact with other active particles 42, long strand PTFE fibrils 22, short strand PTFE fibrils 24, or combinations thereof, are fixed in the machined matrix in a physical and / or chemical manner. That is, the term "interaction" refers to physical forces (e.g., friction, gravity, compression, tension, electricity, magnetism, spring force, applied force, or normal force) or chemical forces (e.g., van der Waals forces, Debey forces, Keesom forces, London dispersion forces, dipole-dipole forces, or hydrogen bonds) between two or more active particles, between an active particle and a short strand PTFE fibrils (or multiple short strand PTFE fibrils), between an active particle and a long strand PTFE fibrils (or multiple long strand PTFE fibrils), or combinations thereof.

[0097] The active particles 42 may have one or more configurations in which they interact with short-stranded PTFE fibrils 24, long-stranded PTFE fibrils 22, or both. In some embodiments, at least a portion of the active particles and at least a portion of the PTFE fibrils adopt a chain structure, an aggregated structure, or both. In some embodiments, at least a portion of the active particles 42 forms a chain structure around one or more short-stranded PTFE fibrils 24, one or more long-stranded PTFE fibrils 22, or both; at least a portion of the active particles 42 forms an aggregated structure with one or more short-stranded PTFE fibrils 24, one or more long-stranded PTFE fibrils 22, or both; or a combination thereof.

[0098] The chain structure is a self-supporting network of active particles 42, which encapsulates at least a portion of one or more PTFE fibrils. Figure 4A This is a schematic diagram of the chain structure 80. In the chain structure, active particles 42 form a self-supporting network encapsulating at least a portion of one or more PTFE fibrils 22 / 24 (e.g., one or more long-stranded PTFE fibrils, one or more short-stranded PTFE fibrils, or both). While the self-supporting network may contact and / or interact with its at least partially encapsulated one or more PTFE fibrils, the primary interaction holding the chain structure together is the physical interaction between adjacent particles. It is not intended to be theoretically construed that if the at least partially encapsulated (or fully encapsulated) PTFE fibrils could be removed, the self-supporting network of the particles would remain undisturbed. The individual active particles involved in the chain structure may not be explicitly defined, as active particles may merge with each other to form a self-supporting network. Figure 25A This is a scanning electron micrograph showing the chain-like structure in the expanded matrix.

[0099] The self-supporting network of active particles can encapsulate a portion of a single PTFE fibril, a portion of multiple PTFE fibrils, the entire PTFE fibril, or multiple PTFE fibrils within a chain-like structure. The self-supporting network of active particles can encapsulate at least a portion of one or more short-stranded PTFE fibrils, at least a portion of one or more long-stranded PTFE fibrils, or both, within a chain-like structure. It is generally considered that the chain-like structure primarily consists of encapsulating at least a portion of one or more short-stranded PTFE fibrils.

[0100] To avoid being bound by theory, it is believed that the chain-like structure can reduce the likelihood of particles detaching from the machined matrix. Furthermore, it is thought that active particles with a chain-like structure can possess a large exposed surface area due to their spacing and the number of exposed surfaces. This property can enhance their activity as catalysts, adsorbents, seed crystals, MOFs, or any combination thereof by improving the accessibility of active sites and the diffusion rate through porous microstructures.

[0101] Agglomerated structures are active particles or aggregates of active particles held together at least partially by one or more PTFE fibrils (e.g., short-stranded or long-stranded PTFE fibrils). Unlike chain structures, the particles in aggregated structures do not form a self-supporting network that is typically independent of the PTFE fibrils. In aggregated structures, the active particles or aggregates are held in place by interaction with one or more PTFE fibrils (e.g., short-stranded PTFE fibrils) extending through (e.g., passing through) the particles or aggregates. An aggregate of active particles is a cluster of two or more active particles, each interacting with at least one other active particle in that cluster. In aggregated structures including aggregates, the aggregates are held together by both interactions between the active particles and interactions between the active particles and the PTFE fibrils. The active particles in aggregated structures are typically well-defined, unlike chain structures.

[0102] Figure 4B This is a schematic diagram of two aggregate structures 91 and 92 consistent with the embodiments disclosed herein. Aggregate structure 91 is a PTFE fibrils 22 / 24 (short-strand or long-strand PTFE fibrils) passing through (i.e. interacting with) a single active particle 42. Aggregate structure 92 is several PTFE fibrils 22 / 24 passing through (i.e. interacting with) an aggregate containing the active particle 42. Figure 25B and Figure 25C It is a scanning electron micrograph of the aggregated structure.

[0103] Without being bound by theory, it is believed that agglomeration structures can impart a degree of mechanical stability to at least a portion of the active particles, at least a portion of the PTFE fibrils (e.g., long-strand PTFE fibrils, short-strand PTFE fibrils, or both). For example, it is believed that agglomeration structures can at least partially inhibit the shrinkage (i.e., length reduction) of one or more PTFE fibrils involved in the agglomeration structure. Furthermore, it is believed that agglomeration structures reduce the likelihood of particle detachment due to the strength imparted by the PTFE fibrils interacting with the particles in the agglomeration structure.

[0104] This disclosure describes a strip having a first machining direction and a second machining direction. The strip comprises a machining matrix or a machining substrate. The machining matrix has long strands of PTFE fibrils and nodes. The long strands of PTFE fibrils form an orientation network. Nodes are distributed in the orientation network. Nodes typically have active particles and short strands of PTFE distributed within the active particles. In some embodiments, the orientation network comprises a first portion and a second portion of long strands of PTFE fibrils. The first portion of the long strands of PTFE fibrils defines a first longitudinal direction. The second portion of the long strands of PTFE fibrils defines a second longitudinal direction. In some embodiments, the first and second longitudinal directions are the same. In other embodiments, the first and second longitudinal directions are different.

[0105] The first longitudinal direction and the first machining direction of the machining substrate define a first angle α-10 (α-10) from 0 degrees to 90 degrees. 10 In some embodiments, the first portion of the long-strand PTFE fibrils is oriented substantially along a first machining direction of the machined matrix. In some such embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the first portion of the long-strand PTFE fibrils is oriented at an α-10 degree of 20 degrees or less. In some embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the first portion of the long-strand PTFE fibrils is oriented at an α-10 degree of 10 degrees or less. In some embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the first portion of the long-strand PTFE fibrils is oriented at an α-10 degree of 5 degrees or less. In some embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the first portion of the long-strand PTFE fibrils is oriented at an α-10 degree of 1 degree or less. The percentage of PTFE fibrils with a specific α-10 orientation can be calculated according to dimensional analysis testing methods.

[0106] The second longitudinal direction and the second machining direction of the machining matrix define a second angle α-11 (α-11) from 0 degrees to 90 degrees. 11In some embodiments, the second portion of the long-strand PTFE fibrils is oriented substantially along a second machining direction of the machined matrix. In some such embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the second portion of the long-strand PTFE fibrils is oriented at an α-11 degree of 20 degrees or less. In some embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the second portion of the long-strand PTFE fibrils is oriented at an α-11 degree of 10 degrees or less. In some embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the second portion of the long-strand PTFE fibrils is oriented at an α-11 degree of 5 degrees or less. In some embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the second portion of the long-strand PTFE fibrils is oriented at an α-11 degree of 1 degree or less. The percentage of PTFE fibrils with a specific α-11 orientation can be calculated according to dimensional analysis testing methods.

[0107] The first and second longitudinal directions define an angle α-12 from 0 to 90 degrees (α-12). 12 In some embodiments, α-12 can be 0 degrees or greater, 5 degrees or greater, 10 degrees or greater, 15 degrees or greater, 20 degrees or greater, 25 degrees or greater, 30 degrees or greater, 50 degrees or greater, or 75 degrees or greater. In some embodiments, α-12 can be 90 degrees or less, 75 degrees or less, 50 degrees or less, 30 degrees or less, 25 degrees or less, 20 degrees or less, 15 degrees or less, 10 degrees or less, or 5 degrees or less. In some embodiments, α-12 is 0 degrees. When α-12 is 0 degrees, the first longitudinal direction and the second longitudinal direction are the same.

[0108] The first machining direction and the second machining direction define an angle α-3 (α3). In some embodiments, α-3 can be 0 degrees or greater, 5 degrees or greater, 10 degrees or greater, 15 degrees or greater, 20 degrees or greater, 25 degrees or greater, 30 degrees or greater, 50 degrees or greater, or 75 degrees or greater. In some embodiments, α-1 can be 90 degrees or less, 75 degrees or less, 50 degrees or less, 30 degrees or less, 25 degrees or less, 20 degrees or less, 15 degrees or less, 10 degrees or less, or 5 degrees or less. In some embodiments, α-3 is 0 degrees. When α-3 is 0 degrees, the first machining direction and the second machining direction are the same. When α-3 is approximately 90 degrees, the machining substrate is cross-machined.

[0109] In some embodiments, a first portion of 50% or more of the long-strand PTFE fibrils is oriented at a first angle α-10 (α-10). In some embodiments, a second portion of 50% or more of the long-strand PTFE fibrils is oriented at a second angle α11 (α-11). In some embodiments, a first portion of 50% or more of the long-strand PTFE fibrils is oriented at a first angle α-10 (α10), and a second portion of 50% or more of the long-strand PTFE fibrils is oriented at a second angle α11 (α-11).

[0110] In some embodiments, the first longitudinal direction and the second longitudinal direction are the same. In some such embodiments, 50% or more, 60% or more, 70% or more, 80% or more, or 90% or more of the total long strand PTFE fibrils (the first and second portions of the long strand PTFE fibrils) define 30% to 70%, or 40% to 60% of the longitudinal direction of α-3. For example, if α-3 is 90 degrees, then 50% or more, 60% or more, 70% or more, 80% or more, or 90% or more of the total long strand PTFE fibrils may be oriented at an angle between 27 degrees and 63 degrees, or between 36 degrees and 54 degrees.

[0111] The strip disclosed herein may have a variety of average thicknesses. In some embodiments, the strip has an average thickness of 0.2 cm or greater, 0.3 cm or greater, 0.4 cm or greater, 0.5 cm or greater, 0.6 cm or greater, 0.7 cm or greater, 0.8 cm or greater, or 0.9 cm or greater. In some embodiments, the strip has an average thickness of 1 cm or less, 0.9 cm or less, 0.8 cm or less, 0.7 cm or less, 0.6 cm or less, 0.5 cm or less, 0.4 cm or less, or 0.3 cm or less.

[0112] This disclosure describes expanded strip. The expanded strip of this disclosure can be formed by subjecting the strip of this disclosure to expansion using the methods described herein.

[0113] Figure 5This is a schematic diagram of the expanded tape 100. The expanded tape 100 includes an expanded matrix 200 or the expanded matrix itself. The expanded matrix 200 has an expansion direction 90. The expanded matrix 200 can be formed by expanding the machined matrix 20 or the tape 10 disclosed herein. The expanded matrix 200 includes long strands of PTFE fibrils 22. The long strands of PTFE fibrils 22 form an orientation network 30. The orientation network 30 of the expanded matrix 200 may have the same overall orientation as the orientation network 30 of the machined matrix 20 that forms the expanded matrix. The orientation network 30 includes at least a portion of the long strands of PTFE fibrils 22 oriented along the expansion direction 90 of the expanded matrix 200. The expansion direction 90 is the direction of expansion of the machined matrix.

[0114] Figure 5 , Figure 6 as well as Figures 7A-7B The relationship between the orientation network 30 of the long strand PTFE fibrils 22 and the expansion direction 90 is shown. As discussed with reference to the machined matrix, the long strand PTFE fibrils 22 define the longitudinal direction 60 ( Figure 5 The longitudinal direction is at least partially defined by the machining direction. Figure 1 , Figure 2 , Figure 3A and Figure 3B (50 in the middle). The longitudinal direction 60 and the expansion direction 90 define the angle α-2 (α2) ( Figure 6 In some embodiments, the longitudinal direction 60 and the machining direction 50 are the same (α-1 = 0 degrees). In some such embodiments, the machining direction 50 and the expansion direction 90 define α-2 (α2). In some embodiments, α-2 can be 0 degrees or greater, 5 degrees or greater, 10 degrees or greater, 15 degrees or greater, 20 degrees or greater, 25 degrees or greater, 30 degrees or greater, 50 degrees or greater, or 75 degrees or greater. In some embodiments, α-2 can be 90 degrees or less, 75 degrees or less, 75 degrees or greater, 50 degrees or less, 30 degrees or less, 25 degrees or less, 20 degrees or less, 15 degrees or less, or 10 degrees or less, or 5 degrees or less. In some embodiments, α-2 is 0 degrees. When α-1 is 0 degrees, the longitudinal direction 60 and the expansion direction 90 are the same. In embodiments, when α-1 and α-2 are 0 degrees, the machining direction 50 and the expansion direction 90 are the same.

[0115] Figure 7AA portion (nodes not shown) of the expansion matrix 200 of the expanded tape 100 is shown, where α-2 is 0 degrees. The expansion matrix 200 comprises an oriented network 30 of long strands of PTFE fibrils 22. The long strands of PTFE fibrils 22 define a longitudinal direction 60. The expansion matrix 200 has a machining direction 50 and an expansion direction 90. The longitudinal direction 60 and the expansion direction 90 define α-2 at 0 degrees; that is, the longitudinal direction 60 and the expansion direction 90 are identical. Furthermore, the expansion matrix is ​​formed of a machining matrix in which the long strands of PTFE fibrils 22 are oriented substantially along the machining direction. In other words, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the long strands of PTFE fibrils are oriented at α-1 (the angle defined by the longitudinal direction 60 and the machining direction 50) at 20 degrees or less (e.g., 0 to 1 degree or 0 to 5 degrees). Therefore, the longitudinal direction 60, the machining direction 50, and the expansion direction 90 are substantially identical.

[0116] Figure 7A A portion (nodes not shown) of the expanded matrix 200 of the expanded tape 100 is shown, where α-2 is greater than 0 degrees. The expanded matrix 200 comprises an oriented network 30 of long strands of PTFE fibrils 22. The long strands of PTFE fibrils 22 define a longitudinal direction 60. The expanded matrix 200 has a machining direction 50 and an expansion direction 90. The longitudinal direction 60 and the expansion direction 90 define an α-2 greater than 0 degrees; that is, the longitudinal direction 60 and the expansion direction 90 are not the same. The expanded matrix is ​​formed of a machined matrix in which the long strands of PTFE fibrils 22 are oriented substantially along the machining direction 50. In other words, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the long strands of PTFE fibrils are oriented at an α-1 (the angle defined by the longitudinal direction 60 and the machining direction 50) of 20 degrees or less (e.g., 0 to 1 degree or 0 to 5 degrees). Figure 7A In the longitudinal direction 60 and the machining direction 50, they are basically the same (α-1 is about 0 degrees), but the expansion direction 90 is different (α-2 is greater than 0 degrees).

[0117] In some embodiments, the long strands of PTFE fibrils are oriented substantially along the expansion direction 90° of the expanded matrix 200. In some such embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the long strands of PTFE fibrils are oriented at an α-2 degree of 20 degrees or less. In some embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the long strands of PTFE fibrils are oriented at an α-2 degree of 10 degrees or less. In some embodiments, 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of the long strands of PTFE fibrils are oriented at an α-2 degree of 5 degrees or less.

[0118] return Figure 5 The expanded matrix contains nodes 40. Nodes 40 can be distributed within the orientation network 30. Nodes 40 can be uniformly distributed within the orientation network 30. Nodes 40 can also be non-uniformly distributed within the orientation network 30. For example, some portions of the orientation network may have a higher concentration of nodes than other portions. Expanded matrix 200 ( Figure 5 The distance between two or more nodes 40 in the expanded matrix can be greater than the distance between the machined matrix 20 forming the expanded matrix. Figure 1 The distance between two or more identical nodes 40 in the expanded matrix 200 and the machined matrix 20. Figure 1 Compared to the same node in ), the size (surface area) may increase.

[0119] Node 40 comprises short-stranded PTFE fibrils 24 and active particles 42. Active particles 42 may be distributed within the short-stranded PTFE fibrils 24. Some active particles 42 may be present in locations other than node 40 within the expanded matrix 200. Active particles 42 are in contact with and / or interact with long-stranded PTFE fibrils 22, short-stranded PTFE fibrils 24, or both. Figure 5 (See box 70). For a given node, the active particles 42 of the expanded matrix 200 can be less densely packed than the active particles 42 of the same node in the machined matrix 20. It is not desirable to be bound by theory, but rather to assume that the accessible surface area of ​​the active particles in the expanded matrix is ​​greater than that in the machined matrix.

[0120] Figure 27A and Figure 27B It is a machining substrate ( Figure 27A ) and the expanded matrix formed from the machined matrix ( Figure 27B Scanning electron micrographs of the matrices and expanded matrices. Both matrices have an active particle loading of 72.7 wt%. The images show one or more nodes. Compared to the matrices, the expanded matrices exhibit greater space between active particles. Additionally, the active particles in the expanded matrices are smaller than those in the matrices. This greater distance between the active particles and the smaller active particles contributes to increased accessible active particle surface area, which theoretically enhances the accessibility of active sites to produce improved catalyst activity.

[0121] Active particles 42 come into contact with and / or interact with long-stranded PTFE fibrils 22, short-stranded PTFE fibrils 24, or both. Figure 5(See frame 70). The active particles 42, which interact with other active particles 42, long-stranded PTFE fibrils 22, short-stranded PTFE fibrils 24, or combinations thereof, are fixed in the machined matrix by physical and / or chemical means. The active particles may have a chain structure, an aggregated structure, or both.

[0122] The expanded tape disclosed herein can have a variety of average thicknesses. In some embodiments, the expanded tape has an average thickness of 10 micrometers or greater, 50 micrometers or greater, 70 micrometers or greater, 100 micrometers or greater, 500 micrometers or greater, 700 micrometers or greater, 1000 micrometers or greater, or 2000 micrometers or greater. In some embodiments, the expanded tape has an average thickness of 2500 micrometers or less, 2000 micrometers or less, 1000 micrometers or less, 700 micrometers or less, 500 micrometers or less, 100 micrometers or less, 70 micrometers or less, or 50 micrometers or less. The average thickness of the expanded tape can depend at least in part on the intended use of the expanded tape. In some embodiments, a thinner expanded tape can allow greater accessibility to the surface area of ​​the active particles.

[0123] Figure 13 This is a scanning electron micrograph of an expanded tape containing CARULITE active particles (available from Carus, Inc., Perle, Illinois). In the SEM image, an orientation network is visible, comprising long strands of PTFE fibrils and nodes distributed within the orientation network. The expanded tape is formed by machining the fiber matrix using the method disclosed herein, wherein the long strands of PTFE fibrils are oriented substantially along the machining direction 50; that is, the longitudinal direction 60 defined by the long strands of PTFE is the same as the machining direction 50 (α-1 is approximately 0 degrees). The machined matrix is ​​then expanded in the expansion direction 90. The expansion direction and the machining direction are the same. Therefore, the PTFE fibrils are oriented substantially along both the expansion direction 90 and the machining direction 50.

[0124] Some of the expanded tapes disclosed herein possess unique structural properties. These properties differ from the network of PTFE fibrils in conventional expanded PTFE (…). Figure 14 and Figure 28 In contrast, some of the expanded tapes of PTFE fibrils disclosed herein are essentially oriented in a single direction. Figure 1 , Figure 5 , Figure 13 and Figure 28Furthermore, compared to conventional PTFE, the nodes of the expanded tape disclosed herein contain active particles. In the expanded tape disclosed herein, active particles are the primary material of the nodes. Without being bound by theory, such networking can explain the unexpected structural flexibility of the tape material with a relatively high active particle loading. Tapes and expanded tapes with relatively high active particle loadings (e.g., greater than 50 wt%, 70 wt%, or 80 wt%) are expected to behave like sintered ceramic materials; that is, brittle and non-flexible. For example, structural cohesion is expected to primarily originate from the linkages of active particles, with PTFE fibrils merely acting as a mechanism for adhesion between aggregates. However, the tapes and expanded tapes disclosed herein are flexible, possessing rubber-like qualities. Without being bound by theory, it is considered that PTFE fibrils impart flexibility while also acting as bridging elements, thereby linking all phases of the material (e.g., long-stranded PTFE, short-stranded PTFE, and active particles) at the microscopic level.

[0125] Unwilling to be bound by theory, short-strand and long-strand PTFE fibrils theoretically possess distinct characteristics, enabling tapes and expanded tapes to exhibit flexibility with minimal to no active particle shedding. It is hypothesized that short-strand PTFE fibrils introduced in the form of emulsified PTFE become unstable during the fabrication of the fiber matrix (from which machined and expanded matrices are formed) due to the addition of active particles. Since the active particles carry a positive electrostatic charge, and the PTFE fibrils inherently carry a negative charge due to the fluorine portion, the instability of the PTFE emulsion leads to charge neutralization between these two substances, thereby promoting electrostatic bonding between the fibrils and particle agglomerates. During the initial fiber matrix formation, these clusters further entangle with long-strand PTFE, resulting in… Figure 1 The network described. For non-fluorinated polymers, this process is defined in the literature as flocculation.

[0126] Following initial flocculation, long-stranded PTFE fibrils are believed to play a role in the formation of mechanically robust tapes, as the initial fiber matrix is ​​a loose aggregate lacking mechanical cohesion. It is presumed that the long-stranded PTFE fibrils introduce mechanical bonding during machining through entanglement and shear thickening. Specifically, machining the entangled network results in the untangling of the long-stranded PTFE fibrils and their orientation along a longitudinal direction relative to the machining direction. Typically, the machining direction determines the longitudinal direction. For example, in some embodiments, the machining direction and the longitudinal direction are similar. Due to the known shear thickening behavior of PTFE, the machined long-stranded PTFE fibrils become more resistant to machining with the application of additional forces. The coupling of these two behaviors ultimately produces a mechanically robust tape network with definable properties. Additional machining may include the application of extreme forces.

[0127] This disclosure describes an expanded tape formed by expanding a tape or machining matrix having a first machining direction and a second machining direction. The expanded tape comprises an expanded matrix or an expanded matrix. The expanded matrix includes a first expansion direction and a second expansion direction. The expanded matrix typically comprises long strands of PTFE fibrils and nodes. The long strands of PTFE fibrils form an orientation network. Nodes are distributed within the orientation network. The orientation network typically comprises a first portion and a second portion of long strands of PTFE fibrils. The first portion of the long strands of PTFE fibrils defines a first longitudinal direction. The second portion of the long strands of PTFE fibrils defines a second longitudinal direction. Nodes typically comprise active particles and short strands of PTFE distributed within the active particles.

[0128] The first longitudinal direction and the first expansion direction of the expanding matrix define an angle α-20 from 0 degrees to 90 degrees (α-20). 20 ), such as 0 to 70 degrees, 0 to 50 degrees, 0 to 30 degrees, 0 to 20 degrees, or 0 to 10 degrees. The second longitudinal direction and the second expansion direction of the expansion matrix define an angle α-21 (α) of 0 to 90 degrees. 21 (e.g., 0 to 70 degrees, 0 to 50 degrees, 0 to 30 degrees, 0 to 20 degrees, or 0 to 10 degrees). In some embodiments, the first machining direction and the first expansion direction are the same. In some embodiments, the first machining direction and the first expansion direction are not the same. In some embodiments, the second machining direction and the second expansion direction are the same. In some embodiments, the second machining direction and the second expansion direction are not the same. In some embodiments, 50% or more of the first portion of the long-strand PTFE fibrils is oriented at α-20, and 50% or more of the second portion of the long-strand PTFE fibrils is oriented at α-21.

[0129] The first expansion direction and the second expansion direction define the angle α-22 (α 22 In some embodiments, α-22 can be 0 degrees or greater, 5 degrees or greater, 10 degrees or greater, 15 degrees or greater, 20 degrees or greater, 25 degrees or greater, 30 degrees or greater, 50 degrees or greater, or 75 degrees or greater. In some embodiments, α-22 can be 90 degrees or less, 75 degrees or less, 50 degrees or less, 30 degrees or less, 25 degrees or less, 20 degrees or less, 15 degrees or less, 10 degrees or less, or 5 degrees or less. In some embodiments, α-22 is 0 degrees. In some embodiments, α-22 is 90 degrees. In some embodiments, α-21 is 90 degrees and α-22 is 90 degrees. In some such embodiments, the first machining direction and the first expansion direction are the same, and the second machining direction and the second expansion direction are the same.

[0130] This disclosure describes higher-level structures that can be made from and / or include the strips or expanded strips disclosed herein. Examples of higher-level structures that may include strips or expanded strips include, but are not limited to, cinnamon roll structures, filled bed structures, honeycomb structures, pleated structures, etc. A strip or expanded strip can be constructed into a cinnamon roll structure, for example, by winding the strip or expanded strip into a cylindrical shape. Alternatively, a strip or expanded strip can be constructed into a cinnamon roll structure by laminating the strip or expanded strip with one or more other materials and winding these layers to form a cylindrical structure. A strip or expanded strip can be included in a filled bed structure, for example, by cutting small segments of strip and laminating the segments with or without other materials in a housing. A strip or expanded strip can be included in a filled bed structure, for example, by laminating discs of strip or expanded strip and creating holes across the stacked discs.

[0131] This disclosure describes a method for manufacturing the strip disclosed herein. Figure 8A This is a flowchart outlining a method 500 for manufacturing the strip disclosed herein. The method includes machining a fiber matrix in a machining direction to form a machined matrix (step 510).

[0132] Figure 10 This is a schematic diagram of the fiber matrix 300. The fiber matrix 300 comprises short-strand PTFE fibrils 24, long-strand PTFE fibrils 22, and active particles 42. Unlike the tapes and expanded tapes disclosed herein, both the long-strand PTFE fibrils 22 and the short-strand PTFE fibrils 24 in the fiber matrix 300 are relatively disordered within the fiber matrix. The active particles 42 are distributed throughout the fiber matrix 300 and are in contact with and / or interact with the long-strand PTFE fibrils 22, the short-strand PTFE fibrils 24, or both. The active particles may have a chain-like structure, an aggregated structure, or both.

[0133] In some embodiments, method 500 further includes forming a fibrous matrix. The fibrous matrix is ​​formed from at least a short-strand PTFE resin, a long-strand PTFE resin, and a solid particulate composition.

[0134] Figure 9This is a flowchart outlining a method 700 for manufacturing a fibrous matrix. Forming the fibrous matrix may include aerating an emulsion to form an aerated emulsion (step 710), the emulsion and the aerated emulsion comprising short-stranded PTFE resin and a dispersant (710c). In some embodiments, the emulsion and the aerated emulsion may further comprise a surfactant, such as polyethylene glycol trimethyl nonyl ether. The dispersant may comprise water, one or more organic solvents, or both. Examples of organic solvents that may be included in the dispersant include methanol, acetone, tetrahydrofuran, dimethylformamide, acetonitrile, isopropanol, ethanol, ISOPAR-K, and any combination thereof. An aerated emulsion, mixture, or suspension is characterized by the presence of bubbles and / or cavitation. For example, an aerated emulsion may be characterized by having bubbles on its surface. Aeration can be achieved using a variety of techniques, such as mechanical oscillation, gas injection, bottom-up bubbling, or combinations thereof.

[0135] Method 700 may include adding a solid particulate composition and a long-stranded PTFE resin to an aerated emulsion to form a matrix premix (step 720), the matrix premix comprising a short-stranded PTFE resin, a long-stranded PTFE resin, a dispersant, and a solid particulate composition (720c). The long-stranded PTFE resin and the solid particulate composition may be added simultaneously or sequentially. The solid particulate composition comprises solid particulates. The solid particulates comprise active particles and / or components that form active particles. In some embodiments, the solid particulate composition comprises 100 wt% solid particulates (i.e., the solid particulate composition does not contain other components). In some embodiments, the solid particulate composition comprises solid particulates and a liquid carrier. The liquid carrier may comprise water or one or more organic solvents, as described herein.

[0136] Method 700 may include aerating a matrix premix to form an aerated matrix premix (step 730). The aerated matrix premix comprises short-stranded PTFE resin, long-stranded PTFE resin, a dispersant, and a solid particulate composition (730c).

[0137] In some embodiments, the matrix premix and / or aerated matrix premix comprises one or more additives. Additives include those described herein, such as polymeric binders, ceramic binders, inorganic fibers, or any combination thereof. In addition to the solid particulate composition and long-strand PTE resin, one or more additives may be added to the aerated emulsion to form the matrix premix. One or more additives may be added to the aerated matrix premix.

[0138] One or more additives can be added as an additive composition to aerated emulsions or aerated matrix premixes. The additive composition comprises one or more additives. In some embodiments, the additive composition comprises a liquid carrier. Example: The liquid carrier comprises a solvent capable of dissolving the additive. For example, in some embodiments, when one or more additives include a polymeric additive, the additive composition comprises a polymeric additive and a liquid carrier. The polymeric additive can be dissolved in the liquid carrier. In some embodiments, the additive composition does not contain a liquid carrier. In some embodiments, the additive composition is only one or more additives. For example, in some embodiments, one or more additives in the form of solid powder or solid fibers are added to the aerated emulsion, aerated matrix premix, or both.

[0139] Method 700 may include mixing an aerated matrix premix to form a hydrated solid (step 750). The hydrated solid comprises active particles, short-stranded PTFE, long-stranded PTFE, at least a portion of a dispersant, at least a portion of a surfactant (if present), and at least a portion of a liquid carrier (if present) (740c). The mixing time may be, for example, from 10 min to 24 hours. Mixing can be achieved by a variety of methods, including mechanical rotation (e.g., on a rotary table), mechanical agitation, submersion blending, vibration agitation, ultrasonic agitation, or any combination thereof. In some embodiments, it may be desirable to use a mixing technique that does not involve shear forces. Using a mixing technique that does not involve shear forces can result in less fibrillation of PTFE fibrils, which in turn can impart characteristics that make the composition more processable. Mixing fibrillates (elongates) the PTFE resin into PTFE fibrils and emulsifies the PTFE resin. Mixing also homogenizes the active particles within the aerated matrix premix and forms chain structures and / or aggregate structures with the fibrillated and / or orthofibrillated PTFE fibrils.

[0140] Method 700 may include drying hydrated solids to form a fiber matrix (step 750). Drying the hydrated solids includes removing at least a portion of the dispersant from the hydrated solids. In embodiments using surfactants, drying includes removing at least a portion of the surfactant from the hydrated solids. In embodiments using liquid carriers, drying includes removing at least a portion of any liquid carrier from the hydrated solids. Drying can be carried out to varying degrees (i.e., the amount of dispersant, liquid carrier, and / or surfactant that may be present in the fiber matrix after drying the hydrated solids). The dried fiber matrix may contain 50 wt% or less, 20 wt% or less, 10 wt% or less, 5 wt% or less, or 1 wt% or less of dispersant, liquid carrier (if present), and / or surfactant (if present) based on the total weight of the fiber matrix. Some residual dispersant and / or liquid carrier may be used for strip and / or expanded strip formation. For example, in embodiments where the dispersant includes processing aids, retaining at least a portion of the processing aids may be beneficial for strip formation. Therefore, in some embodiments, the hydrated solids are dried to such an extent that the composition contains a certain amount of dispersant and / or liquid carrier (if present) (e.g., 0.1 wt-% to 50 wt-% water / liquid carrier based on the total weight of the composition), which is suitable for achieving strip formation without the need to add additional dispersant, liquid carrier or processing aid.

[0141] In some embodiments, the fiber matrix includes processing aids. Processing aids are materials that facilitate the machining of the fiber matrix. Processing aids may be added during fiber matrix formation, after fiber matrix formation, or both. Processing aids may be contained in a dispersant or liquid carrier. Examples of processing aids include mineral oil, naphtha, and ISOPAR-K (available from ExxonMobil, Irvine, Texas). In some embodiments, processing aids are at least partially removed during the production of the strip or expanded strip. Therefore, the strip or expanded strip disclosed herein may or may not contain residual processing aids.

[0142] return Figure 8AMethod 500, which includes machining a fiber matrix in a machining direction to form a machined matrix (step 510). Machining is applying pressure to the fiber matrix to form the machined matrix disclosed herein. The fiber matrix is ​​a stretchable solid. During the machining process, the fiber matrix is ​​flattened and formed into an expanded matrix in the form of a strip. Without being bound by theory, it is believed that applying pressure during the machining process enhances the interactions between PTFE fibrils, between active particles, and between active particles and PTFE fibrils. Furthermore, it is believed that the machining process involves forming an orientation network 30 of long strands of PTFE fibrils 22. The long strands of PTFE fibrils are self-aligned in a longitudinal direction 60 that is the same as or similar to the machining direction 50 (see...). Figure 1 Furthermore, it is believed that the nodes are formed during the machining process.

[0143] In some embodiments, prior to machining, the fiber matrix can be formed into a fiber matrix strip containing the fiber matrix but not the machining matrix. For example, the fiber matrix can be rolled, compressed, or otherwise flattened into a fiber matrix strip having a thickness suitable for machining. For example, the fiber matrix can be flattened into a fiber matrix strip having a thickness of 10 cm or less, 5 cm or less, 2 cm or less, 1 cm or less, or 0.5 cm or less. The fiber matrix can be flattened into a fiber matrix strip having a thickness of 0.1 cm or more, 0.5 cm or more, 1 cm or more, 2 cm or more, or 5 cm or more. It is not desirable to be bound by theory, but it is assumed that flattening the fiber matrix into a strip will not cause the formation of an expanding matrix because the pressure applied during strip formation is less than the pressure applied during machining. In some embodiments, the fiber matrix can be rolled using vertical rollers to form the fiber matrix strip.

[0144] Machining can be achieved using a variety of techniques. For example, the fiber matrix can be machined by rolling, such as using clamping rollers and / or sliding rollers. In some embodiments, machining may include a sequence of steps of applying pressure (greater than the pressure used to form the fiber matrix strip) to the fiber matrix or fiber matrix strip. For example, the fiber matrix or fiber matrix strip may be fed sequentially through clamping rollers and / or sliding rollers, with the gap between these rollers decreasing sequentially. For example, the fiber matrix or fiber matrix strip may be fed through horizontal clamping rollers and / or sliding rollers, with the gap between these rollers decreasing sequentially, to form a machined matrix with a desired thickness. In some embodiments, the thickness of the machined matrix is ​​5000 micrometers or less, 2000 micrometers or less, 1000 micrometers or less, 500 micrometers or less, 200 micrometers or less, or 100 micrometers or less. In some embodiments, the thickness of the machined matrix is ​​100 micrometers or more, 200 micrometers or more, 500 micrometers or more, 1000 micrometers or more, or 2000 micrometers or more.

[0145] In some embodiments, machining and / or any pre-machining steps of the fiber matrix can occur at elevated temperatures. Machining and / or any pre-machining steps can enhance bonding. For example, in embodiments containing one or more polymer additives, heating the fiber matrix during machining and / or any pre-machining steps can enhance bonding. In some embodiments where the fiber matrix contains polymer additives, the fiber matrix is ​​exposed to (or heated to) temperatures within the glass transition phase of the polymer. Such heating can allow for thermal crosslinking between the polymer phase and the PTFE / particle network.

[0146] This disclosure describes a method for manufacturing a strip comprising a machining matrix having a first machining direction and a second machining direction. Figure 8B This is a flowchart outlining a method 800 for manufacturing the strip of this disclosure. The machining processes in method 800 are consistent with those discussed herein. The method includes machining a fiber matrix in a first machining direction and machining the fiber matrix in a second machining direction to form a machined matrix (step 810). In some embodiments, method 800 further includes forming a fiber matrix (step 530). The fiber matrix in method 810 comprises short-strand PTFE fibrils, long-strand PTFE fibrils, and active particles (step 810c). The short-strand PTFE fibrils, long-strand PTFE fibrils, and active particles are consistent with those discussed herein.

[0147] This disclosure describes a method for manufacturing the expanded strip disclosed herein. Figure 11AThis is a flowchart outlining a method 600 for manufacturing the expanded tape disclosed herein. The method includes machining a fiber matrix in a machining direction to form a machined matrix as described herein (step 510). In some embodiments, the method includes forming a fiber matrix as described herein (step 530). The method includes expanding the machined matrix in an expansion direction to form an expanded matrix (step 610).

[0148] Techniques for expanding a machining substrate include stretching, pulling, etc., along the expansion direction. For example, tensile pulling can be used to expand a machining substrate. Machining orientation machines can be used to expand a machining substrate. The relationship between the machining direction, the longitudinal direction, and the expansion direction can be as described herein. For example, in some embodiments, the machining direction and / or the longitudinal direction, as well as the expansion direction, define an angle (α2) from 0 to 20 degrees (see...). Figure 6 In some embodiments, the machining direction and the expansion direction are substantially the same.

[0149] The expansion rate of the machined substrate can vary. Figure 12 The diagram illustrates how the expansion rate is calculated. Before expansion, the machined matrix 20 has a first dimension D1 and a second dimension D2. During expansion along the expansion direction 90, the first machined dimension D1 expands to a first expansion dimension D3 of the expanded matrix 200, and the second machined dimension D2 expands or contracts to a second expansion dimension D4 of the expanded matrix. Typically, the expansion from the first machined dimension D1 to the first expansion dimension D3 is greater than the expansion from the second machined dimension D2 to the second expansion dimension D4. In some embodiments, the expansion from the second machined dimension D2 to the second expansion dimension D4 is minimal. In some embodiments, the contraction from the second machined dimension D2 to the second expansion dimension D4 is minimal.

[0150] The expansion rate is the difference between the first expansion dimension D3 and the first machining dimension D1. Figure 12The expansion rate is calculated by dividing Δ(D3-D1) by the amount of time taken to complete the expansion. For any initial first machining dimension, the expansion rate can be expressed as any unit length / any unit time. In some embodiments, for a machining substrate with a first machining dimension of 1 cm, the expansion rate is 0.001 mm / s or greater, 0.01 mm / s or greater, 0.05 mm / s or greater, 0.07 mm / s or greater, 1 mm / s or greater, 1.5 mm / s or greater, or 2 mm / s or greater. In some embodiments, for a machining substrate with a first machining dimension of 1 cm, the expansion rate can be 5 mm / s or less, 3 mm / s or less, 1.5 mm / s or less, 1 mm / s or less, 0.07 mm / s or less, 0.05 mm / s or less, or 0.01 mm / s or less.

[0151] The degree of expansion can also be expressed as a percentage expansion per unit time. Percentage expansion is calculated by dividing the expansion rate (D3-D1 divided by the expansion time; the unit is distance / time) by the first expansion size D3 and then multiplying by 100. In some embodiments, the percentage expansion rate can be 0.01% / s or greater, 0.1% / s or greater, 0.5% / s or greater, 1% / s or greater, 2% / s or greater, 3% / s or greater, 4% / s or greater, 5% / s or greater, 6% / s or greater, 7% / s or greater, 8% / s or greater, 9% / s or greater, 10% / s or greater, 20% / s or greater, 50% / s or greater, 75% / s or greater, 100% / s or greater, 125% / s or greater, 150% / s or greater, or 175% / s or greater. In some embodiments, the expansion percentage rate may be 200% / s or less, 175% / s or less, 150% / s or less, 125% / s or less, 100% / s or less, 75% / s or less, 50% / s or less, 20% / s or less, 15% / s or less, 12% / s or less, 10% / s or less, 9% / s or less, 8% / s or less, 7% / s or less, 6% / s or less, 5% / s or less, 4% / s or less, 3% / s or less, 2% / s or less, 1% / s or less, 0.5% / s or less, or 0.1% / s or less.

[0152] The machined matrix disclosed herein exhibits unusual elongation behavior. Machined matrices with relatively high active particle loadings (e.g., 50 wt% or more, or 70 wt% or more) are not expected to undergo expansion because their composition is predominantly ceramic. For example, ceramics are expected to deteriorate, sinter, and / or shrink upon exposure to elevated temperatures. Furthermore, applying tensile forces to the ceramic body fails to move it, or if the applied force exceeds the tensile modulus, it results in complete mechanical failure of the ceramic body. The material also does not expand in a manner comparable to any known PTFE extrusion. Conventionally, expanded PTFE typically expands at rates ranging from 30% / s to 5000% / s, depending on the properties of the PTFE used and the desired final porosity. Therefore, the elongation behavior of the machined matrix disclosed herein differs from that of both ceramic materials and conventional PTFE. Specifically, the machined matrix disclosed herein is expandable without deterioration compared to ceramic materials. The expansion rate of the machined matrix is ​​lower compared to conventional expanded PTFE. Excessively high machinability expansion rates can lead to expanded strips with undesirable structures, such as... Figure 21A and Figure 21B The example shown is shown in the image.

[0153] Figure 11B This is a flowchart outlining a method 900 for manufacturing an expanded strip, the expanded strip comprising an expanded matrix having a first expansion direction and a second expansion direction. The method includes machining the fiber matrix in a first machining direction and machining the fiber matrix in a second machining direction to form a machined matrix (step 810). In some embodiments, the method includes forming a fiber matrix as described herein (step 530). The method includes expanding the machined matrix in the first expansion direction and expanding the machined matrix in the second expansion direction to form an expanded matrix (step 910). In some embodiments, the machined matrix may expand simultaneously in the first and second expansion directions. In some embodiments, the machined matrix may expand sequentially in the first and second expansion directions. The techniques used to expand the machined matrix are consistent with those discussed herein. The fiber matrix in this method is consistent with those discussed herein.

[0154] Methods 500, 800, 600, or 900 may further include drying the machined matrix, drying the expanded matrix, or both. Drying may be performed after or in combination with any step of the method. Drying may include removing at least a portion of a washing solution, incubation solution, processing aid, or other liquid present in any step of the method. Removing at least a portion of a washing solution, incubation solution, processing aid, or other liquid may be advantageous to prevent combustion of the fluid during expansion when the machined matrix is ​​exposed to temperatures between 190°C and 220°C. Drying techniques include sun drying, hot air drying, contact drying, infrared drying, freeze drying, fluidized bed drying, dielectric drying, etc. In some embodiments, drying includes exposing the machined matrix and / or expanded matrix to an elevated temperature for a sustained drying time. For example, the machined matrix and / or expanded matrix may be exposed to an elevated temperature by drying in an oven. The absolute values ​​of the elevated temperature and drying time may vary at least in part depending on the type and / or amount of liquid to be removed. In some embodiments, drying includes exposing the machined substrate and / or expanded substrate to temperatures of 25 degrees Celsius or higher, 50 degrees Celsius or higher, 75 degrees Celsius or higher, 100 degrees Celsius or higher, 125 degrees Celsius or higher, 150 degrees Celsius or higher, or 175 degrees Celsius or higher. In some embodiments, drying includes exposing the machined substrate and / or expanded substrate to temperatures of 200 degrees Celsius or lower, 175 degrees Celsius or lower, 150 degrees Celsius or lower, 125 degrees Celsius or lower, 100 degrees Celsius or lower, 75 degrees Celsius or higher, or 50 degrees Celsius or lower. Illustrative Examples

[0155] The techniques described herein are defined in the claims. However, a non-exhaustive list of non-limiting embodiments is provided below. Any one or more features of these embodiments may be combined with any one or more features of another instance, embodiment, or aspect described herein.

[0156] Example A1 is a strip comprising a machined matrix having a machining orientation. The machined matrix comprises long strands of PTFE fibrils forming an oriented network. The oriented network comprises long strands of PTFE fibrils. These long strands of PTFE fibrils define a longitudinal direction. The machined matrix comprises nodes distributed within the oriented network. These nodes comprise active particles and short strands of PTFE distributed within these active particles.

[0157] Example A2 is a strip as described in Example A1, wherein the longitudinal direction and the machining direction of the machining substrate are defined at an angle of 0 to 20 degrees.

[0158] Example A3 is a strip as described in Example A1 or A2, wherein 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of these long strands of PTFE fibrils are oriented at an angle of 0 to 20 degrees relative to the machining direction.

[0159] Example A4 is a strip as described in any one of Examples A1 to A3, wherein the machining matrix contains 50 wt% or more or 60 wt% or more of these active particles.

[0160] Example A5 is a strip as described in any one of Examples A1 to A4, wherein the machined matrix contains 70 wt% or more, 80 wt% or more, or 90 wt% or more of these active particles.

[0161] Example A6 is a strip as described in any one of Examples A1 to A5, wherein the machined matrix comprises 0.01 wt% or more, 5 wt% or more, 15 wt% or more, 25 wt% or more, 45 wt% or more, 55 wt% or more, or 65 wt% or more of these short-strand PTFE fibrils.

[0162] Example A7 is a strip as described in any one of Examples A1 to A6, wherein the machined matrix comprises 0.01 wt% or more, 1 wt% or more, 5 wt% or more, 10 wt% or more, or 20 wt% or more of these long strands of PTFE fibrils.

[0163] Example A8 is a tape as described in any one of Examples A1 to A7, wherein the active particles comprise a catalyst, an electroactive material, an absorbent, an adsorbent, a seed crystal, a metal-organic framework, a polymeric framework, or a combination of two or more thereof; and wherein the adsorbent is a physical adsorbent, a chemical adsorbent, or a physical-chemical adsorbent hybrid.

[0164] Example A9 is a strip as described in any one of Examples A1 to A8, wherein the catalyst is capable of destroying ozone.

[0165] Example A10 is a strip as described in any one of Examples A1 to A9, wherein the catalyst comprises manganese oxide, copper oxide, cerium dioxide, or a combination of two or more thereof.

[0166] Example A11 is a tape as described in any one of Examples A1 to A10, wherein the adsorbent is capable of adsorbing alkaline gases, acidic gases, gaseous organic compounds, gaseous inorganic compounds, or combinations of two or more thereof.

[0167] Example A12 is a strip as described in any one of Examples A1 to A11, wherein the nodes have an average diameter in the range of 0.1 micrometers to 50 micrometers.

[0168] Example A13(a) is a strip as described in any one of Examples A1 to A11, wherein the strip contains additives.

[0169] Example A13(b) is a strip as described in any one of Examples A1 to A11, wherein the machining matrix contains additives.

[0170] Example A14 is a strip as described in Example A13, wherein the additive is a ceramic binder, a polymer binder, or both.

[0171] Example A15 is a strip as described in Example A14, wherein the ceramic binder comprises kaolinite, bentonite, silicon carbide, fumed silica, zeolite, or any combination thereof.

[0172] Example A16 is a tape as described in Example A14, wherein the polymer binder includes polyamide (nylon); polyamide-imide (Torlon); polyacrylate; polyurethane; styrene-butadiene rubber (SBR rubber); polyvinyl alcohol (PVA); polyvinyl chloride (PVC); silicone; polypropylene; polyethylene; aramid (Kevlar); polystyrene; polyethylene terephthalate (PET); polyvinylidene fluoride (PVDF); polyvinyl acetate; polyacrylonitrile; pre-formed PTFE fibers; or any combination thereof.

[0173] Example A17 is a tape as described in Example A14, wherein the polymer binder includes gelatin, methylcellulose, ethylcellulose, pectin, polyethylene glycol, sodium alginate, agar, xanthan gum, or any combination thereof.

[0174] Example A18 is a strip as described in Example A13, wherein the additive comprises inorganic fibers.

[0175] Example A19 is a strip as described in Example A18, wherein the inorganic fiber includes carbon fiber, activated carbon fiber, metal fiber, ceramic fiber (e.g., glass fiber), or any combination thereof.

[0176] Example A20(a) is a strip as described in any one of Examples A13 to A19, wherein the strip contains 1 wt-% to 50 wt-%, 5 wt-% to 50 wt-%, 10 wt-% to 50 wt-%, 10 wt-% to 40 wt-%, 10 wt-% to 30 wt-%, 10 wt-% to 20 wt-%, or 20 wt-% to 50 wt-% of total additives based on the total weight of the strip.

[0177] Example A20(b) is a strip as described in any one of Examples A13 to A19, wherein the machining matrix comprises 1 wt-% to 50 wt-%, 5 wt-% to 50 wt-%, 10 wt-% to 50 wt-%, 10 wt-% to 40 wt-%, 10 wt-% to 30 wt-%, 10 wt-% to 20 wt-%, or 20 wt-% to 50 wt-% of total additives based on the total weight of the machining matrix.

[0178] Example A21(a) is a strip as described in any one of Examples A13 to A20, wherein the strip contains 0.1 wt-% to 10 wt-%, 1 wt-% to 10 wt-%, or 5 wt-% to 10 wt-% of total additives based on the total weight of the strip.

[0179] Example A21(b) is a strip as described in any one of Examples A13 to A20, wherein the machining matrix contains 0.1 wt-% to 10 wt-%, 1 wt-% to 10 wt-%, or 5 wt-% to 10 wt-% of total additives based on the total weight of the machining matrix.

[0180] Example B1 is an expanded tape comprising an expanded matrix having an expansion direction. The expanded matrix comprises long strands of PTFE fibrils forming an oriented network. The oriented network comprises long strands of PTFE fibrils. These long strands of PTFE fibrils define a longitudinal direction. The expanded matrix comprises nodes distributed within the oriented network. These nodes comprise active particles and short strands of PTFE distributed within these active particles.

[0181] Example B2 is an expanded strip as described in Example B1, wherein the longitudinal direction and the expansion direction are defined at an angle of 0 to 20 degrees.

[0182] Example B3 is an expanded tape as described in Example B1 or B2, wherein the orientation angles of these long strands of PTFE fibrils relative to the expansion direction follow a normal distribution.

[0183] Example B4 is an expanded tape as described in any one of Examples B1 to B3, wherein 60% or more, 70% or more, 80% or more, 90% or more, or 95% or more of these long strands of PTFE fibrils are oriented at an angle of 0 to 20 degrees relative to the expansion direction.

[0184] Example B5 is an expanded tape as described in any one of Examples B1 to B4, wherein the expanded matrix contains 50 wt% or more, 60 wt% or more of these active particles.

[0185] Example B6 is an expanded tape as described in any one of Examples B1 to B5, wherein the expanded matrix contains 70 wt% or more, 80 wt% or more, or 90 wt% or more of these active particles.

[0186] Example B7 is an expanded tape as described in any one of Examples B1 to B6, wherein the expanded matrix comprises 0.01 wt% or more, 5 wt% or more, 15 wt% or more, 25 wt% or more, 45 wt% or more, 55 wt% or more, or 65 wt% or more of these short-strand PTFE fibrils.

[0187] Example B8 is an expanded tape as described in any one of Examples B1 to B7, wherein the expanded matrix comprises 0.01 wt% or more, 1 wt% or more, 5 wt% or more, 10 wt% or more, or 20 wt% or more of these long strands of PTFE fibrils.

[0188] Example B9 is an expanded tape as described in any one of Examples B1 to B8, wherein the active particles comprise a catalyst, an electroactive material, an absorbent, an adsorbent, a seed crystal, a metal-organic framework, a polymeric framework, or a combination of two or more thereof; and wherein the adsorbent is a physical adsorbent, a chemical adsorbent, or a physical-chemical adsorbent hybrid.

[0189] Example B10 is an expanded strip as described in any one of Examples B1 to B9, wherein the catalyst is capable of destroying ozone.

[0190] Example B11 is an expanded strip as described in any one of Examples B1 to B10, wherein the catalyst comprises manganese oxide, copper oxide, cerium dioxide, or a combination of two or more thereof.

[0191] Example B12 is an expanded tape as described in any one of Examples B1 to B11, wherein the adsorbent is capable of adsorbing alkaline gases, acidic gases, gaseous organic compounds, gaseous inorganic compounds, or combinations of two or more thereof.

[0192] Example B13 is an expanded strip as described in any one of Examples B1 to B12, wherein the nodes have an average diameter in the range of 0.1 micrometers to 50 micrometers.

[0193] Example B14(a) is a strip as described in any one of Examples B1 to B13, wherein the strip contains an additive.

[0194] Example B14(b) is an expanded strip as described in any one of Examples B1 to B13, wherein the expanded matrix contains additives.

[0195] Example B15 is an expanded tape as described in Example B14, wherein the additive is a ceramic binder, a polymer binder, or both.

[0196] Example B16 is an expanded tape as described in Example B15, wherein the ceramic binder comprises kaolinite, bentonite, silicon carbide, fumed silica, zeolite, or any combination thereof.

[0197] Example B17 is an expanded tape as described in Example B15, wherein the polymer binder comprises polyamide (nylon); polyamide-imide (Torlon); polyacrylate; polyurethane; styrene-butadiene rubber (SBR rubber); polyvinyl alcohol (PVA); polyvinyl chloride (PVC); silicone; polypropylene; polyethylene; aramid (Kevlar); polystyrene; polyethylene terephthalate (PET); polyvinylidene fluoride (PVDF); polyvinyl acetate; polyacrylonitrile; pre-formed PTFE fibers; or any combination thereof.

[0198] Example B17 is an expanded tape as described in Example B15, wherein the polymer binder includes gelatin, methylcellulose, ethylcellulose, pectin, polyethylene glycol, sodium alginate, agar, xanthan gum, or any combination thereof.

[0199] Example B18 is an expanded tape as described in Example B14, wherein the additive comprises inorganic fibers.

[0200] Example B19 is an expanded tape as described in Example B18, wherein the inorganic fiber includes carbon fiber, activated carbon fiber, metal fiber, ceramic fiber (e.g., glass fiber), or any combination thereof.

[0201] Example B20(a) is an expanded strip as described in any one of Examples B14 to B19, wherein the strip contains 1 wt-% to 50 wt-%, 5 wt-% to 50 wt-%, 10 wt-% to 50 wt-%, 10 wt-% to 40 wt-%, 10 wt-% to 30 wt-%, 10 wt-% to 20 wt-%, or 20 wt-% to 50 wt-% of total additives based on the total weight of the strip.

[0202] Example B20(b) is an expanded strip as described in any one of Examples B14 to B19, wherein the expanded matrix comprises 1 wt-% to 50 wt-%, 5 wt-% to 50 wt-%, 10 wt-% to 50 wt-%, 10 wt-% to 40 wt-%, 10 wt-% to 30 wt-%, 10 wt-% to 20 wt-%, or 20 wt-% to 50 wt-% of total additives based on the total weight of the expanded matrix.

[0203] Example B21(a) is an expanded tape as described in any one of Examples B14 to B19, wherein the tape contains 0.1 wt-% to 10 wt-%, 1 wt-% to 10 wt-%, or 5 wt-% to 10 wt-% of total additives based on the total weight of the expanded tape.

[0204] Example B21(b) is an expanded strip as described in any one of Examples B14 to B19, wherein the strip contains 0.1 wt-% to 10 wt-%, 1 wt-% to 10 wt-%, or 5 wt-% to 10 wt-% of total additives based on the total weight of the strip.

[0205] Example B21(b) is an expanded strip as described in any one of Examples B14 to B19, wherein the expanded matrix contains 0.1 wt-% to 10 wt-%, 1 wt-% to 10 wt-%, or 5 wt-% to 10 wt-% of total additives based on the total weight of the expanded matrix.

[0206] Example C1 is a method for manufacturing a strip as described in any one of Examples A1 to A21, the method comprising machining a fiber matrix in a machining direction to form the machined matrix. The fiber matrix comprises short-strand PTFE fibrils; long-strand PTFE fibrils; and active particles.

[0207] Example C2 is the method as described in Example C1, wherein the fiber matrix further comprises one or more additives, such as those in Examples A13 to A19.

[0208] Example D1 is a method for manufacturing an expanded strip as described in any one of Examples B1 to B21, the method comprising expanding a machined substrate as described in Example C1 or C2 in the expansion direction to form the expanded substrate.

[0209] Example D2 is the method as described in Example D1, wherein the longitudinal direction and the expansion direction define an angle of 0 to 20 degrees.

[0210] Example D3 is the method as described in Example D1 or Example D2, wherein expanding the machining substrate further includes expanding at a rate of 10% to 100% elongation per second.

[0211] Example D3 is the method as described in Examples D1 to D3, wherein expanding the machining substrate includes expanding at a rate of 100% to 110% elongation per second.

[0212] Example E1 is an expanded tape comprising an expanded matrix having an expansion direction. The expanded matrix comprises long strands of PTFE fibrils forming an oriented network, the oriented network comprising these long strands of PTFE fibrils. These long strands of PTFE fibrils define a longitudinal direction. The expanded matrix comprises nodes distributed within the oriented network. These nodes comprise short strands of PTFE fibrils and active particles distributed within these short strands of PTFE fibrils. The expanded matrix is ​​formed by a method comprising machining the fiber matrix in a machining direction to form a machined matrix. The fiber matrix comprises short strands of PTFE fibrils; long strands of PTFE fibrils; and active particles. The machined matrix comprises an oriented network. The oriented network comprises long strands of PTFE fibrils. These long strands of PTFE fibrils define a longitudinal direction. The machined matrix comprises nodes distributed within the oriented network. These nodes comprise these short strands of PTFE fibrils and active particles distributed within these short strands of PTFE fibrils. The method comprises expanding the machined matrix in the expansion direction to form the expanded matrix.

[0213] Example E2 is a strip as described in Example E1, wherein the longitudinal direction and the machining direction are at an angle of 0 to 20 degrees.

[0214] Example E3 is a strip as described in Example E1 or E2, wherein the longitudinal direction and the expansion direction are at an angle of 0 to 20 degrees.

[0215] Example F1 is a strip comprising a machined matrix having a first machining direction and a second machining direction. The machined matrix comprises long strands of PTFE fibrils forming an orientation network. The orientation network comprises a first portion defining a first longitudinal direction and a second portion defining a second longitudinal direction. The machined matrix includes nodes distributed within the orientation network. These nodes comprise active particles and short strands of PTFE distributed within these active particles.

[0216] Example F2 is a strip as described in Example F1, wherein the first longitudinal direction and the first machining direction of the machining substrate define a first angle of 0 to 20 degrees, and the second longitudinal direction and the second machining direction of the machining substrate define a second angle of 0 to 20 degrees.

[0217] Example F3 is a strip as described in Example F1 or F2, wherein a first portion of more than 50% or more of these long strand PTFE fibrils is oriented at a first angle, and a second portion of more than 50% or more of these long strand PTFE fibrils is oriented at a second angle.

[0218] Example G1 is an expanded tape comprising an expanded matrix having a first expansion direction and a second expansion direction. The expanded matrix comprises long strands of PTFE fibrils forming an oriented network. The oriented network comprises a first portion defining a first longitudinal direction and a second portion defining a second longitudinal direction of the long strands of PTFE fibrils. The expanded matrix comprises nodes distributed within the oriented network. These nodes comprise active particles and short strands of PTFE distributed within these active particles.

[0219] Example G2 is an expanded strip as described in Example G1, wherein the longitudinal direction and the expansion direction are defined at an angle of 0 to 20 degrees.

[0220] Example G3 is a strip as described in Example G1 or G2, wherein the first longitudinal direction and the first expansion direction of the expanded matrix define a third angle of 0 to 20 degrees, and the second longitudinal direction and the second expansion direction of the expanded matrix define a fourth angle of 0 to 20 degrees.

[0221] Example G4 is a strip as described in any one of Examples G1 to G3 or 35, wherein more than 50% of the first portion of these long strand PTFE fibrils is oriented at the third angle, and more than 50% of the second portion of these long strand PTFE fibrils is oriented at the fourth angle.

[0222] Example H1 is a method for manufacturing a strip as described in any one of Examples F1 to F3, the method comprising machining a fiber matrix in a first machining direction and machining the fiber matrix in a second machining direction to form the machined matrix. The fiber matrix comprises short-strand PTFE fibrils; long-strand PTFE fibrils; and active particles.

[0223] Example I1 is a method for manufacturing an expanded strip as described in any one of Examples G1 to G4, the method comprising expanding a machined substrate as described in Example H1 in a first expansion direction and expanding the machined substrate as described in Example H1 in a second expansion direction to form the expanded substrate. Example

[0224] These examples are for illustrative purposes only and are not intended to unduly limit the scope of the appended claims. While the numerical ranges and parameters that set forth the broad scope of this disclosure are approximations, the values ​​set forth in the specific examples are reported as precisely as possible. However, any numerical value inherently contains some error that must be introduced by the standard deviation found in its corresponding test measurement. At least, and not in an attempt to limit the scope of the claims, the doctrine of equivalence should be applied, and each numerical parameter should be interpreted at least according to the number of significant digits reported and by applying general rounding methods.

[0225] Unless otherwise stated, all parts, percentages, ratios, etc., in the examples and the remainder of the instructions are by weight, and all reagents used in the examples are obtained or available from general chemical suppliers such as Sigma-Aldrich in St. Louis, Missouri; Carus in Perru, Illinois; Calgon Carbon in Moontown, Pennsylvania; Ultramet in Los Angeles, California; Chemours in Wilmington, Delaware; or can be synthesized by conventional methods.

[0226] The following abbreviations may be used in the following examples: Mn = number average molecular weight; ppm = parts per million; ppb = parts per billion; mL = milliliter; L = liter; LPM = liters per minute; m = meter; mm = millimeter; min = minute; s = second; cm = centimeter; μm = micrometer; kg = kilogram; g = gram; min = minute; s = second; h = hour; ° = degree; °C = degree Celsius; °F = degree Fahrenheit; wt-% = weight percentage; M = mole; % = percentage; and DI water = deionized water.

[0227] Table 1 is the materials list, which provides a list of the components used in the examples and their relevant supplier sources, abbreviations, and Chemical Abstracts Service (CAS) numbers. Table 1. Materials and related information.

[0228] Test method:

[0229] Ozone Depletion Test

[0230] Ozone depletion was assessed using the following test method. The sample was subjected to a temperature ramp with an airflow rate of 1.3 L / min (1.3 LPM), ozone generation = 2V (TG-10; ozone solution), and downstream temperatures ranging from 80–160°F (26.6–76.1°C). Ozone concentration was measured using a Model 202 2B Technologies O3 detector (available from 2B Technologies, Zurich, Switzerland). Blank experiments were performed under these conditions, and the experimental O3 conversion was calculated using the blank O3 concentration at each temperature point, as the thermal stability of O3 decreases with increasing temperature. The conversion / catalyst weight was then used to account for changes in catalytic activity due to variations in the mass of the sample used for testing. The conversion was calculated as follows: Among them, C0, C t and g 催化剂 These are i) blank O3 concentration (parts per billion; ppb) measured at a flow rate of 2 LPM at a specific temperature, ii) O3 concentration (ppb) in a catalyst bed measured at a flow rate of 2 LPM at a specific temperature, and iii) the weight (g) of the catalyst material loaded on the plate.

[0231] Size Analysis

[0232] Size and morphology analyses of various compositions in the examples were performed using scanning electron microscopy (SEM) on a JSM-7100F microscope. Before imaging, the samples were coated with gold / palladium sputtering for 120 seconds to prevent charging. Measurements were then performed using ImageJ software to calculate the average length of long-strand PTFE fibrils, the average resin particle size of long-strand PTFE resin, the average length of short-strand PTFE fibrils, the average resin particle size of short-strand PTFE resin, the average diameter of short-strand PTFE fibrils, the average diameter of long-strand PTFE fibrils, the average particle size of multiple active particles, the average particle size of free active particles, and the average porosity. Ten repeated measurements of length / width / diameter / particle size were performed to generate average values ​​for each element.

[0233] Compositional analysis

[0234] The amount of each component in the machined and expanded matrices is calculated according to the following method. The solids loading capacity of each component (e.g., active particles, short-strand PTFE, long-strand PTFE) in the heat-treated machined and expanded matrices is calculated based on the initial fiber matrix formulation, assuming uniform mixing of solids and complete loss of the dispersant / surfactant mixture. As an example, the solids content of CARULITE / PTFE-12 microns is calculated using a material basis of 21.3 g; this contains 13.3 g of CARULITE, 5 g of PTFE-E, and 3 g of PTFE-12 by weight. As detailed by the manufacturer, the PTFE-E material is known to consist of 60 wt-% PTFE solids, and the derived weight of PTFE solids is the product of the weight fraction of PTFE solids and the weight used (e.g., 60% if 5 g of PTFE-E is used). PTFE-固体 × 5 g 乳液 = 3 g PTFE固体 Then, based on the dry composition, the solids content of each component is calculated—without considering any contribution from water or surfactant components—as follows: Where X i and M i These are defined respectively as the weight percentage of a single component after drying and the individual mass (g) of the solid component used in a paste formulation without any solvent. Therefore, for example, if a composition containing 10 g CARULITE, 5 g PTFE-E, and 3 g PTFE-12 is formulated, the solid fraction of CARULITE can be defined as: .

[0235] Based on this, an exemplary fraction (i.e., loading or capacity) of CARULITE would be 62.5 wt-%, and the material would contain 16.6 wt-% of short-strand PTFE fibrils and 27.7 wt-% of long-strand PTFE fibrils. Example 1: Formation of fibrous paste (Putty)

[0236] The following general techniques are used to form an example of a fibrous paste:

[0237] 1. In a first container, a solid particulate composition containing active particles and / or components used to manufacture the active particles is mixed with PTFE-12. In some cases, the solid particulate composition contains only solids.

[0238] 2. In the second bottle, the PTFE-E (short-strand PTFE resin) emulsion is aerated by stirring.

[0239] 3. Add the aerated PTFE-E emulsion to the first container. Gently stir the first container to incorporate the emulsion into the solids in the first container.

[0240] 4. Add the dispersant and / or processing aid to the first container. Vigorously agitate the first container to incorporate the dispersant and / or processing aid. The dispersant comprises water, or water and IPA.

[0241] 5. Add the remaining dispersant to the first container and stir the first container vigorously.

[0242] 6. The first container is stirred on a mixing table at 30 rpm for 24 hours. After 24 hours, a hydrated solid is formed.

[0243] 7. Remove the hydrated solids from the first container and wrap them in paper towels. This step is included to remove excess dispersant from the hydrated solids. Let the hydrated solids sit in the paper towels for five minutes. Replace the paper towels and repeat the drying process twice more. Example 2: Machining methods to form strip

[0244] The following general techniques are used to form the machining substrate (strip):

[0245] 1. Using a rolling pin and applying limited pressure, flatten a palm-sized sheet of fiber matrix to a thickness of approximately 0.5 cm. First, roll the fiber matrix in one direction, and then roll it in a second direction at a 90-degree angle to the first direction. Use calipers to measure the thickness of the flattened fiber matrix.

[0246] 2. The flattened fiber substrate is machined using a hand-operated sliding roller at ambient temperature. The flattened fiber substrate is rolled through gradually narrowing gaps on the sliding roller. Specifically, the flattened fiber substrate is rolled unidirectionally (along the machining direction) through sliding roller gaps of 1 cm (twice), 0.5 cm (twice), and 0.1 cm (twice). In Example 3, the machined strip is then rolled through a sliding roller with a gap of 0.1 cm in a direction 90 degrees to the machining direction used in the previous rolling step. In Example 4, the cross-machining step is omitted.

[0247] 3. Dry the machined substrate (machined strip) in high-flow-rate air at 100°C for 1 hour. Note that the machined strip and expanded strip should maintain mechanical stability to at least 250°C, with the expected stability to remain up to approximately 350°C, after which PTFE begins to deteriorate. Example 3: Method for expanding to form expanded strip

[0248] The following general techniques are used to form the expanded matrix (expanded tape) of the example:

[0249] 1. Cut the machining substrate into sections (e.g., 1 cm × 1 cm sections) at an angle relative to the machining direction.

[0250] 2. Secure each segment to a dog-bone support on an RSA-G2 analyzer (TA Instruments, Newcastle, Delaware) for dynamic mechanical analysis (DMA).

[0251] 3. The strip is machined in the expansion direction using a dog-bone support and an RSA-G2 analyzer. The expansion rate is varied (0.1 mm / s, 1 mm / s, and 10 mm / s). The expansion temperature is 175 degrees Celsius, 200 degrees Celsius, or 225 degrees Celsius.

[0252] For clarity, Figure 19 The relationship between the machining direction, the cutting angle, and the expansion direction is illustrated. The machining matrix 20 has an orientation network comprising long strands of PTFE fibrils 22 oriented substantially along the machining direction 50. 1 cm × 1 cm segments of the machining matrix are cut at various angles (0 degrees = frame A; 75 degrees = frame B; and 90 degrees = frame C) such that these segments have straight edges that can be attached to a dog-bone scaffold. The segments are then expanded in the expansion direction 90. The cutting angle is defined by the machining direction 50 and the expansion direction 90. In other words, the cutting angle is α-2. Example 4: Unexpected behavior observed during the processing of fibrous pastes

[0253] This example describes unusual behavior observed during the processing of fibrous paste. This unusual behavior led to experiments in forming and expanding the strip.

[0254] According to Example 1, a fiber matrix was manufactured using 46 wt% CARULITE, 3.5 wt% PTFE-601X, 3.5 wt% PTFE-E, 35.3 wt% water, and 10.6 wt% IPA.

[0255] Attempts to extrude the fiber matrix into a self-supporting honeycomb structure were unsuccessful. Extrusion was performed via plunger extrusion through a channel die. Due to the complexity of the barrel design, the extrusion of the honeycomb structure was unsuccessful. However, the fiber matrix was observed to become mechanically stable under applied load; although the desired geometry was not formed due to uneven flow rates at the die exit. Figure 15More specifically, the extruded fiber matrix has a continuous solid phase without any visible, distinguishable PTFE resin solids. Furthermore, structural defects were observed on the surface of the fiber paste along the direction of the applied force. This behavior is somewhat consistent with that observed in conventional PTFE processing, as applying shear force to PTFE typically causes the PTFE fibrils to orient along the machining direction (due to expansion caused by the applied frictional resistance). However, fibrillation of the resin is undesirable in conventional PTFE processing because it leads to fibril breakage, poor flow behavior, and loss of cohesiveness in the extrudate. When improperly processed, conventional PTFE resin extrudates lose flexibility and become completely non-flowable. In contrast, Figure 15 The failed extrusion retains flexibility and ductility, even though it was not extruded in a uniform manner. Regarding the ductility and uniformity of the extrusion, theoretically, the radial force applied to the material can further induce bonding between multiple PTFE fibrils by elongating the fibrils, resulting in shear thickening and entanglement of oriented long-strand fibrils. Example 5: Using manual roll forming to form strip

[0256] According to Example 1, a fiber matrix was manufactured using 37.7 wt% CARULITE, 11.3 wt% PTFE-601X, 14.2 wt% PTFE-E, and 36.8 wt% water.

[0257] To manufacture the strip, the fibrous paste was manually machined in a unidirectional direction using a rolling pin to elongate it. Unidirectional rolling was observed to strengthen the paste in the direction of the applied force; however, when machining was performed with force applied in a perpendicular plane, the resulting material was prone to tearing. Applying the rolling technique rationally to a perpendicular (i.e., cross-machining) direction in a plane 90 degrees relative to the initial rolling direction resulted in a significantly stronger composite material that exhibited a significant reduction in particle shedding. Figure 16 As shown, the machined paste is presented as a strip approximately 100 micrometers thick, exhibiting a surface texture similar to latex. The strip is cohesive after drying and contains 65.5 wt% MnO2 (19.7 wt% PTFE-601X and 14.8 wt% PTFE-E by weight). Example 6: Forming strip using sliding rollers and bidirectional machining

[0258] This example describes the formation and properties of various machining substrates.

[0259] Nine fiber matrices with different formulations were manufactured according to Example 1. According to Example 2, the fiber matrices were machined into machined matrices (strips). In addition to machining in the first direction, the fiber matrices were further rolled through sliding rollers with a gap of 0.1 cm in a direction 90 degrees to the first machining direction. Table 2 shows the formulations used to manufacture the fiber matrices, and Table 3 shows the characteristics of the machined matrices (strips) formed from the fiber matrices. In Tables 2 and 3, the IDs of the fiber matrices and machined matrices are related. For example, machined matrice 1 is formed from fiber matrice 1. Higher forces were applied to machined fiber matrices 1 to 7 compared to fiber matrices 8 and 9. In fiber matrices 8 and 9, IPA was added as a processing aid. Table 2. Table 3.

[0260] As shown in Table 3, the machined matrix (strip) has an active particle loading of up to 93.7 wt% (machined matrix 9). These particle loadings are very high. For example, machined matrix 9 is almost entirely composed of active particles. This high loading can be advantageous due to the large amount of active material in a given surface area of ​​the machined matrix (strip).

[0261] Distinguished active particles have a higher surface area accessible to chemicals in contact with the machined matrices. To determine the accessibility of active particles, the surface morphology of machined matrices 1, 4, 6, and 8 was examined using scanning electron microscopy (SEM). Figures 17A-17B As shown, with increased PTFE loading, the surface is essentially non-porous. For example, machined matrix 1 (catalyst loading of 54.7 wt%) exhibits a texture comparable to machined metals or wet-laid polymers. Figure 17A With the catalyst loading increased to 66% (machined matrix 4; Figure 17B ) and 72% (machining matrix 6; Figure 17C The surface exhibits more individualized active particles and some discernible spacing between them. At the highest catalyst loading (93.7 wt%; machined matrix 9;), Figure 17D The surface was observed to be porous with highly distinguishable catalyst particles.

[0262] The machined strip exhibited unexpected behavior. Initially, it was expected that the machined strip would behave similarly to conventional PTFE extrusions, given that short-strand PTFE / long-strand PTFE was assumed to be the source of mechanical strength and abrasion resistance in the machined matrix. High forces were applied to induce rapid expansion of conventional PTFE extrusions without active particles, effectively inducing fiber expansion. In contrast, applying small forces to the machined matrix resulted in PTFE fibrillar / particle phase shift and localized thinning of the machined matrix in the direction of the applied force.

[0263] From a bioactivity perspective, retaining different active particles may be advantageous. For example, it is expected that... Figure 17A The closed surfaces in the substrate have lower accessibility to active sites. In contrast, machined matrices (strips) with an expected active particle loading of 72% or more can have enhanced catalytic performance due to increased accessibility to active particles.

[0264] To test the activity of the active particles, the ability of the machined matrix 6 to decompose ozone was tested based on ozone destruction, with a temperature of 100 degrees Celsius, a flow rate of 1.2 L / min, and an inlet ozone concentration of 140,000 ppb O3. In any experiment, approximately 35 in 2 The material is filled into the bed, allowing contaminated air to flow parallel to the surface of the active material. For example... Figure 18 As shown, the ozone destructive behavior of the machined matrix 6 is almost identical to that of the unmachined fiber matrix (sheet) (80% conversion rate, no performance loss); within acceptable error tolerances of the experimental setup. Such results indicate high activity in the machined matrix (strip), which is particularly unexpected considering i) the machined matrix did not undergo any effort to induce fiber expansion and ii) the experiment was conducted at 150X atmospheric concentration. Example 7: Forming expanded strip using sliding rollers and unidirectional machining

[0265] This example describes the method and properties of an expanded substrate (expanded strip) formed from a machined substrate. The machined substrate is formed from a fiber substrate 7 machined in a single machining direction according to Example 2. The machined substrate is then cut into 1 cm segments, and each segment is subjected to expansion in an expansion direction at an angle (α2) of 0 degrees, 45 degrees, or 90 degrees relative to the machining direction. Expansion is performed according to Example 3, wherein the expansion rate (0.1 mm / s, 1 mm / s, or 10 mm / s) and expansion temperature (175 degrees Celsius or 200 degrees Celsius) are varied. The expansion behavior is then evaluated as a function of pulling speed, temperature, and cutting angle using the experimental design in Table 4. Table 4.

[0266] The percentage shear from the expansion DMA experiment is considered the mechanical failure point. For proper expansion, the recommended percentage shear is considered to be approximately 10% lower than the measured value. Shear behavior in Figure 20A and Figure 20B As shown in the figure, the elongation stress is observed to be several orders of magnitude lower than that typically observed for PTFE materials. For example, conventional PTFE materials exhibit forces in the range of 2–5 MPa when expanded under comparable conditions. On the other hand, ceramic materials (CARULITE can be considered as one type) generally do not undergo expansion in any form. Ceramic materials tend to shrink and sinter when heat is applied. Given the rigid nature of high-load ceramics, it is expected that high-load ceramics will deteriorate under strain. However, it is evident that machined strips can be elongated, effectively demonstrating that their viscoelastic behavior is neither similar to that of ceramic phases nor that of conventional PTFE.

[0267] exist Figure 20A and Figure 20B The sharp drop in stress after the yield point is likely a result of cracking in the ceramic “surface,” and PTFE is the primary driver of further expansion. Higher strain rates allow for greater elongation when stretched at 175°C. For both expansion rates of 1 mm / s and 10 mm / s, a long plateau region from approximately 50% to 110% strain indicates plastic flow, more specifically, non-equilibrium steady-state flow. This flow is characterized by the disruption of amorphous regions, where polymer chains are sheared and / or straightened, causing the material to expand. When stretched at 200°C, the plastic flow region is much longer and requires less force to achieve. The stress observed throughout the plastic flow region hovers around 0 kPa, which is likely close to the instrument’s detection level. This indicates that the force required for expansion and flow is very low. 200°C is far above the Tg of PTFE, causing the material to behave more like a soft rubber state, making the amorphous regions readily flowable and deformable. Complete deformation and alignment within the amorphous regions allows for the formation of PTFE nanofibers. These PTFE nanofibers are generated by the alignment of polymer chains and the remaining crystalline regions of PTFE. The alignment of the polymer chains can be seen from the slight increase in stress at high strain %, which represents... Figure 20B The strain hardening region within.

[0268] Given the atypical expansion behavior observed on the DMA of the machined matrix, and to confirm that fibrillary expansion was truly achieved, SEM images of the expanded matrix (expanded tape) were collected. The matrix was machined by cutting in a plane parallel to the machining direction (0-degree cut; machining and expansion directions are the same) and then expanded at 175 degrees Celsius. Figure 21A , Figure 21B and Figure 21C It is clearly shown that fibrillation becomes more advantageous as the rate decreases. For example, at a rate of 10 mm / s, the surface remains essentially non-porous, and this rate can be considered as 200% elongation per second relative to a 1 cm sheet of material. Figure 21A Reducing the stretching rate by an order of magnitude to 1 mm / s (110% elongation / second), the surface begins to open; however, noticeable breakage of the PTFE fibrils can be seen in the newly formed surface openings. Figure 21B In contrast, expanding the material at 0.1 mm / s (101% elongation / second) does not cause the fibrils to break; instead, it results in well-oriented fibrils with distinguishable length and uniform width. Figure 21C As noted herein, the expansion conditions of the machined matrix (strip) in this example differ from those of conventional PTFE stretching, where literature indicates that stretching can be performed anywhere between 30% and 5000% elongation per second, depending on the properties of the PTFE used and the desired final porosity.

[0269] To avoid being bound by theory, the aforementioned expansion behavior and its differences with the particulate phase or PTFE phase can be explained by the interfacial interactions between short-stranded PTFE fibrils, long-stranded PTFE fibrils, and the solid phase. Specifically, the expansion matrix of this embodiment (175 degrees Celsius, 0.1 mm / s, 0-degree cutting angle) is used. Figure 22 ) and conventionally formed PTFE membranes that do not contain solid particles ( Figure 14 A comparison reveals that there are some similar binding mechanisms between the two. For example, Figure 14 This demonstrates a well-known phenomenon where PTFE resin self-adhedes at spaced locations (nodes), with taut PTFE fibers of discernible width between them. The expanded matrix (expanded tape) exhibits comparable networking after expansion. Figure 13 In this network, active particles act as PTFE bonding nodes, rather than the nodes being formed by the protofibrils themselves. This networking is believed to explain the unusual expansion behavior and structural flexibility of both the machined and expanded matrices. Regarding the unusual expansion behavior, theoretically, the particles acting as PTFE nodes allow tensile forces to be applied to the active particles rather than the PTFE fibers, thus causing the protofibrils to expand at a significantly reduced rate. Simultaneously, the mechanical flexibility of the machined and expanded matrices may be attributed to the PTFE protofibrils acting in a manner similar to ceramic bridges, thereby ensuring that all phases are mechanically linked at the microscopic level. However, given that PTFE is flexible while conventionally sintered ceramic bridges are rigid, the machined and expanded matrix bands retain rubber-like qualities. This type of bonding can be interpreted as a form of cold sintering, where the sintering process is achieved through flexible bonding phases, replacing rigid clay binders such as porcelain, bentonite, kaolinite, etc.

[0270] ImageJ software was used to determine Figure 14 and Figure 22 The angle of the original fiber direction relative to the x-axis. Specifically, in this example, the angle of the original fiber is (175 degrees Celsius, 0.1 mm / s, 0-degree cutting angle); Figure 22 ) and conventionally formed PTFE membranes that do not contain solid particles ( Figure 14 Comparisons show that the expanded matrix (expanded tape) exhibits a narrowing of the fibril orientation parallel to the machining direction. In contrast, conventionally manufactured PTFE tapes show a more random fibril angular orientation. This phenomenon may be due to the different mechanisms that promote PTFE-PTFE bonding compared to the formation of particle / PTFE networks.

[0271] The expansion DMA curve of the machining matrix expanding in an expansion direction at a 90-degree angle to the machining direction is shown in... Figure 23 The diagram shows (expansion occurred at 200 degrees Celsius). Again, it was found that stress increases with the expansion rate, but the overall expansion behavior remains inconsistent with the expansion behavior of ceramic materials or conventional PTFE-based materials without active particles. That is, the elongation behavior is different from... Figure 20A and Figure 20B The elongation behavior is relatively consistent. Specifically, similar orders of magnitude and relationships between the stretching rate and stress are observed.

[0272] The microstructure of the expanded matrix formed by the expansion of the machining matrix at a 90-degree angle to the machining direction is... Figure 24A , Figure 24B and Figure 24C As shown (expansion was carried out at 200 degrees Celsius). Unlike expanded matrices formed by expanding the machined matrix in the same expansion direction as the machining direction, no clear relationship between the expansion rate and the microstructure was observed. An expansion rate of 0.1 mm / s produced excellent fibrillary expansion; however, the extent to which a lower expansion rate opens the catalyst layer is unclear. Figure 24A The increase in porosity appears to be more pronounced when the expansion rate is 1.0 mm / s. Figure 24B The worst porosity occurred at the fastest expansion rate (10.0 mm / s); Figure 24C This result indicates that an expansion direction similar to the machining direction can produce a more permeable microstructure compared to an expansion direction that is significantly different from the machining direction.

Claims

1. A strip comprising: A machining matrix having a machining direction, the machining matrix comprising: Long strands of PTFE fibrils forming an orientation network, the orientation network comprising the long strands of PTFE fibrils defining a longitudinal direction; and The nodes distributed in the orientation network include active particles and short strands of PTFE fibrils distributed in the active particles.

2. The strip as described in claim 1, wherein, The longitudinal direction and the machining direction of the machining substrate are defined by an angle of 0 to 20 degrees.

3. The strip as described in claim 1 or 2, wherein, 90% or more of the long strands of PTFE fibrils are oriented at an angle of 0 to 20 degrees relative to the machining direction.

4. The strip as described in any one of claims 1 to 3, wherein, The machining matrix contains 60 wt% or more of the active particles.

5. The strip as described in claim 4, wherein, The machining matrix contains 80 wt% or more of the active particles.

6. The strip as described in any one of claims 1 to 5, wherein, The machined matrix comprises 0.01 wt% to 20 wt% of the short-strand PTFE fibrils.

7. The strip as claimed in any one of claims 1 to 6, wherein, The machined matrix comprises 0.01 wt% to 20 wt% of the long-stranded PTFE fibrils.

8. The strip as claimed in any one of claims 1 to 7, wherein, The active particles comprise a catalyst, an electroactive material, an absorbent, an adsorbent, a seed crystal, a metal-organic framework, a polymeric framework, or a combination of two or more thereof; and wherein the adsorbent is a physical adsorbent, a chemical adsorbent, or a physical-chemical adsorbent hybrid.

9. The strip as claimed in claim 8, wherein, The catalyst is capable of destroying ozone.

10. The strip as claimed in any one of claims 1 to 9, wherein, The catalyst comprises manganese oxide, copper oxide, cerium dioxide, or a combination of two or more thereof.

11. The strip as claimed in claim 8, wherein, The adsorbent can adsorb alkaline gases, acidic gases, gaseous organic compounds, gaseous inorganic compounds, or combinations of two or more of them.

12. The strip as claimed in any one of claims 1 to 11, wherein, The nodes have an average diameter ranging from 0.1 micrometers to 50 micrometers.

13. An expandable strip comprising: An expanding matrix having an expansion direction, the expanding matrix comprising: Long strands of PTFE fibrils forming an orientation network, the orientation network comprising the long strands of PTFE fibrils defining a longitudinal direction; and The nodes distributed in the orientation network include active particles and short strands of PTFE fibrils distributed in the active particles.

14. The expandable strip as claimed in claim 13, wherein, The longitudinal direction and the expansion direction are defined by an angle of 0 to 20 degrees.

15. The expandable strip as claimed in claim 13 or 14, wherein, The orientation angle of the long PTFE fibrils relative to the expansion direction follows a normal distribution.

16. The expandable strip as claimed in any one of claims 13 to 15, wherein, 90% or more of the long strands of PTFE fibrils are oriented at an angle of 0 to 20 degrees relative to the direction of expansion.

17. The expandable strip as claimed in any one of claims 13 to 15, wherein, The expanded matrix contains 60 wt% or more of the active particles.

18. The expandable strip as claimed in claim 17, wherein, The expanded matrix contains 80 wt% or more of the active particles.

19. The expandable strip as described in any one of claims 13 to 18, wherein, The expanded matrix comprises 0.01 wt% to 20 wt% of the short-strand PTFE fibrils.

20. The expandable strip as claimed in any one of claims 13 to 19, wherein, The expanded matrix comprises 0.01 wt% to 20 wt% of the long-stranded PTFE fibrils.

21. The expandable strip as claimed in any one of claims 13 to 20, wherein, The active particles comprise a catalyst, an electroactive material, an absorbent, an adsorbent, a seed crystal, a metal-organic framework, a polymeric framework, or a combination of two or more thereof; and wherein the adsorbent is a physical adsorbent, a chemical adsorbent, or a physical-chemical adsorbent hybrid.

22. The expandable strip as claimed in claim 21, wherein, The catalyst is capable of destroying ozone.

23. The expandable strip as claimed in claim 22, wherein, The catalyst comprises manganese oxide, copper oxide, cerium dioxide, or a combination of two or more thereof.

24. The expandable strip as claimed in claim 21, wherein, The adsorbent can adsorb alkaline gases, acidic gases, gaseous organic compounds, gaseous inorganic compounds, or combinations of two or more of them.

25. The expandable strip as described in any one of claims 13 to 24, wherein, The nodes have an average diameter ranging from 0.1 micrometers to 50 micrometers.

26. A method for manufacturing a strip as described in any one of claims 1 to 12, the method comprising: The fiber matrix is ​​machined in a machining direction to form the machined matrix, the fiber matrix comprising: Short-strand PTFE fibrils; Long-strand PTFE fibrils; and Active particles.

27. A method for manufacturing an expanded strip as described in any one of claims 13 to 25, the method comprising: The fiber matrix is ​​machined in a machining direction to form a machined matrix, the fiber matrix comprising: Short-strand PTFE fibrils; Long strand PTFE fibrils; and Active particles; and The machining substrate is expanded in the expansion direction to form the expanded substrate.

28. The method of claim 27, wherein, The longitudinal direction and the expansion direction define an angle of 0 to 20 degrees.

29. The method of claim 26 or claim 27, wherein, The expansion of the machining substrate further includes expanding at a rate of 10% to 100% elongation per second.

30. The method of claim 29, wherein, Expanding the machined substrate involves expanding at a rate of 100% to 110% elongation per second.

31. An expandable strip comprising: An expanding matrix having an expansion direction, the expanding matrix comprising: Long strands of PTFE fibrils forming an orientation network, the orientation network comprising the long strands of PTFE fibrils defining a longitudinal direction; and The nodes distributed in the orientation network include short strands of PTFE fibrils and active particles distributed in the short strands of PTFE fibrils; The expanded matrix is ​​formed by a method comprising the following: The fiber matrix is ​​machined in a machining direction to form a machined matrix, the fiber matrix comprising: Short-strand PTFE fibrils; Long-strand PTFE fibrils; and Active particles; The machined matrix includes an orientation network comprising the long strands of PTFE fibrils defining the longitudinal direction; and nodes distributed in the orientation network, the nodes comprising the short strands of PTFE fibrils and the active particles distributed in the short strands of PTFE fibrils; as well as The machining substrate is expanded in the expansion direction to form an expanded substrate.

32. The expandable strip as claimed in claim 31, wherein, The longitudinal direction and the machining direction are at an angle of 0 to 20 degrees.

33. The expandable strip as claimed in claim 31, wherein, The longitudinal direction and the expansion direction are angles of 0 to 20 degrees.

34. A strip comprising: A machining matrix having a first machining direction and a second machining direction, the machining matrix comprising: Long strands of PTFE fibrils forming an orientation network, the orientation network comprising the long strands of PTFE fibrils, a first portion of the long strands of PTFE fibrils defining a first longitudinal direction and a second portion of the long strands of PTFE fibrils defining a second longitudinal direction; The nodes distributed in the orientation network include active particles and short strands of PTFE fibrils distributed in the active particles.

35. The strip as described in claim 34, wherein, The first longitudinal direction and the first machining direction of the machining substrate define a first angle of 0 to 20 degrees, and the second longitudinal direction and the second machining direction of the machining substrate define a second angle of 0 to 20 degrees.

36. The strip as described in claim 34 or 35, wherein, A first portion of more than 50% or more of the long strand PTFE fibrils is oriented at the first angle, and a second portion of more than 50% or more of the long strand PTFE fibrils is oriented at the second angle.

37. An expandable strip comprising: An expanding matrix having a first expansion direction and a second expansion direction, the expanding matrix comprising: Long strands of PTFE fibrils forming an orientation network, the orientation network comprising the long strands of PTFE fibrils, a first portion of the long strands of PTFE fibrils defining a first longitudinal direction and a second portion of the long strands of PTFE fibrils defining a second longitudinal direction; and The nodes distributed in the orientation network include active particles and short strands of PTFE fibrils distributed in the active particles.

38. The expandable strip as claimed in claim 37, wherein, The longitudinal direction and the expansion direction are defined by an angle of 0 to 20 degrees.

39. The strip as claimed in claim 34, wherein, The first longitudinal direction and the first expansion direction of the expanded matrix define a third angle of 0 to 20 degrees, and the second longitudinal direction and the second expansion direction of the expanded matrix define a fourth angle of 0 to 20 degrees.

40. The strip as described in claim 34 or 35, wherein, More than 50% of the first portion of the long-stranded PTFE fibrils is oriented at the third angle, and more than 50% of the second portion of the long-stranded PTFE fibrils is oriented at the fourth angle.

41. A method for manufacturing a strip as described in any one of claims 34 to 36, the method comprising: The fiber matrix is ​​machined in a first machining direction and then machined in a second machining direction to form the machined matrix, the fiber matrix comprising: Short-strand PTFE fibrils; Long-strand PTFE fibrils; and Active particles.

42. A method for manufacturing an expanded strip as described in any one of claims 37-39, the method comprising: The machining substrate as described in claim 41 is expanded in the first expansion direction and the machining substrate as described in claim 41 is expanded in the second expansion direction to form the expanded substrate.

43. A honeycomb structure comprising a strip as claimed in any one of claims 1 to 12 or an expanded strip as claimed in any one of claims 13 to 25.

44. A cinnamon roll-like structure comprising a strip as claimed in any one of claims 1 to 12 or an expanded strip as claimed in any one of claims 13 to 25.

45. A packed bed structure comprising a strip as claimed in any one of claims 1 to 12 or an expanded strip as claimed in any one of claims 13 to 25.

Images