Porous structure and manufacturing method

Abstract

The porous body includes a base material including a longitudinal axis along the length L of the base material, which defines a spiral shape when viewed in a plane perpendicular to the longitudinal axis, and a plurality of discrete spacer particles attached to the base material.

Description

Technical Field

[0001] The following relates to a porous structure and a method for manufacturing the same.

Background Art

[0002] Porous structures made from ceramic bodies and metal bodies are known. Ceramic bodies are typically formed by conventional processes (e.g., extrusion, subtractive pore-forming processes, etc.). Some metal bodies are formed by winding a metal sheet to form a corrugated structure that defines channels therein. FIGS. 1 and 2 show diagrams of products formed by conventional methods. The industry continues to pursue improvements in porous structures.

Brief Description of the Drawings

[0003] This disclosure can be better understood by referring to the accompanying drawings, and many of its features and advantages will be apparent to those skilled in the art.

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Summary of the Invention

[0004] According to a first aspect, the porous body includes an outer tubular structure having an inner surface and an outer surface, a first plurality of discrete spacer particles attached to the inner surface of the outer tubular structure, and a first inner tubular structure having an inner surface and an outer surface, wherein the outer surface of the first inner tubular structure abuts against the first plurality of discrete spacer particles.

[0005] In one aspect, the porous body includes an outer tubular structure having an inner surface and an outer surface, a plurality of inner tubular structures each having an inner surface and an outer surface, and a plurality of discrete spacer particles dispersed within the porous body. A coating covering at least a portion of the surface of the porous body, the coating including a metal organic framework (MOF).

[0006] In another aspect, the porous body includes an outer tubular structure having an inner surface and an outer surface, a plurality of inner tubular structures each having an inner surface and an outer surface, and a plurality of discrete spacer particles dispersed within the porous body.

[0007] In another aspect, the porous body includes an outer tubular structure having an inner surface and an outer surface, a plurality of inner tubular structures each having an inner surface and an outer surface, and a plurality of discrete spacer particles dispersed within the porous body, wherein each of the plurality of discrete spacer particles contains an active material.

[0008] In yet another aspect, the porous body includes an outer tubular structure having an inner surface and an outer surface, a plurality of inner tubular structures each having an inner surface and an outer surface, and a plurality of discrete spacer particles dispersed within the porous body, and the porous body contains an active material on at least a portion of the porous body.

[0009] In another aspect, the porous body includes an outer tubular structure having an inner surface and an outer surface, a plurality of inner tubular structures each having an inner surface and an outer surface, and a plurality of discrete spacer particles dispersed within the porous body, wherein each of the plurality of discrete spacer particles includes a multi-arm shape, and the multi-arm shape forms a contact point with the outer tubular structure, the plurality of inner tubular structures, or a combination thereof.

[0010] In another aspect, the porous body is a substrate that includes a longitudinal axis along the length L of the substrate and defines a helical shape when viewed in a plane perpendicular to the longitudinal axis, and a plurality of discrete spacer particles attached to the substrate.

[0011] In another aspect, the porous body is a substrate that includes a longitudinal axis along the length L of the substrate and defines a helical shape when viewed in a plane perpendicular to the longitudinal axis, a plurality of discrete spacer particles attached to the substrate, and a coating that covers at least a portion of the surface of the porous body, wherein the coating includes a metal-organic framework (MOF).

[0012] In yet another aspect, the porous body includes a substrate that includes a longitudinal axis along the length L of the substrate and defines a spiral shape when viewed in a plane perpendicular to the longitudinal axis, and a plurality of discrete spacer particles attached to the substrate, wherein each of the plurality of discrete spacer particles includes an average solidity of at least 0.6 and 1 or less.

[0013] In another aspect, the porous body includes a substrate that includes a longitudinal axis along the length L of the substrate and defines a spiral shape when viewed in a plane perpendicular to the longitudinal axis, and the plurality of discrete spacer particles attached to the substrate include an active material.

[0014] In yet another aspect, the porous body includes a substrate that includes a longitudinal axis along the length L of the substrate and defines a spiral shape when viewed in a plane perpendicular to the longitudinal axis, and a plurality of discrete spacer particles attached to the substrate, and the porous body includes an active material on at least a portion of the porous body.

[0015] In yet another aspect, the porous body includes a substrate that includes a longitudinal axis along the length L of the substrate and defines a spiral shape when viewed in a plane perpendicular to the longitudinal axis, and a plurality of discrete spacer particles attached to the substrate, wherein each of the plurality of discrete spacer particles includes a multi-armed shape and the multi-armed shape forms a contact point with the substrate.

Mode for Carrying Out the Invention

[0016] The following are the following applications, namely, filtration, separation, heat and mass transfer, heterogeneous catalysis and catalyst carriers, air and gas purification and separation, carbon capture and conversion, capture and conversion of volatile organic compounds, dehumidification, harmful smoke reduction, liquid treatment including drinking water and wastewater, liquid treatment and separation, chemical synthesis, petroleum refining, automotive catalytic conversion, fuel cell air purification, selective absorption and adsorption, reactors, ion extraction, selective (ionic) transport materials / membranes, lithium capture, packed bed adsorption, absorption, reaction, and separation, gases (e.g., CO 2 、NO XRelates to a porous article that can be used for capture and / or conversion etc. (such as). The porous body can be used in pharmaceutical and / or biochemical and / or biomedical applications.

[0017] In one embodiment, what can promote the manufacture and / or performance improvement of a porous body having any one or more of the features described herein can be formed according to the process outlined in FIG. 3. The process for forming the porous body can start with step 301 of obtaining a suitable substrate. The substrate can be one or more substantially sheet-like materials. FIGS. 4a and 4b show perspective views of suitable shapes of the substrate. Generally, the substrate has a sheet-like structure in which the dimensions of length and width are substantially larger than the thickness, so that the length is greater than or equal to the width, and the width and length are greater than the thickness. In at least one embodiment, the body of the substrate has a length that is at least 10 times, or at least 100 times, or even at least 1000 times the thickness of the body of the substrate. In another embodiment, the width of the body of the substrate can be at least 10 times, or at least 100 times, or at least 1000 times the thickness of the body.

[0018] According to one non-limiting embodiment, in order to reduce the wall thickness of the porous body, it may be desirable for the average thickness of the main body of the substrate to be relatively thin, which can facilitate the improved operation of the porous body, including but not limited to a certain suitable pressure drop of the porous body. In one embodiment, the average thickness of the main body can be 100 mm or less, for example, 90 mm or less, or 80 mm or less, or 70 mm or less, or 60 mm or less, or 50 mm or less, or 40 mm or less, or 30 mm or less, or 20 mm or less, or 10 mm or less, or 5 mm or less, or 1 mm or less. In still other embodiments, the average thickness of the main body can be at least 0.05 mm, or at least 0.1 mm, or at least 0.2 mm, or at least 0.3 mm, or at least 0.4 mm, or at least 0.5 mm, or at least 0.6 mm, or at least 0.7 mm, or at least 0.8 mm. The average thickness of the main body can be, for example, but not limited to, a value between any of the above minimum and maximum values, including but not limited to a range of at least 0.05 mm and 100 mm or less, or at least 0.1 mm and 10 mm or less, or at least 0.5 mm and 5 mm or less.

[0019] According to one aspect, the material of the substrate can include any suitable material that can facilitate the manufacture and / or performance improvement of the porous body. In one embodiment, the substrate can include a metal, a metal alloy, a ceramic, a polymer, or any combination thereof. In one embodiment, the substrate can be a monolithic and non-porous main body such as a metal sheet. In still other embodiments, the substrate can be a fibrous body, including but not limited to, for example, a woven fabric structure, a non-woven fabric structure, etc. According to another embodiment, the substrate can include one or more materials including a polycrystalline phase, an amorphous material, a single crystal phase, or any combination thereof. The substrate can consist essentially of any one or more of the features described herein.

[0020] According to one embodiment, the substrate may include a woven fabric or a mesh. In another non-limiting embodiment, the substrate may define a continuous structure that can be used to transport heat either inside or outside the system in order to better control the temperature, temperature response, and temperature uniformity within the system. To facilitate heat transfer, the substrate is preferably composed of a thermally conductive material such as metal, steel, aluminum, alumina, etc. There may also be other cases where heat insulation is required, in which case polymers, silica, quartz, glass fibers, etc. may be used as part or all of the substrate. In other situations, a combination of a thermally conductive material and a heat insulating material may be utilized. Specific design criteria can be adapted according to the application and the nature of the endothermic and / or exothermic processes.

[0021] According to one embodiment, the porous body may contain an active material that can promote the production and / or performance improvement of the porous body. In one embodiment, at least a part of the porous body may contain the active material. In one embodiment, the active material may be a coating that covers at least a part of the porous body. In one embodiment, the substrate may further contain the active material. The active material is a material configured to interact (e.g., chemically react, adsorb) with the material flowing through the porous body. In one embodiment, the active material may be a discrete phase or structure that is part of a composite substrate structure such as a substrate having a core and a coating, and the coating may contain the active material. Alternatively, in another non-limiting embodiment, the substrate may consist essentially of the active material. In one non-limiting embodiment, examples of the active material may include ceramics, glasses, fiber materials, natural materials, oxides, carbides, nitrides, halides, hydroxides, clays, polymers, metals, metal alloys, or any combination thereof. Some suitable non-limiting examples of the active material include activated carbon, metal organic frameworks, zeolites, boron nitride, titanium dioxide, silicon dioxide, zirconium dioxide, vanadium pentoxide, cerium oxide, lanthanum oxide, and alumina doped with platinum, palladium, rhodium, gold, silver, and other noble metals, layered double hydroxides, cordierite, lithium bayerite, including but not limited to lithium titanate oxide, lithium manganate oxide, lithium iron phosphate, graphene, carbon nanotubes, manganese dioxide, manganese oxide, lanthanum strontium manganite, antibacterial materials (e.g., antibacterial materials, antifungal materials, antiviral materials, or any combination thereof), polymers, metals, metal alloys, ceramics, ion exchange resins containing glasses, or any combination thereof.

[0022] According to one non-limiting embodiment, the substrate may desirably be relatively flexible. In at least one non-limiting example, the flexibility of the substrate may be balanced with the average thickness of the substrate to ensure suitable manufacturability and performance of the porous body. In one example, the flexibility of the substrate may be similar to that of paper, may be similar to that of sheet metal, or may be similar to woven or non-woven fabrics of various weights.

[0023] After obtaining a suitable substrate in step 301, in step 303, the process may continue by placing discrete spacer particles on the substrate. The discrete spacer particles can be fixed to the substrate using any suitable means (e.g., brazing), including, for example, but not limited to, mechanical attachment, chemical bonding, adhesives or other intermediate attachment materials, or any combination thereof. The discrete spacer particles can be placed on the substrate to help define the channels of the porous body. The discrete spacer particles can help control the spacing between the layers of the substrate when the substrate is manipulated (e.g., rolled) into another shape or at that time, and can direct the flow of fluid around and through the pores of the discrete spacer particles. See, for example, FIGS. 6a and 6b.

[0024] According to one embodiment, certain aspects of the discrete spacer particles can be adapted to obtain the desired performance of the porous body. For example, the shape of the discrete spacer particles (blocky, plate-like, needle-like, rod-like, conical, spherical, etc.), the particle size distribution of the discrete spacer particles (e.g., D50, D10, D90, D10 - D90, etc.), the length, height, width, composition, porosity, helix angle, morphology of the discrete spacer particles (e.g., porous aggregates or non-aggregates), and the porosity of the discrete spacer particles can be controlled to obtain the desired performance of the porous body. It will be understood that any combination of aspects of the discrete spacer particles can be combined to facilitate the manufacture and / or performance improvement of the porous body.

[0025] Figure 7 shows an example of a porous body 700 according to an embodiment. In one embodiment, the porous body 700 can include a substrate 701, and the substrate 701 can include a longitudinal axis 703 along the length L of the substrate 701. FIG. 7b is a perspective view of the porous body 700. In one embodiment, the substrate 701 of the porous body 700 can define a spiral shape when viewed in a plane perpendicular to the longitudinal axis 703. In yet another embodiment, the porous body 700 can include a plurality of discrete spacer particles 705 attached to the substrate 701.

[0026] In one embodiment, the porous body can be formed by any suitable manufacturing method for forming the continuous monolithic body described herein. FIG. 8a is an example of a porous body according to one embodiment. The porous body 800 can include an outer tubular structure 801 having an inner surface 803 and an outer surface 805, and a first plurality of discrete spacer particles 807 attached to the inner surface 803 of the outer tubular structure 801. The porous body 800 can include a first inner tubular structure 809 having an inner surface closest to the central structure 830 and an outer surface closest to the outer tubular structure 801, and the outer surface of the first inner tubular structure 809 is in contact with the first plurality of discrete spacer particles 807. In certain embodiments, the porous body can further include a second plurality of discrete spacer particles 813 attached to the inner surface of the first inner tubular structure 809. The porous body 800 can include a second inner tubular structure 811 having an inner surface closest to the central structure 830 and an outer surface closest to the outer tubular structure 801, and the outer surface of the second inner tubular structure 811 is in contact with the second plurality of discrete spacer particles 813. The porous body 800 can include a third plurality of discrete spacer particles 815 attached to the inner surface of the second inner tubular structure 811. The porous body 800 can include a third inner tubular structure 817 having an inner surface closest to the central structure 830 and an outer surface closest to the outer tubular structure 801, and the outer surface of the third inner tubular structure 817 is in contact with the third plurality of discrete spacer particles 815. The porous body 800 can include a fourth plurality of discrete spacer particles 819 attached to the inner surface of the third inner tubular structure 817. The fourth plurality of discrete spacer particles 819 can contact a central structure 830 that defines a central portion of the porous body 800. As used herein, the first inner tubular structure, the second inner tubular structure, the third inner tubular structure, and the central structure can each include any of the features of the plurality of inner tubular structures described herein.

[0027] In yet another embodiment, the porous body may include a plurality of inner tubular structures that can facilitate the manufacture and / or performance improvement of the porous body. In certain embodiments, the porous body may include at least one inner tubular structure, such as at least two inner tubular structures, or at least three inner tubular structures, or at least four inner tubular structures, or at least five inner tubular structures, or at least six inner tubular structures, or at least seven inner tubular structures, or at least eight inner tubular structures. In certain embodiments, the porous body may include 20 or fewer inner tubular structures, such as 18 or fewer inner tubular structures, or 15 or fewer inner tubular structures, or 12 or fewer inner tubular structures, or 10 or fewer inner tubular structures. The porous body may include any number of inner tubular structures between any of the above minimum and maximum values, for example, but not limited to, inner tubular structures within a range of at least 1 and 20 or fewer, or inner tubular structures within a range of at least 2 and 10 or fewer.

[0028] Referring again to FIG. 8a, the discrete spacer particles can extend along a non-linear path along the circumferential surface of the inner tubular structure. In one embodiment, the discrete spacer particles can extend along a helical path along the circumferential surface of the inner tubular structure that defines a helix angle that can facilitate improvement in the performance of the porous body 800. In one embodiment, the discrete spacer particles can extend along a helical path along the circumferential surface of the substrate of the porous body 850. The helix angle of the discrete spacer particles dispersed within the porous body can be calculated by measuring the angle between the helical path defined by the discrete spacer particles and the central axis of the porous body when viewed from the side. For example, as shown in FIG. 8b showing a perspective view of the porous body 850, the porous body 850 includes a central axis 851 and discrete spacer particles 853 that define a helical path 855 along the circumferential surface of the substrate. The helical path 855 and the central axis 851 define a helix angle 857. In one embodiment, the discrete spacer particles can define a helix angle of at least 30 degrees, such as at least 31 degrees, at least 32 degrees, at least 33 degrees, at least 34 degrees, at least 35 degrees, at least 36 degrees, at least 37 degrees, at least 38 degrees, at least 39 degrees, at least 40 degrees, at least 41 degrees, at least 42 degrees, at least 43 degrees, at least 44 degrees, at least 45 degrees, at least 46 degrees, at least 47 degrees, at least 48 degrees, at least 49 degrees, at least 50 degrees, at least 51 degrees, at least 52 degrees, at least 53 degrees, at least 54 degrees, at least 55 degrees, at least 56 degrees, at least 57 degrees, at least 58 degrees, at least 59 degrees, or at least 60 degrees. In yet another embodiment, the discrete spacer particles can have a helix angle of 89 degrees or less, such as 88 degrees or less, or 87 degrees or less, or 86 degrees or less, or 85 degrees or less, or 84 degrees or less, or 83 degrees or less, or 82 degrees or less, or 81 degrees or less, or 80 degrees or less, or 79 degrees or less, or 78 degrees or less, or 77 degrees or less, or 76 degrees or less, or 75 degrees or less, or 74 degrees or less, or 73 degrees or less, or 72 degrees or less, or 71 degrees or less, or 70 degrees or less, or 69 degrees or less, or 68 degrees or less, or 67 degrees or less, or 66 degrees or less, or 65 degrees or less, or 64 degrees or less, or 63 degrees or less, or 62 degrees or less, or 61 degrees or less.The discrete spacer particles may have a helix angle between any of the above minimum and maximum values, for example, including but not limited to within a range of at least 30 degrees to 89 degrees or less, or at least 40 degrees to 80 degrees or less, or at least 50 degrees to 65 degrees or less.

[0029] According to one aspect, the materials of the outer tubular structure 801 and the plurality of inner tubular structures 809, 811, 817 may include any suitable materials that can facilitate the manufacture and / or performance improvement of the porous body. In one embodiment, the materials may include metals, metal alloys, ceramics, polymers, or any combination thereof. In still other embodiments, the outer tubular structure 801 and the plurality of inner tubular structures 809, 811, 817 may be fibrous bodies including, but not limited to, woven fabric structures, non-woven fabric structures, etc. According to another embodiment, the outer tubular structure 801 and the plurality of inner tubular structures 809, 811, 817 may include one or more materials including polycrystalline phases, amorphous materials, single crystal phases, or any combination thereof. The outer tubular structure 801 and the plurality of inner tubular structures 809, 811, 817 may consist essentially of any one or more of the features described herein.

[0030] According to one embodiment, the outer tubular structure 801 and the plurality of inner tubular structures 809, 811, 817 may include a woven fabric or a mesh. In another non-limiting embodiment, the outer tubular structure 801 and the plurality of inner tubular structures 809, 811, 817 may define a continuous structure that can be used to transport heat either inside or outside the system to better control the temperature, temperature response, and temperature uniformity within the system. To facilitate heat transfer, the outer tubular structure 801 and the plurality of inner tubular structures 809, 811, 817 are preferably composed of a heat-conductive material such as, for example, metal, steel, aluminum, alumina, etc. There may be other cases where heat insulation is required, in which case polymers, silica, quartz, glass fibers, etc. may be used as part or all of the outer tubular structure 801 and the plurality of inner tubular structures 809, 811, 817. In other situations, a combination of a heat-conductive material and a heat-insulating material may be utilized. Specific design criteria can be adapted according to the application and the nature of the endothermic and / or exothermic process.

[0031] According to one embodiment, the outer tubular structure 801 and the plurality of inner tubular structures 809, 811, 817 may contain an active material that can promote the production and / or improve the performance of the porous body. In one embodiment, the active material may be a coating that covers at least a portion of the outer tubular structure 801 and the plurality of inner tubular structures 809, 811, 817. The active material is a material configured to interact (e.g., chemically react, adsorb) with the material flowing through the porous body. The active material may be a separate phase or structure that is part of a composite substrate structure such as the outer tubular structure 801 and the plurality of inner tubular structures 809, 811, 817 having a core and a coating, and the coating may contain the active material. Alternatively, in another non-limiting embodiment, the outer tubular structure 801 and the plurality of inner tubular structures 809, 811, 817 may consist essentially of the active material. In one non-limiting embodiment, examples of the active material may include ceramics, glasses, fiber materials, natural materials, oxides, carbides, nitrides, halides, hydroxides, clays, polymers, metals, metal alloys, or any combination thereof. Some suitable non-limiting examples of the active material include activated carbon, metal-organic frameworks, zeolites, boron nitride, titanium dioxide, silicon dioxide, zirconium dioxide, vanadium pentoxide, cerium oxide, lanthanum oxide, and alumina doped with platinum, palladium, rhodium, gold, silver, and other noble metals, layered double hydroxides, cordierite, lithium biotite, including but not limited to lithium titanate, lithium manganate, lithium iron phosphate, graphene, carbon nanotubes, manganese dioxide, manganese oxide, lanthanum strontium manganite, antibacterial materials (e.g., antibacterial materials, antifungal materials, antiviral materials, or any combination thereof), polymers, metals, metal alloys, ceramics, ion exchange resins containing glass, or any combination thereof.

[0032] Figures 9a - 9h are various two - dimensional views of the shape of discrete spacer particles. The embodiments of this specification are not strictly limited to the shapes shown in Figures 9a - 9h. The shape of the discrete spacer particles can be modified to improve the manufacture of the porous product and / or the operation of the porous product. According to one non - limiting embodiment, the discrete spacer particles can have any regular or irregular shape, for example, a regular or irregular polygonal shape, a complex shape including, but not limited to, an arcuate portion having concave or convex portions. In one embodiment, the spacing particles can include shapes such as trilobes, rings, disks, particles having regular or irregular rough surfaces (e.g., grooves, dimples, protrusions, etc.). The discrete spacer particles can have a controlled porosity and / or permeability that creates smaller flow paths through the volume of the discrete spacer particles.

[0033] Figures 9f - 9h are various two - dimensional views of discrete spacer particles having a multi - arm shape. Figure 10a is a three - dimensional view of discrete spacer particles having a multi - arm shape. In one embodiment, the spacer particle 1001 can include a plurality of arms 1005 extending from a central portion 1003. Figure 10b is a view of the multi - arm shaped discrete spacer particles 1001 in a porous body according to one embodiment of this specification. In a particular embodiment, the discrete spacer particle 1001 can form a contact point 1007 with an outer tubular structure 1009, a plurality of inner tubular structures 1011, or a combination thereof. As used herein, a contact point is used to describe the portion of the porous body where a portion of the discrete spacer particle is in contact with one or more of the outer tubular structure, the substrate, the plurality of inner tubular structures, or a combination thereof. In one embodiment, the contact point forms a continuous connection between the discrete spacer particle 1001 and the outer tubular structure, the plurality of inner tubular structures, the substrate, or a combination thereof. In the example shown in Figure 10b, the multi - arm shaped discrete spacer particle 1001 forms a contact point 1007 with the inner tubular structure 1011 and a contact point (not shown) with the outer tubular structure 1009. In the example shown in Figure 7b, the discrete spacer particle 705 forms a contact point 709 with the substrate 701.

[0034] In certain embodiments, discrete spacer particles having a multi-armed shape may include at least 1 arm, such as at least 2 arms, or at least 3 arms, or at least 4 arms, or at least 5 arms, or at least 6 arms, or at least 7 arms, or at least 8 arms, or at least 9 arms, or at least 10 arms, or at least 11 arms, or at least 12 arms. In yet another embodiment, the discrete spacer particles may include 50 or fewer arms, such as 40 or fewer arms, or 30 or fewer arms, or 20 or fewer arms. The discrete spacer particles may include any number of arms between any of the above minimum and maximum values, such as, but not limited to, including arms in the range of at least 1 to 50 or fewer, or in the range of at least 6 to 20 or fewer.

[0035] According to one embodiment, the discrete spacer particles may include a material that can promote the production and / or improve the performance of a porous body. In one embodiment, the discrete spacer particles may include ceramics, glass, metals, metal alloys, polymers, natural materials, synthetic materials, fibrous materials (such as natural fibers like glass fibers or cotton), porous materials (such as foams), or any combination thereof. The discrete spacer particles may include an amorphous phase, a polycrystalline phase, a single crystal phase, or any combination thereof. In a particular embodiment, the discrete spacer particles may include an active material provided in the embodiments of this specification. In a particular embodiment, the discrete spacer particles may consist essentially of one or more active materials described in the embodiments of this specification.

[0036] In at least one non-limiting embodiment, the discrete spacer particles may contain an active material. In one embodiment, the discrete spacer particles may consist essentially of the active material. In yet another embodiment, the active material may be incorporated into the discrete spacer particles as a discrete phase. In one embodiment, the active material may be a coating on at least a portion of the discrete spacer particles. The active material or active particles may include materials configured to interact (e.g., undergo a chemical reaction with or adsorb the fluid) with a fluid that contacts the discrete spacer particles and flows through the porous body. In one non-limiting embodiment, the discrete spacer particles may include ceramics, glasses, fibrous materials, natural materials, oxides, carbides, nitrides, halides, hydroxides, clays, polymers, metals, metal alloys, or any combination thereof. Some suitable non-limiting examples of materials for use in discrete spacer particles include activated carbon, metal-organic frameworks, zeolites, boron nitride, titanium dioxide, silicon dioxide, zirconium dioxide, vanadium pentoxide, cerium oxide, lanthanum oxide, and alumina doped with platinum, palladium, rhodium, gold, silver, and other noble metals, layered double hydroxides, cordierite, lithium bayerite, lithium titanate oxide, lithium manganese oxide, lithium iron phosphate, graphene, carbon nanotubes, manganese dioxide, manganese oxide, lanthanum strontium manganite, ion exchange resins including antibacterial materials (e.g., antibacterial materials, antifungal materials, antiviral materials, or any combination thereof), or any combination thereof.

[0037] In at least one non-limiting embodiment, the discrete spacer particles can have a specific shape defined by solidity that can facilitate the manufacture and / or performance improvement of the porous body. The solidity of the discrete spacer particles is measured by dividing the actual area of the body of the discrete spacer particles as viewed in two dimensions by the convex hull area of the body of the discrete spacer particles as viewed in two dimensions. The measurement of the actual area and the convex hull area of the discrete spacer particles can be performed by taking an image of a statistically relevant sample size of discrete spacer particles from a batch. The image can be taken at a suitable magnification (e.g., 10 to 20 times) by a suitable optical imaging device (e.g., Olympus DSX). The image is then saved and analyzed using image processing software such as ImageJ. A separate image is created for each spacer particle. Each of the images of the discrete spacer particles is converted to a black and white only image. FIG. 11 is a two-dimensional black and white image of discrete spacer particles according to one embodiment. Using an image such as the image of FIG. 11, the image processing software calculates the white area as the actual area of the body of the discrete spacer particles as viewed in two dimensions of length and width or length and thickness. Using the image processing software and using the shape filter plugin of ImageJ, a convex hull is drawn around the discrete spacer particles. Next, the image processing software calculates the area within the convex hull. The solidity is calculated for each particle based on the value obtained by dividing the actual area of each discrete spacer particle by the convex hull area. The average solidity is the average of the solidity values for all of the measured discrete spacer particles. The solidity standard deviation is also calculated from all of the solidity values measured from the discrete spacer particles in the sample.

[0038] In one embodiment, the discrete spacer particles can have a particular solidity that can facilitate the manufacture and / or performance improvement of the porous body. For example, the discrete spacer particles can have a solidity of at least 0.5, or at least 0.55, or at least 0.6, or at least 0.65, or at least 0.70, or at least 0.75, or at least 0.80, or at least 0.85. In another non-limiting embodiment, the discrete spacer particles can have an average solidity of 1.0 or less, or 0.9999 or less, or 0.95 or less, or 0.90 or less, or 0.85 or less. It will be appreciated that the average solidity of the discrete spacer particles can be within a range including either of the above minimum and maximum values, for example, but not limited to, within a range of at least 0.5 to 0.9999 or less, or at least 0.55 to 0.95 or less.

[0039] In one embodiment, the porous body can have a particular porosity that can facilitate the manufacture and / or performance improvement. In at least one non-limiting embodiment, the porous body can have a particular porosity as defined herein. The porosity of the porous body is measured by dividing the solid volume of the porous body by the cylinder volume of the porous body and subtracting 1 from the result. See the following equation:

[0040]

Equation

[0041] The solid volume is defined as the true volume of the porous body being measured. The cylinder volume is the solid volume of the porous body calculated using the outer cylinder, i.e., the outer tubular structure, used herein. To calculate the solid volume, a 3D model of the porous body is created using CAD software such as Solid Works or OnShape to obtain the solid volume. The cylinder volume can be calculated using the geometric formula V = πr 2 h, where r is the radius of the porous body and h is the height of the porous body defined by the central axis 851.

[0042] According to one embodiment, the porous body can have a specific porosity that can promote the production of the porous body and / or the improvement of its performance. For example, the porous body can have a porosity of at least about 0.5, or at least about 0.55, or at least about 0.6, or at least about 0.65, or at least about 0.70. In another non-limiting embodiment, the porous body can have a porosity of 0.9999 or less, or 0.95 or less, or 0.90 or less, or 0.85 or less, or 0.8 or less, or 0.75 or less. It will be understood that the porosity of the porous body can be within a range including either of the above minimum and maximum values, for example, but not limited to, at least 0.5 to 0.9999 or less, or at least 0.60 to 0.8 or less.

[0043] In one embodiment, the porous body can have a crush strength that can promote the production of the porous body and / or the improvement of its performance. In one embodiment, the porous body can have a crush strength of at least 1 N, for example, at least 2 N, or at least 3 N, or at least 4 N, or at least 5 N, or at least 6 N, or at least 7 N, or at least 8 N, or at least 9 N, or at least 10 N, or at least 15 N, or at least 20 N, or at least 25 N, or at least 30 N, or at least 35 N, or at least 40 N, or at least 45 N, or at least 50 N. In yet another embodiment, the porous body can have a crush strength of 200 N or less, for example, 180 N or less, or 160 N or less, or 140 N or less, or 120 N or less, or 100 N or less, or 80 N or less, or 60 N or less. The crush strength of the porous body can be a value between any of the above minimum and maximum values, including, for example, but not limited to, at least 10 N to 200 N or less, or at least 20 N to 160 N or less. The crush strength of the porous body can be measured using the standard test method for the single pellet crush strength of the formed catalyst and catalyst support, ASTM standard ASTM D4179.

[0044] As described herein, in addition to the mode of dispersion of discrete spacer particles on one or more major surfaces of a substrate, it can be controlled and adapted to facilitate the desired manufacture and / or performance of a porous body. The dispersion of the discrete spacer particles can include the spacing distance between adjacent (e.g., closest) discrete spacer particles, the position of the discrete spacer particles in a plane, the orientation of one or more dimensions of the discrete spacer particles relative to the X or Y direction of the substrate, the areal density or coverage of the discrete spacer particles on one or more major surfaces of the substrate, or any combination thereof. In one embodiment, the position of at least a portion (e.g., at least 25% of all discrete spacer particles, or at least 50% of all discrete spacer particles, or at least 75% of all discrete spacer particles, or at least 90% of all discrete spacer particles, or even substantially all of the discrete spacer particles) of the discrete spacer particles can define a controlled dispersion that can have short-range order and / or long-range order. For example, the position of at least a portion of the discrete spacer particles can define a pattern, and the pattern can include a minimum unit that is repeated over at least a portion of at least one surface region of the major surface of the substrate. Examples of patterns can include, but are not limited to, axial paths, wavy paths, anisotropic structures, and patterns that create structures for paths with baffles.

[0045] In at least one embodiment, it may be desirable for the positions of the discrete spacer particles to be staggered from each other in at least one of the X or Y directions, such that when the porous structure is created, the discrete spacer particles that are configured in a staggered manner define a meandering path, and thus the channels extending through the body are non-linear or further meander. FIGS. 12a-12d are images of a sample porous body produced by attaching discrete spacer particles to a substrate to show the dispersion of the discrete spacer particles and the manipulation (e.g., winding) of the substrate to create a porous body having a substantially linear flow path extending through the porous body. In FIG. 12a, the discrete spacer particles are aligned in one direction (e.g., the Y direction) and can create a linear path in the Y direction in the porous body. FIGS. 13a-13c are images of a sample porous body produced by attaching discrete spacer particles to a substrate to show the dispersion of the discrete spacer particles and the manipulation (e.g., winding) of the substrate to create a porous body having a substantially non-linear flow path extending through the porous body. The dispersion of the discrete spacer particles in FIGS. 13a-13c is different and thus they are staggered and define a non-linear path in at least one direction (e.g., the Y direction) rather than in both directions (i.e., X and Y).

[0046] It will be appreciated that combinations of the dispersion of the discrete spacer particles with the above-described aspects of the discrete spacer particles may be employed.

[0047] In one aspect, a process for disposing discrete spacer particles on a substrate may include disposing discrete spacer particles on at least one major surface of the substrate. In another embodiment, a process for disposing discrete spacer particles on a substrate may include disposing discrete spacer particles on first and second major surfaces of the substrate, the substrate having a substantially sheet-like body defining a length and a width of the body with first and second major surfaces and a thickness extending in a direction perpendicular to a plane defined by the length and the width, the thickness defining a dimension separating the first and second major surfaces. Suitable processes for disposing discrete spacer particles may include, but are not limited to, deposition, drop casting, spray deposition, lithography, screen printing, extrusion, pressing, ink printing, pick-and-place operations (e.g., automated pick-and-place apparatus), templating, gravity-assisted deposition, electrostatic-assisted deposition, vibration-assisted deposition, or any combination thereof.

[0048] The process may continue at step 305 by operating on the substrate to form a porous body. Operating on the body may include modifying the body to change the shape of the substrate. For example, in one instance, the substrate and discrete spacer particles may be wound around a cylindrical body generally having a circumference and a length. In such a case, the body may have a helical configuration when viewed in cross-section, and the distance between adjacent layers within the helix is controlled by one or more aspects of the discrete spacer particles and one or more aspects of the dispersion of the discrete spacer particles. See, for example, FIGS. 6a and 6b.

[0049] In another embodiment, the body including the substrate and discrete spacer particles may be segmented or folded to create a multi-layer structure. For example, the body including the substrate and discrete spacer particles may be cut into sections and then joined together to form a multi-layer structure. In one embodiment, the distance between adjacent layers may be controlled by one or more aspects of the discrete spacer particles and one or more aspects of the dispersion of the discrete spacer particles.

[0050] Referring again to FIG. 3, the process for forming the porous body may further include coating the porous body at step 307. The coating may be performed at any point or multiple points during the process. For example, the coating may be performed before and / or after the operation. According to one embodiment, some suitable non-limiting processes for coating may include dip coating, spray coating, curtain coating, and the like. In one embodiment, the coating may cover at least a portion of the surface of the porous body. In yet another embodiment, the coating may cover the entire surface of the porous body.

[0051] According to one aspect, the coating may comprise a material selected from the group of ceramics, glasses, metals, metal alloys, cermets, polymers, or any combination thereof. In a particular embodiment, the coating may comprise a ceramic such as an oxide, nitride, carbide, boride, or any combination thereof. In another embodiment, the coating may comprise one or more active materials provided in the embodiments herein. In another non-limiting embodiment, the coating may consist essentially of one or more active materials provided in the embodiments herein. According to one embodiment, the coating may comprise an active material or active particles. For example, the coating may comprise a ceramic, glass, fiber material, natural material, oxide, carbide, nitride, halide, hydroxide, clay, polymer, metal, metal alloy, or any combination thereof. Some suitable non-limiting examples of materials for use in the coating include activated carbon, metal-organic frameworks, zeolites, boron nitride, titanium dioxide, silicon dioxide, zirconium dioxide, vanadium pentoxide, cerium oxide, lanthanum oxide, and alumina doped with platinum, palladium, rhodium, gold, silver, and other noble metals, layered double hydroxides, cordierite, lithium bayerite, lithium titanate oxide, lithium manganese oxide, lithium iron phosphate, graphene, carbon nanotubes, manganese dioxide, manganese oxide, lanthanum strontium manganite, ion exchange resins containing antibacterial materials (e.g., antibacterial materials, antifungal materials, antiviral materials, or any combination thereof), or any combination thereof.

[0052] In one embodiment, the coating may include a metal-organic framework (MOF) that can facilitate the production and / or performance improvement of the porous body. In one embodiment, the coating may include a metal-organic framework (MOF) and a binder, and the binder may include an organic polymer. In one embodiment, examples of the organic polymer may include organic crosslinked polymers. In one embodiment, examples of the organic crosslinked polymer may include reaction products of a water-insoluble polymer and a water-soluble polymer. In yet another embodiment, examples of the water-soluble polymer may include polysaccharides. In one embodiment, examples of the polysaccharides may include cellulose derivatives, or starch derivatives, alginates, or alginate derivatives. In yet another embodiment, examples of the water-soluble polymer may include carboxymethyl cellulose. In one embodiment, examples of the water-insoluble polymer may include at least one polyacrylate, polystyrene, epoxide polymer, polyurethane, polyester, polyether, polyamide, polyimide, or any combination or copolymer thereof. In yet another embodiment, examples of the water-insoluble polymer may include polyacrylate, or polystyrene, or polyacrylate-polystyrene copolymer. In yet another embodiment, examples of the crosslinked polymer binder may include crosslinked polyacrylate, crosslinked epoxide, or crosslinked polyurethane, or crosslinked polyimide, or crosslinked polyamide, or any combination thereof. In one embodiment, examples of the crosslinked polymer binder may include crosslinked polyacrylate. As used herein, the term "metal-organic framework" (MOF) relates to any compound that forms a network of metal ions with coordinated organic ligands. The MOF contained in the coating of the porous body of the present disclosure is not limited to a specific type of MOF. The selection of the MOF may vary depending on the intended use of the porous body of the present disclosure. Non-limiting examples of the MOF can be networks containing metal or transition metal ions such as aluminum, copper, iron, zirconium, zinc, or beryllium, and organic ligands, for example, monovalent, divalent, trivalent, or tetravalent organic ligands.Examples of commercially available MOFs can be Mil-100, Numat 11, Numat25, HKUST-1, UIO-66, MOF-0, MOF-2, MOF-3, MOF-4, MOF-5, MOF-6, MOF-7, MOF-8 MOF-9, MOF-11, MOF-12, MOF-20, MOF-25, MOF-26, MOF-31, MOF-32, MOF-33, MOF-34, MOF-36, MOF-37, MOF-38, MOF-39, MOF-47, MOF-49, MOF-69a, MOF-69b, MOF-74, MOF-101, MOF-102, MOF-107, MOF-108, MOF-110, MOF-177, MOF-j, MOF-n, IRMOF-1, IRMOF-2, IRMOF-3, IRMOF-4, IRMOF-5, IRMOF-6, IRMOF-7, IRMOF-8, IRMOF-9, IRMOF-10, IRMOF-11, IRMOF-12, IRMOF-13, IRMOF-14, IRMOF-15, IRMOF-16, IRMOF-17, IRMOF-18, IRMOF-19, IRMOF-20, AS16, AS27-2, AS32, AS54-3, AS61-4, AS68-7, BPR43G2, BPR48A2, BPR49B1, BPR68D10, BPR69B1, BPR73E4, BPR76D5, BPR80D5, BPR92A2, BPR95C5, UiO-67, UiO-68, NO13, NO29, NO305, NO306A, NO330, NO332, NO333, NO335, NO336, HKUST-1, or MIL101. In one embodiment, the MOF coating can be prepared according to the method described in U.S. Patent Application No. 17 / 453,644 by KIDD et al.

[0053] It will be appreciated that the coating may have a particular morphology that promotes the suitable manufacture and / or performance of the porous body. For example, the coating may have an average surface roughness (Ra) of at least 1 micron, or at least 3 microns, or at least 5 microns, or at least 10 microns, or at least 25 microns, or at least 50 microns, or at least 100 microns. In another non-limiting embodiment, the coating may have a surface roughness of 1000 cm or less, or 500 cm or less, or 100 cm or less, or 75 cm or less, or 50 cm or less, or 10 cm or less, or 1 cm or less, or 800 microns or less, or 500 microns or less. It will be appreciated that the coating may have an average surface roughness within a range including any of the above minimum and maximum values.

[0054] Any one or combination of the embodiments herein may be suitable for forming a porous body having certain characteristics including, for example, but not limited to, a specific pressure drop, geometric surface area, fluid path length, Reynolds number, or combinations thereof across the porous body. According to one non-limiting embodiment, the porous body may have a pressure drop of 1000 Pa or less, for example, 900 Pa or less, or 800 Pa or less, or 700 Pa or less, or 600 Pa or less, or 500 Pa or less, or 400 Pa or less, or 300 Pa or less for a water flow rate of 10 mg / s. In still other embodiments, the porous body may have a pressure drop of at least 0.01 Pa, for example, at least 10 Pa, or at least 20 Pa, or at least 30 Pa, or at least 40 Pa, or at least 50 Pa, or at least 60 Pa, or at least 70 Pa, or at least 80 Pa, or at least 90 Pa, at least 100 Pa for a water flow rate of 10 mg / s. The porous body may have a pressure drop between any of the above minimum and maximum values, including, for example, but not limited to, within a range of at least 0.01 Pa to 1000 Pa or less for a water flow rate of 10 mg / s, or within a range of at least 100 Pa to 400 Pa or less for a water flow rate of 10 mg / s.

[0055] In another non-limiting embodiment, the effective surface area of the porous body can be controlled to control the performance of the porous body. For example, in one example, the porous body has an effective surface area of at least 10,000 mm 2 or at least 11,000 mm 2 or at least 12,000 mm 2 or at least 13,000 mm 2 or at least 14,000 mm 2 or at least 14,500 mm 2 or at least 15,000 mm 2 In still other embodiments, the porous body can have an effective surface area of 100,000 mm 2 or less, for example, 90,000 mm 2 or less, or 80,000 mm 2 or less, or 70,000 mm 2 or less, or 60,000 mm 2 or less, or 50,000 mm 2 or less. The porous body can have an effective surface area between any of the above minimum and maximum values, including, for example, but not limited to, within the range of 10,000 mm 2 to 100,000 mm 2 or less, or at least 11,000 mm 2 to 90,000 mm 2 or less. To calculate the effective surface area, a 3D model of the porous body is created using CAD software such as Solid Works or OnShape to obtain the effective surface area.

[0056] In another non-limiting embodiment, the water adsorption of the porous body can be controlled to control the performance of the porous body. According to one non-limiting embodiment, the porous body has a water adsorption of at least 5 mg, such as at least 6 mg, or at least 7 mg, or at least 8 mg, or at least 9 mg, or at least 10 mg, or at least 11 mg, or at least 12 mg, or at least 13 mg, or at least 14 mg, or at least 15 mg, or at least 16 mg with respect to an air flow of 1 L / min or less. In still other embodiments, the porous body can have a water adsorption of 100 mg or less, such as 90 mg or less, or 80 mg or less, or 70 mg or less, or 60 mg or less, or 50 mg or less with respect to an air flow of 1 L / min or less. The porous body can have a water adsorption between any of the above minimum and maximum values, including, for example, but not limited to, in the range of at least 5 mg to 100 mg or less with respect to an air flow of 1 L / min or less, or in the range of at least 10 mg to 50 mg or less with respect to a water flow rate of 10 mg / s.

[0057] Embodiment Embodiment 1. A porous body comprising: an outer tubular structure having an inner surface and an outer surface; a first plurality of discrete spacer particles attached to the inner surface of the outer tubular structure; a first inner tubular structure having an inner surface and an outer surface, wherein the outer surface of the first inner tubular structure abuts against the first plurality of discrete spacer particles.

[0058] Embodiment 2. A porous body comprising: an outer tubular structure having an inner surface and an outer surface; a plurality of inner tubular structures each having an inner surface and an outer surface; a plurality of discrete spacer particles dispersed within the porous body.

[0059] Embodiment 3. A porous body comprising: an outer tubular structure having an inner surface and an outer surface; A plurality of inner tubular structures each having an inner surface and an outer surface, A plurality of discrete spacer particles dispersed within the porous body, A coating covering at least a portion of the surface of the porous body, A coating containing a metal-organic framework (MOF), and a porous body comprising the coating.

[0060] Embodiment 4. A porous body, An outer tubular structure having an inner surface and an outer surface, A plurality of inner tubular structures each having an inner surface and an outer surface, A plurality of discrete spacer particles dispersed within the porous body, wherein each of the plurality of discrete spacer particles contains an active material, and a porous body comprising the plurality of discrete spacer particles.

[0061] Embodiment 5. A porous body, An outer tubular structure having an inner surface and an outer surface, A plurality of inner tubular structures each having an inner surface and an outer surface, A plurality of discrete spacer particles dispersed within the porous body, A porous body, wherein the porous body contains an active material on at least a portion of the porous body.

[0062] Embodiment 6. A porous body, An outer tubular structure having an inner surface and an outer surface, A plurality of inner tubular structures each having an inner surface and an outer surface, A plurality of discrete spacer particles dispersed within the porous body, wherein each of the plurality of discrete spacer particles includes a multi-armed shape, A porous body comprising the plurality of discrete spacer particles, wherein the multi-armed shape forms a contact point with the outer tubular structure, the plurality of inner tubular structures, or a combination thereof.

[0063] Embodiment 7. A porous body, A substrate including a longitudinal axis along the length L of the substrate, the substrate defining a helical shape when viewed in a plane perpendicular to the longitudinal axis, A porous body comprising a plurality of discrete spacer particles attached to a substrate.

[0064] Embodiment 8. A porous body, A substrate including a longitudinal axis along the length L of the substrate, the substrate defining a helical shape when viewed in a plane perpendicular to the longitudinal axis, and A plurality of discrete spacer particles attached to the substrate, each of the plurality of discrete spacer particles having an average solidity of at least 0.6 and 1 or less, a porous body comprising the plurality of discrete spacer particles.

[0065] Embodiment 9. A porous body, A substrate including a longitudinal axis along the length L of the substrate, the substrate defining a helical shape when viewed in a plane perpendicular to the longitudinal axis, and A plurality of discrete spacer particles attached to the substrate, and A coating covering at least a portion of the surface of the porous body, the coating including a metal-organic framework (MOF), a porous body comprising the coating.

[0066] Embodiment 10. A porous body, A substrate including a longitudinal axis along the length L of the substrate, the substrate defining a helical shape when viewed in a plane perpendicular to the longitudinal axis, and A plurality of discrete spacer particles attached to the substrate, each of the plurality of discrete spacer particles including an active material, a porous body comprising the plurality of discrete spacer particles.

[0067] Embodiment 11. A porous body, A substrate including a longitudinal axis along the length L of the substrate, the substrate defining a helical shape when viewed in a plane perpendicular to the longitudinal axis, and A plurality of discrete spacer particles attached to the substrate, and The porous body includes an active material on at least a portion of the porous body, a porous body.

[0068] Embodiment 12. A porous body, A substrate including a longitudinal axis along the length L of the substrate, the substrate defining a helical shape when viewed in a plane perpendicular to the longitudinal axis, and a plurality of discrete spacer particles attached to the substrate, each of the plurality of discrete spacer particles including a multi-armed shape, the multi-armed shape forming a contact point with the substrate, and a plurality of discrete spacer particles, a porous body.

[0069] Embodiment 13. The porous body according to Embodiment 1, further including a second plurality of discrete spacer particles attached to the inner surface of the first inner tubular structure.

[0070] Embodiment 14. The porous body according to Embodiment 13, further including a second inner tubular structure having an inner surface and an outer surface, the outer surface of the second inner tubular structure abutting against the second plurality of discrete spacer particles.

[0071] Embodiment 15. The porous body according to Embodiment 14, further including a third plurality of discrete spacer particles attached to the inner surface of the second inner tubular structure.

[0072] Embodiment 16. The porous body according to Embodiment 15, further including a third inner tubular structure having an inner surface and an outer surface, the outer surface of the third inner tubular structure abutting against the third plurality of discrete spacer particles.

[0073] Embodiment 17. The porous body according to Embodiment 16, further including a fourth plurality of discrete spacer particles attached to the inner surface of the third inner tubular structure.

[0074] Embodiment 18. The porous body according to Embodiment 17, wherein the fourth plurality of discrete spacer particles abut against a central structure defining a central axis of the porous body.

[0075] Embodiment 19. The porous body according to Embodiment 1, wherein the outer tubular structure and the first inner tubular structure include a metal, a metal alloy, a ceramic, a polymer, or a combination thereof.

[0076] Embodiment 20. The porous body according to Embodiment 1, wherein the outer tubular structure and the first inner tubular structure include a woven fabric structure, a non-woven fabric structure, or a combination thereof.

[0077] Embodiment 21. The porous body according to Embodiment 1, wherein the outer tubular structure and the first inner tubular structure include a polycrystalline phase, an amorphous material, a single crystal phase, or a combination thereof.

[0078] Embodiment 22. The porous body according to Embodiment 14, wherein the second inner tubular structure includes a metal, a metal alloy, a ceramic, a polymer, or a combination thereof.

[0079] Embodiment 23. The porous body according to Embodiment 16, wherein the third inner tubular structure includes a metal, a metal alloy, a ceramic, a polymer, or a combination thereof.

[0080] Embodiment 24. The porous body according to any one of Embodiments 2, 3, 4, 5, or 6, wherein the outer tubular structure and the plurality of inner tubular structures include a metal, a metal alloy, a ceramic, a polymer, or a combination thereof.

[0081] Embodiment 25. The porous body according to any one of Embodiments 2, 3, 4, 5, or 6, wherein the outer tubular structure and the plurality of inner tubular structures include a woven fabric structure, a non-woven fabric structure, or a combination thereof.

[0082] Embodiment 26. The porous body according to any one of Embodiments 2, 3, 4, 5, or 6, wherein the outer tubular structure and the plurality of inner tubular structures include a polycrystalline phase, an amorphous material, a single crystal phase, or a combination thereof.

[0083] Embodiment 27. The porous body according to any one of Embodiments 7, 8, 9, 10, 11, or 12, wherein the base material includes a metal, a metal alloy, a ceramic, a polymer, or a combination thereof.

[0084] Embodiment 28. The porous body according to any one of Embodiments 7, 8, 9, 10, 11, or 12, wherein the base material includes a woven fabric structure, a non-woven fabric structure, or a combination thereof.

[0085] Embodiment 29. The porous body according to any one of Embodiments 7, 8, 9, 10, 11, or 12, wherein the base material includes a polycrystalline phase, an amorphous material, a single crystal phase, or a combination thereof.

[0086] Embodiment 30. The porous body according to Embodiment 1, wherein the first plurality of discrete spacer particles include a ceramic, a glass, a metal, a metal alloy, a polymer, a natural material, a synthetic material, a fiber material, a porous material, or a combination thereof.

[0087] Embodiment 31. The porous body according to Embodiment 13, wherein the second plurality of discrete spacer particles include a ceramic, a glass, a metal, a metal alloy, a polymer, a natural material, a synthetic material, a fiber material, a porous material, or a combination thereof.

[0088] Embodiment 32. The porous body according to Embodiment 15, wherein the third plurality of discrete spacer particles include a ceramic, a glass, a metal, a metal alloy, a polymer, a natural material, a synthetic material, a fiber material, a porous material, or a combination thereof.

[0089] Embodiment 33. The porous body according to Embodiment 17, wherein the fourth plurality of discrete spacer particles include a ceramic, a glass, a metal, a metal alloy, a polymer, a natural material, a synthetic material, a fiber material, a porous material, or a combination thereof.

[0090] Embodiment 34. The porous body according to any one of Embodiments 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, wherein the plurality of discrete spacer particles include a ceramic, a glass, a metal, a metal alloy, a polymer, a natural material, a synthetic material, a fiber material, a porous material, or a combination thereof.

[0091] Embodiment 35. The porous body according to Embodiment 1, wherein the first plurality of discrete spacer particles include a regular or irregular shape.

[0092] Embodiment 36. The porous body according to Embodiment 1, wherein the first plurality of discrete spacer particles include a regular or irregular polygonal shape.

[0093] Embodiment 37. The porous body according to Embodiment 1, wherein the first plurality of discrete spacer particles include a multi-armed shape.

[0094] Embodiment 38. The porous body according to any one of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, wherein the plurality of discrete spacer particles include a regular or irregular shape.

[0095] Embodiment 39. The porous body according to any one of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, wherein the plurality of discrete spacer particles include a regular or irregular polygonal shape.

[0096] Embodiment 40. The porous body according to any one of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, wherein the plurality of discrete spacer particles include a multi-armed shape.

[0097] Embodiment 41. The porous body according to any one of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, wherein the porous body has a porosity of at least 0.5, or at least 0.55, or at least 0.6, or at least 0.65, or at least 0.70.

[0098] Embodiment 42. The porous body according to any one of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, wherein the porous body has a porosity of 0.9999 or less, or 0.95 or less, or 0.90 or less, or 0.85 or less, or 0.8 or less, or 0.75 or less.

[0099] Embodiment 43. The porous body according to any one of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, having a pressure drop of at least 0.01 Pa, for example, at least 10 Pa, or at least 20 Pa, or at least 30 Pa, or at least 40 Pa, or at least 50 Pa, or at least 60 Pa, or at least 70 Pa, or at least 80 Pa, or at least 90 Pa, at least 100 Pa with respect to a water flow rate of 10 mg / s.

[0100] Embodiment 44. The porous body according to any one of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, having a pressure drop of 1000 Pa or less, for example, 900 Pa or less, or 800 Pa or less, or 700 Pa or less, or 600 Pa or less, or 500 Pa or less, or 400 Pa or less, or 300 Pa or less with respect to a water flow rate of 10 mg / s.

[0101] Embodiment 45. The porous body according to any one of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, having an effective surface area of at least 10,000 mm 2 or at least 11,000 mm 2 or at least 12,000 mm 2 or at least 13,000 mm 2 or at least 14,000 mm 2 or at least 14,500 mm 2 or at least 15,000 mm 2

[0102] Embodiment 46. The porous body according to any one of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, having an effective surface area of 100,000 mm 2 or less, for example, 90,000 mm 2 or less, or 80,000 mm 2 or less, or 70,000 mm 2 or less, or 60,000 mm 2 or less, or 50,000 mm 2The porous body according to any one of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, having the following effective surface area.

[0103] Embodiment 47. The porous body has at least 5 mg of water adsorption, for example, at least 6 mg, or at least 7 mg, or at least 8 mg, or at least 9 mg, or at least 10 mg, or at least 11 mg, or at least 12 mg, or at least 13 mg, or at least 14 mg, or at least 15 mg, or at least 16 mg of water adsorption with respect to an air flow of 1 L / min or less. The porous body according to any one of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12.

[0104] Embodiment 48. The porous body has 100 mg or less of water adsorption, for example, 90 mg or less, or 80 mg or less, or 70 mg or less, or 60 mg or less, or 50 mg or less of water adsorption with respect to an air flow of 1 L / min or less. The porous body according to any one of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12.

[0105] Embodiment 49. The discrete spacer particles extend in a helical path along the circumferential surface of the base material of the porous body that defines a helical angle of at least 30 degrees, for example, at least 31 degrees, at least 32 degrees, at least 33 degrees, at least 34 degrees, at least 35 degrees, at least 36 degrees, at least 37 degrees, at least 38 degrees, at least 39 degrees, at least 40 degrees, at least 41 degrees, at least 42 degrees, at least 43 degrees, at least 44 degrees, at least 45 degrees, at least 46 degrees, at least 47 degrees, at least 48 degrees, at least 49 degrees, at least 50 degrees, at least 51 degrees, at least 52 degrees, at least 53 degrees, at least 54 degrees, at least 55 degrees, at least 56 degrees, at least 57 degrees, at least 58 degrees, at least 59 degrees, or at least 60 degrees. The porous body according to any one of Embodiments 7, 8, 9, 10, 11, or 12.

[0106] Embodiment 50. The discrete spacer particles extend along a helical path along the circumferential surface of the substrate of the porous body defining a helical angle of 89 degrees or less, for example, 88 degrees or less, or 87 degrees or less, or 86 degrees or less, or 85 degrees or less, or 84 degrees or less, or 83 degrees or less, or 82 degrees or less, or 81 degrees or less, or 80 degrees or less, or 79 degrees or less, or 78 degrees or less, or 77 degrees or less, or 76 degrees or less, or 75 degrees or less, or 74 degrees or less, or 73 degrees or less, or 72 degrees or less, or 71 degrees or less, or 70 degrees or less, or 69 degrees or less, or 68 degrees or less, or 67 degrees or less, or 66 degrees or less, or 65 degrees or less, or 64 degrees or less, or 63 degrees or less, or 62 degrees or less, or 61 degrees or less. The porous body according to any one of Embodiments 7, 8, 9, 10, 11, or 12.

[0107] Embodiment 51. Each discrete spacer particle of the first plurality of discrete spacer particles has an average solidity of at least 0.5, or at least 0.55, or at least 0.6, or at least 0.65, or at least 0.70, or at least 0.75, or at least 0.80, or at least 0.85. The porous body according to Embodiment 1.

[0108] Embodiment 52. Each discrete spacer particle of the first plurality of discrete spacer particles has an average solidity of 1 or less, or 0.9999 or less, or 0.95 or less, or 0.90 or less, or 0.85 or less. The porous body according to Embodiment 1.

[0109] Embodiment 53. Each of the plurality of discrete spacer particles has an average solidity of 1 or less, or 0.9999 or less, or 0.95 or less, or 0.90 or less, or 0.85 or less. The porous body according to any one of Embodiments 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12.

[0110] Embodiment 54. The porous body according to any one of Embodiments 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, wherein each of the plurality of discrete spacer particles has an average solidity of at least 0.5, or at least 0.55, or at least 0.6, or at least 0.65, or at least 0.70, or at least 0.75, or at least 0.80, or at least 0.85.

[0111] Embodiment 55. The porous body according to any one of Embodiments 3 or 9, wherein the coating further contains a binder, and the binder contains an organic polymer.

[0112] Embodiment 56. The porous body according to any one of Embodiments 3 or 9, wherein the MOF contains aluminum, copper, iron, zirconium, zinc, beryllium.

[0113] Embodiment 57. The porous body according to any one of Embodiments 4, 5, 10, or 11, wherein the active material contains ceramics, glass, fiber materials, natural materials, oxides, carbides, nitrides, halides, hydroxides, clays, polymers, metals, metal alloys, or any combination thereof.

[0114] Embodiment 58. The porous body according to any one of Embodiments 4, 5, 10, or 11, wherein the active material contains activated carbon, metal organic frameworks, zeolites, boron nitride, titanium dioxide, silicon dioxide, zirconium dioxide, vanadium pentoxide, cerium oxide, lanthanum oxide, and alumina doped with platinum, palladium, rhodium, gold, silver, and other noble metals, layered double hydroxides, cordierite, lithium byalite, ion exchange resins, lithium titanate, lithium manganese oxide, lithium iron phosphate, graphene, carbon nanotubes, manganese dioxide, manganese oxide, lanthanum strontium manganite, antibacterial materials, polymers, metals, metal alloys, ceramics, glass, or any combination thereof.

[0115] Embodiment 59. The porous body according to any one of Embodiments 6, 12, 37, or 40, wherein the multi-arm shape includes a plurality of arms extending from a central portion.

[0116] Embodiment 60. The porous body according to Embodiment 59, wherein the multi-arm shape forms a contact point with an outer tubular structure, a plurality of inner tubular structures, a substrate, or a combination thereof.

[0117] Embodiment 61. The porous body according to any one of Embodiments 2, 3, 4, 5, 7, 8, 9, 10, or 11, wherein a plurality of discrete spacer particles form a contact point with an outer tubular structure, a plurality of inner tubular structures, or a combination thereof.

[0118] Embodiment 62. The porous body according to any one of Embodiments 7, 8, 9, 10, or 11, wherein a plurality of discrete spacer particles form a contact point with the substrate.

[0119] Embodiment 63. The porous body according to any one of Embodiments 6 or 61, wherein the contact point forms a continuous connection between a plurality of discrete spacer particles and an outer tubular structure, a plurality of inner tubular structures, or a combination thereof.

[0120] Embodiment 64. The porous body according to any one of Embodiments 12 or 62, wherein the contact point forms a continuous connection between a plurality of discrete spacer particles and the substrate.

[0121] Embodiment 65. The porous body according to any one of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, wherein the porous body has a crushing strength of at least 1 N, for example, at least 2 N, or at least 3 N, or at least 4 N, or at least 5 N, or at least 6 N, or at least 7 N, or at least 8 N, or at least 9 N, or at least 10 N, or at least 15 N, or at least 20 N, or at least 25 N, or at least 30 N, or at least 35 N, or at least 40 N, or at least 45 N, or at least 50 N.

[0122] Embodiment 66. The porous body has a crushing strength of 200 N or less, for example, 180 N or less, or 160 N or less, or 140 N or less, or 120 N or less, or 100 N or less, or 80 N or less, or 605 N or less, and is the porous body according to any one of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12.

Examples

[0123] Geometry of discrete spacer particles Using CAD model simulations with software COMSOL Multiphysics software (registered trademark), according to one embodiment including various geometries described herein, to determine the effects of various geometries on pressure drop and species consumption, a sample of the porous body was formed. A first conventional sample porous body C1 including a straight channel and having no discrete spacer particles inside was formed. A second sample porous body S1 was formed according to one embodiment having spherical discrete spacer particles dispersed inside. A third sample porous body S2 was formed according to one embodiment having multi-armed discrete spacer particles dispersed inside. Samples C1, S1, and S2 can be seen in FIGS. 14a, 14b, and 14c, respectively.

[0124] FIG. 15 is a plot of the pressure drop (Pa) at a water flow rate of 10 mg / s and the species consumption (mol / m 3 at an inflow concentration of 10 mol / m 3 ). The pressure drop plot is represented by square points, and the species consumption plot is represented by round points. Sample C1 showed a low pressure drop and low species consumption, while samples S1 and S2 showed increased species consumption.

[0125] Angle of discrete spacer particles Using CAD model simulations with the software COMSOL Multiphysics software (registered trademark), a sample of the porous body was formed according to one embodiment including multi-armed discrete spacer particles having various helix angles as described herein to determine the effect of the helix angle on pressure drop and species consumption. A sample S3 having discrete spacer particles with a helix angle of 0 degrees was formed. A sample S4 having discrete spacer particles with a helix angle of 30 degrees was formed. A sample S5 having discrete spacer particles with a helix angle of 60 degrees was formed.

[0126] Figure 16 is a plot of the pressure drop (Pa) at a water flow rate of 10 mg / s and the species consumption (mol / m 3 ) at an inlet concentration of 10 mol / m 3 . The pressure drop plot is represented by square points and the species consumption plot is represented by round points. Samples S3 and S4 showed similar pressure drops and species consumptions, and sample S5 showed increased species consumption.

[0127] Porosity of discrete spacer particles Using CAD model simulations with the software COMSOL Multiphysics software (registered trademark), a sample of the porous body was formed according to one embodiment including multi-armed discrete spacer particles having various porosities as described herein to determine the effect of the porosity on pressure drop and species consumption. A sample S6 including discrete spacer particles having a porosity of 0.5 was formed. A sample S7 including discrete spacer particles having a porosity of 0.58 was formed. A sample S8 including discrete spacer particles having a porosity of 0.65 was formed.

[0128] Figure 17 is a plot of the pressure drop (Pa) at a water flow rate of 10 mg / s and the species consumption (mol / m 3 ) at an inlet concentration of 10 mol / m 3 . The pressure drop plot is represented by square points and the species consumption plot is represented by round points. Samples S6 and S7 showed increased pressure drops when compared to sample S8. All samples showed similar species consumptions.

[0129] Figure 18 is a plot of pressure drop (Pa) at a water flow rate of 10 mg / s and species consumption (mol / m 3 ) at an inlet concentration of 10 mol / m 3 , showing only Sample C1 and Sample S8. As shown, Sample S8 with multi-arm discrete spacer particles having a helix angle of 60 degrees and a porosity of 0.65 showed a pressure drop similar to that of Sample C1 and an approximately three-fold increased species consumption.

[0130] Effective surface area of the porous body Using the CAD software SolidWorks, the effective surface areas of Sample C1, Sample S1, and Sample S8 were measured using 3D models of the samples. The effective surface areas measured for each sample are shown in Table 1.

[0131]

Table 1

[0132] Water adsorption Sample S8 was dip-coated to form a coating on the porous body, forming Sample S9. The coating composition contained a MOF (metal-organic framework) coating. Next, the water adsorption of Samples C1 and S9 was measured. Figure 20 is the experimental configuration used to measure the water adsorption of the samples. The configuration includes an air flow hose 2001, a flow rate controller 2002, an Erlenmeyer flask 2003, a porous body 2004, and a 3D printed chamber 2005 for holding the porous body. In each measurement, the sample was placed in the 3D printed chamber 2005, approximately 200 mL of water was placed in the flask 2003, the water was boiled at 100 °C, and the air flow was started. The water adsorption of each sample was measured over various air flow rates. The results can be seen in Figure 21. As shown, Sample S9 showed increased water adsorption when compared to C1.

[0133] Pressure drop The pressure drop was measured in the laboratory for samples C1, S1, and S9. Figure 22 shows the experimental setup used to measure the pressure drop of the samples. The setup includes a flow meter 2201, a 1-inch diameter stainless steel tube 2202, an air flow hose 2203, and a pressure gauge 2204 filled with water. In each measurement, the sample was placed in the stainless steel tube, and the surroundings of the sample were sealed to allow the sample to pass through the air flow. Then, the air flow was initiated through the stainless steel tube, and the pressure drop was measured using the water-filled pressure gauge over various air flow rates. Figure 19 is a plot of pressure drop (Pa) versus air flow rate (m.s-1) for samples C1, S1, and S9. As shown, samples S9 and C1 have similar pressure drop trends, while sample S1 showed an increasing pressure drop with increasing air flow.

[0134] The subject matter disclosed above should be considered illustrative rather than limiting, and the appended claims are intended to encompass all such modifications, enhancements, and other embodiments that fall within the true scope of the invention. Accordingly, to the maximum extent permitted by law, the scope of the invention should be determined by the broadest permissible interpretation of the following claims and their equivalents, and should not be limited or restricted by the foregoing detailed description.

[0135] The abstract is provided to comply with patent law and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Additionally, in the foregoing "Detailed Description of the Invention," various features may be grouped together or described in a single embodiment for the purpose of simplifying the disclosure. The disclosure should not be construed as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, the subject matter of the invention may be directed to less than all of the features of any of the disclosed embodiments, as reflected by the following claims. Accordingly, the following claims are incorporated into the "Detailed Description of the Invention," and each claim stands on its own as defining a separately claimed subject matter.

Claims

**Claim 1** A porous body comprising: an outer tubular structure having an inner surface and an outer surface; a first plurality of discrete spacer particles attached to the inner surface of the outer tubular structure; a first inner tubular structure having an inner surface and an outer surface, wherein the outer surface of the first inner tubular structure is in contact with the first plurality of discrete spacer particles. **Claim 2** The porous body according to claim 1, further comprising a second plurality of discrete spacer particles attached to the inner surface of the first inner tubular structure. **Claim 3** The porous body according to claim 2, further comprising a second inner tubular structure having an inner surface and an outer surface, wherein the outer surface of the second inner tubular structure is in contact with the second plurality of discrete spacer particles. **Claim 4** The porous body according to claim 1, wherein the first plurality of discrete spacer particles include a multi-armed shape. **Claim 5** The porous body according to claim 1, wherein the first plurality of discrete spacer particles include a regular or irregular shape. **Claim 6** The porous body according to claim 1, having a porosity of at least 0.5 and 0.99 or less. **Claim 7** The porous body according to claim 1, wherein the first plurality of discrete spacer particles extend in a helical path along the circumferential surface of the first inner tubular structure of the porous body, defining a helical angle of at least 30 degrees and 89 degrees or less. **Claim 8** A porous body comprising: a substrate including a longitudinal axis along the length L of the substrate, the substrate defining a helical shape when viewed in a plane perpendicular to the longitudinal axis; a plurality of discrete spacer particles attached to the substrate. **Claim 9** The porous body according to claim 8, further comprising a coating covering at least a portion of the surface of the porous body. **Claim 10** The porous body according to claim 9, wherein the coating includes a metal-organic framework (MOF). **Claim 11** The porous body according to claim 10, wherein the coating further includes a binder, and the binder includes an organic polymer. **Claim 12** The porous body according to claim 8, wherein each of the plurality of discrete spacer particles includes an average solidity of at least 0.5 and 1 or less. **Claim 13** The porous body according to claim 8, wherein the plurality of discrete spacer particles contain an active material, and the active material includes activated carbon, metal-organic frameworks, zeolites, boron nitride, titanium dioxide, silicon dioxide, zirconium dioxide, vanadium pentoxide, cerium oxide, lanthanum oxide, and alumina doped with platinum, palladium, rhodium, gold, silver, and other noble metals, layered double hydroxides, cordierite, lithium biotite, ion exchange resins, lithium titanate, lithium manganate, lithium iron phosphate, graphene, carbon nanotubes, manganese dioxide, manganese oxide, lanthanum strontium manganite, antibacterial materials, polymers, metals, metal alloys, ceramics, glasses, or any combination thereof.

14. A porous body, comprising: a substrate including a longitudinal axis along the length L of the substrate, the substrate defining a helical shape when viewed in a plane perpendicular to the longitudinal axis; and a plurality of discrete spacer particles attached to the substrate, each of the plurality of discrete spacer particles including a multi-armed shape; a plurality of discrete spacer particles, wherein the multi-armed shape forms a contact point with the substrate.

15. The porous body according to claim 14, wherein the contact point forms a continuous connection between the plurality of discrete spacer particles and the substrate.

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