Hydrophobic sorbent polymer composite articles for adsorption - Patent Application 20070122997

Abstract

To provide a polymer composite article with good sorption properties. A sorbent polymer composite article for adsorption is disclosed. The sorbent polymer composite article includes a composite layer comprising a porous polymer and a sorbent material. The sorbent polymer composite article also includes at least one hydrophobic layer on either side of a first composite region.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Application No. 63 / 157,426, filed March 5, 2021, and U.S. Provisional Application No. 63 / 302,847, filed January 25, 2022, the disclosures of each of which are incorporated herein by reference in their entirety.

[0002] Field The present disclosure relates to sorptive polymer composite articles, methods of forming sorptive polymer composite articles, and methods of using sorptive polymer composite articles for adsorption purposes, including adsorption for direct air capture (DAC) of carbon dioxide. [Background technology]

[0003] background Rising carbon dioxide (CO2) levels due to greenhouse gas emissions have been shown to be harmful to the environment. As reported in the Climate.gov article “Climate Change: Atmospheric Carbon Dioxide,” the average atmospheric carbon dioxide level in 2019 was 409.8 ppm, the highest level recorded in the past 800,000 years. The rate at which atmospheric CO2 is increasing is also much higher than in previous decades.

[0004] To mitigate the effects of climate change, it is necessary not only to reduce CO2 emissions to zero but to make them negative in the near future. Several possibilities exist to achieve negative emissions, such as the combustion of biomaterials to generate electricity, combined with CO2 capture from combustion flue gases and subsequent CO2 sequestration ("BECCS") or direct air capture of CO2 ("DAC").

[0005] Gas separation by adsorption has many different applications in industry, such as the removal of specific components from gas streams, where the desired product can be either the component removed from the gas stream, the remaining depleted stream, or both. This allows both minor and major components of the gas stream to be subjected to the adsorption process. One important gas separation application is in the recovery of CO2 from gas streams such as flue gas, exhaust gas, industrial waste gas, biogas, and atmospheric air. Air can be considered a dilute feed stream for CO2.

[0006] Direct capture of CO2 from the atmosphere, known as DAC, is one of several means of mitigating anthropogenic greenhouse gas emissions and has attractive economic prospects as a non-fossil, site-independent source of CO2 for commodity markets and the production of synthetic fuels. Specific advantages of capturing CO2 from the atmosphere include: a) DAC can address the emissions of distributed sources (e.g., land, sea, and air vehicles), which account for a large proportion of global greenhouse gas emissions and which cannot currently be captured at the emission site in an economically viable manner; b) DAC can address conventional emissions and therefore can produce truly negative emissions; and c) DAC systems do not need to be attached to the emission source and are site-independent, meaning they can be installed at the site where the CO2 is further processed or used.

[0007] There is a growing drive to develop and improve these processes to make them more efficient, maximizing the amount of CO2 removed from the atmosphere while minimizing the energy required in the process.

[0008] FIG. 1 is a schematic diagram of the process involved in a conventional DAC system 10. An inlet feed stream 11 containing a mixture of CO2 molecules 16 in a non-CO2 diluent 18 is provided. For example, the inlet feed stream 11 can be an air stream. During the adsorption process, the inlet feed stream 11 is exposed to an adsorbent 12. The CO2 molecules 16 adsorb onto the adsorbent 12, while the non-CO2 diluent 18 passes through the adsorbent 12 and exits the system 10. The adsorbent 12 then undergoes a desorption process to release the CO2 molecules 16 from the adsorbent 12. The desorption process can involve moisture in the form of liquid water or water vapor, or a change in system temperature due to a reaction or energy supplied to the system. This desorption process is referred to as "swing" adsorption to define the cyclical process of repeated CO2 adsorption and desorption. If moisture swing adsorption is used, the adsorbent 12 can be exposed to moisture in the form of water vapor or liquid water, causing the CO2 molecules 16 to desorb. If temperature swing adsorption is used, heat can be applied to the adsorbent 12 to cause desorption of the CO2 molecules 16. These moisture and / or temperature fluctuations can temporarily break the bonds holding the molecules to the adsorbent 12, thereby releasing the CO2 molecules 16. The desorbed CO2 molecules 16 can then be separated from the adsorbent 12 and collected as product 14. The collected CO2 molecules 16 can then be concentrated and subjected to further necessary processing before being used or stored. It is important that the adsorbent 12 used be able to repeatedly withstand the environment required to separate the CO2 molecules 16, e.g., high temperature and humidity conditions.

[0009] Established literature and techniques exist for DAC. One example is the use of an article that includes a substrate, such as a monolith, that supports or is coated with a sorbent material. Alterations are established by varying the type of substrate and the sorbent used. However, these previously established literature and methods are limited in their ability to efficiently cycle between adsorption and desorption states. They also have limitations regarding the durability of the article. Additionally, the article may degrade when exposed to environments with high temperatures or high humidity levels, or a combination thereof, potentially resulting in a shortened lifespan. Summary of the Invention

[0010] Abstract A sorbent polymer composite article for adsorption, including adsorption of DAC, is disclosed. The sorbent polymer composite article includes a composite layer including a porous polymer and a sorbent material. The sorbent polymer composite article also includes at least one hydrophobic layer on either side of the first composite layer.

[0011] According to one example ("Example A"), a sorbent polymer composite article includes a first composite region including a first porous polymer and a sorbent material, wherein the first composite region has a first hydrophobicity, and a second region of a second porous polymer disposed adjacent to a first side of the first composite region, wherein the second region has a second hydrophobicity greater than the first hydrophobicity.

[0012] According to a second example ("Example B"), a method of forming a sorbent polymer composite article includes forming a first composite region comprising a first porous polymer and a sorbent material, and forming a second hydrophobic region comprising a second porous polymer on a first side of the first composite region.

[0013] According to a third example ("Example C"), a method of using a sorbent polymer composite article for adsorption includes providing a sorbent polymer composite article having a first porous polymer and a sorbent and including a first composite region having a first hydrophobicity, and a second region disposed adjacent a first side of the first region and having a second hydrophobicity greater than the first hydrophobicity, directing a feed stream including carbon dioxide across the sorbent polymer composite article, and adsorbing the carbon dioxide into the sorbent polymer composite article.

[0014] According to a fourth example ("Example D"), a sorbent polymer composite article includes a first region having a sorbent material and a screen, a second region including a second polymer disposed adjacent to the first region, and a third region including a third polymer disposed adjacent to the first region.

[0015] According to a fifth example ("Example E"), a sorbent polymer composite article includes a first composite region having a first porous polymer and a sorbent material, wherein the first composite region has a first hydrophobicity; a second region of a second porous polymer disposed adjacent to a first side of the first composite region, wherein the second region has a second hydrophobicity greater than the first hydrophobicity; a third region of a third porous polymer disposed adjacent to a second side of the first composite region, wherein the third region has a third hydrophobicity greater than the first hydrophobicity; and an end seal region disposed between the second region and the third region to surround an end of the first composite region. [Brief explanation of the drawings]

[0016] BRIEF DESCRIPTION OF THE DRAWINGS [Figure 1] FIG. 1 is a schematic diagram of the processes involved in the DAC process.

[0017] [Figure 2] FIG. 2 is an elevational view of a first sorbent polymer composite article of the present disclosure.

[0018] [Figure 2A] FIG. 2A is a schematic elevational view of a first composite region of the first composite article of FIG.

[0019] [Figure 2B] 2B is a schematic elevational view of the first composite region of the first composite article of FIG. 2 in a compressed form.

[0020] [Figure 2C] FIG. 2C is a schematic elevational view of the first composite region of the first composite article of FIG. 2B in a further compressed form.

[0021] [Figure 2D] FIG. 2D is an elevational view of the first sorbent polymer composite article of FIG. 2 shown including an edge seal region of the present disclosure.

[0022] [Figure 3] FIG. 3 is a flow chart illustrating a method of forming the sorbent polymer composite article of FIG.

[0023] [Figure 4] FIG. 4 is an elevational view of a second sorbent polymer composite article of the present disclosure.

[0024] [Figure 5] FIG. 5 is a flow chart illustrating a method of forming the sorbent polymer composite article of FIG.

[0025] [Figure 6] FIG. 6 is an elevational view of a third sorbent polymer composite article of the present disclosure.

[0026] [Figure 7] FIG. 7 is a flow chart illustrating a method of forming the sorbent polymer composite article of FIG.

[0027] [Figure 8]FIG. 8 is a flow chart illustrating a method of using an embodiment of a sorbent polymer composite article according to the present disclosure.

[0028] [Figure 9A] FIG. 9A is an elevational view of a fourth sorbent polymer composite article of the present disclosure.

[0029] [Figure 9B] FIG. 9B is an elevational view of a variation of the sorbent polymer composite article of FIG. 9A.

[0030] [Figure 10A] FIG. 10A is a calibrated SEM image showing an example of a sorbent polymer composite article according to the present disclosure. [Figure 10B] FIG. 10B is a calibrated SEM image showing an example of a sorbent polymer composite article according to the present disclosure. [Figure 10C] FIG. 10C is a calibrated SEM image showing an example of a sorbent polymer composite article according to the present disclosure. [Figure 10D] FIG. 10D is a calibrated SEM image showing an example of a sorbent polymer composite article according to the present disclosure.

[0031] [Figure 11A] FIG. 11A is a calibrated SEM image showing an example of a sorbent polymer composite article according to the present disclosure. [Figure 11B] FIG. 11B is a calibrated SEM image showing an example of a sorbent polymer composite article according to the present disclosure. [Figure 11C] FIG. 11C is a calibrated SEM image showing an example of a sorbent polymer composite article according to the present disclosure. [Figure 11D] FIG. 11D is a calibrated SEM image showing an example of a sorbent polymer composite article according to the present disclosure.

[0032] [Figure 12] 1 is a chart showing CO2 adsorption results consistent with the test procedures performed on samples formed in Examples 4, 5a, 5b, and 6.

[0033] [Figure 13] 1 is a chart showing CO2 adsorption kinetics results consistent with the test procedures performed on samples formed in Examples 4, 5a, 5b, and 6. DETAILED DESCRIPTION OF THE INVENTION

[0034] Detailed Description Definitions and Terminology This disclosure is not intended to be interpreted in a limiting sense. For example, the terms used in this application should be read broadly in the context of the meaning that would be ascribed to them by a specialist in the field.

[0035] With respect to the term imprecision, the terms "about" and "approximately" may be used interchangeably to refer to measurements that include the stated measurement and also measurements that are reasonably close to the stated measurement. A measurement that is reasonably close to the stated measurement deviates from the stated measurement by a reasonably small amount, as understood and easily ascertained by one of ordinary skill in the relevant art. Such deviations may result from measurement errors, differences in calibration of measuring and / or manufacturing equipment, human error in reading and / or setting measurements, fine-tuning made to optimize performance and / or structural parameters given differences in measurements associated with other components, specific implementation scenarios, imprecise adjustment and / or manipulation of the object by a human or machine, and the like. If it is determined that the value of such a reasonably small difference would not be easily ascertainable by one of ordinary skill in the relevant art, the terms "about" and "approximately" may be understood to mean plus or minus 10% of the stated value.

[0036] The term "fibril," as used herein, describes an elongated piece of material, such as a polymer, whose length and width differ substantially from one another. For example, a fibril can resemble a string or piece of fiber, whose width (or thickness) is much shorter or less than its length.

[0037] The term "node," as used herein, describes a connection point of at least two fibrils, which may be defined as a location where two fibrils contact each other, either permanently or temporarily. In some instances, a node may also be used to describe a larger volume of polymer than a fibril and where a fibril begins or ends without a clear continuation of the same fibril through the node. In some instances, a node is wider but shorter than a fibril.

[0038] As used herein, "node" and "fibril" are usually, but not necessarily, connected or interconnected and may be used to describe objects having, for example, microscopic size. A "microscopic" object may be defined as an object having at least one dimension (width, length, or height) so substantially small that the object or details of the object are not visible to the naked eye or are difficult, if not impossible, to observe without the aid of a microscope (such as, but not limited to, a scanning electron microscope or SEM) or an appropriate type of magnifying device.

[0039] Description of Various Embodiments The present disclosure relates to sorbent polymer composite articles, methods of forming sorbent polymer composite articles, and methods of using sorbent polymer composite articles to adsorb and separate one or more desired substances from a source stream. While the sorbent polymer composite articles are described with respect to their use in capturing CO from dilute feed streams such as air, they can also be used in other adsorption processes and applications. These processes include, but are not limited to, the adsorption of substances from various inputs, including other gaseous feed streams (e.g., combustion exhaust) and liquid feed streams (e.g., seawater). The adsorbed substance is not limited to CO. Other adsorbed substances may include, but are not limited to, other gas molecules (e.g., N, CH, CO), liquid molecules, solutes, and the like. In certain embodiments, the input may be diluted, containing the desired substance on the order of parts per million (ppm).

[0040] 2 illustrates a first exemplary sorbent polymer composite article 20 of the present disclosure, including a first composite region 28. The first composite region 28 includes a first porous polymer 22 and a sorbent material 24, 24'. The first composite region 28 can also optionally include a carrier 26. Each element of the first composite region 28 is further described below.

[0041] The first porous polymer 22 of the first composite region 28 can be one of expanded polytetrafluoroethylene (ePTFE), expanded (expanded, expanded, stretched, or foamed) polyethylene (ePE), polytetrafluoroethylene (PTFE), or another suitable porous polymer. It will be understood that nonwoven materials, such as nanospun, meltblown, spunbond, and porous cast films, can be various other suitable porous polymer forms. The first porous polymer 22 can be expanded by stretching the polymer at a controlled temperature and a controlled stretching rate, causing the polymer to fibrillate. After expansion, the first porous polymer 22 can include a microstructure of multiple nodes 30 and multiple fibrils 34 connecting adjacent nodes 30. In these examples, the first porous polymer 22 includes pores 32 bounded by the fibrils 34 and nodes 30. Exemplary node and fibril microstructures are described in U.S. Patent No. 3,953,566 to Gore, which is incorporated herein by reference in its entirety. The pores 32 of the first porous polymer 22 can be considered micropores. Such pores can have a single pore size or can have a distribution of pore sizes. The average pore size can range from 0.1 microns to 100 microns in certain embodiments.

[0042] The sorbent material 24, 24' of the first complex region 28 is a substrate having a surface configured to retain desired substances from the input on the surface by adsorption. The sorbent material 24, 24' varies based on which substances are targeted for adsorption. In various embodiments, the sorbent material 24, 24' is a carbon dioxide sorbent material, including, but not limited to, an ion exchange resin (e.g., a strong base anion exchange resin such as Dowex® Marathon® A resin, Dow Chemical available from the Company), zeolites, activated carbon, alumina, metal-organic frameworks, polyethyleneimine (PEI), desiccants, carbon molecular sieves, carbon adsorbents, graphite, activated alumina, molecular sieves, aluminophosphates, silicoaluminophosphates, zeolite adsorbents, ion-exchanged zeolites, hydrophilic zeolites, hydrophobic zeolites, modified zeolites, natural zeolites, faujasite, clinoptilolite, mordenite, metal-exchanged silicoaluminophosphates, monopolar resins, bipolar resins, aromatic cross-linked polystyrene matrices, brominated aromatic matrices, methacrylate copolymers, graphite-based adsorbents, carbon fibers, carbon nanotubes, nanomaterials, metal salt adsorbents, perchlorates, oxalates, alkaline earth metal particles, ETS, CTS, metal oxides, chemisorbents, amines, organometallic reactants, hydrotalcites, silicalites, zeolitic imadazolate frameworks, and Metal organic frameworks (MOFs), adsorbent compounds, and combinations thereof may be mentioned.

[0043] The sorbent material 24, 24' can be present in the first porous polymer 22 as a coating, filler, entrained particles, and / or in another suitable form, as described further below. In the embodiment shown in FIG. 2, the first porous polymer 22 is coated with the sorbent material 24 such that the sorbent material 24 forms a substantially continuous coating on the nodes 30 and / or fibrils 34 of the first porous polymer 22. It is also within the scope of the present disclosure for the first porous polymer 22 to be filled with the sorbent material 24 such that the sorbent material 24 is incorporated into the nodes 30 and / or fibrils 34 of the first porous polymer 22. In the exemplary embodiment of FIG. 2, the particles of the sorbent material 24 on the carrier 26 are incorporated into the first porous polymer 22 such that the sorbent material 24' occupies the pores 32 between the nodes 30 and fibrils 34 of the first porous polymer 22.

[0044] The optional carrier 26 in the first composite region 28 is a material configured to increase the surface area of ​​the region it occupies, thereby increasing the surface area available for adsorption of the desired substance. The carrier 26 can include mesoporous silica, polystyrene beads, porous polymer beds or spheres, oxide supports, or another suitable carrier material. The carrier 26 can further include a porous film containing a porous inorganic material therein, such as calcium sulfate, alumina, activated carbon, or fumed silica. As described above, the carrier 26 can be present within the pores 32 of the first composite region 28 as high-surface-area particles coated or functionalized with a sorbent material 24′. The combination of the carrier 26 coated with a sorbent material 24′ increases the surface area available for adsorption. In these embodiments, the nodes 30 and fibrils 34 may or may not be coated with a sorbent material 24. The original hydrophobicity of the first porous polymer 22 can be maintained when the nodes 30 and fibrils 34 are uncoated.

[0045] The first composite region 28 of the sorbent polymer composite article 20 includes a first side 72 (e.g., the upper side in FIG. 2 ) and a second side 74 (e.g., the lower side in FIG. 2 ). The sorbent polymer composite article 20 further includes a second region 36 including a second porous polymer 40, the second region 36 being disposed adjacent to the first side 72 of the first composite region 28. In various embodiments, the sorbent polymer composite article also includes a third region 38 including a third porous polymer 48, the third region 38 being disposed adjacent to the second side 74 of the first composite region 28. In this manner, the first composite region 28 can be sandwiched between the second layer 36 on the first side 72 and the third layer on the second side 74. The second porous polymer 40 of the second region 36 can include a plurality of nodes 42, a plurality of fibrils 46 connecting adjacent nodes 42, and a plurality of pores 44 each formed between each node 42 and fibril 46. Similarly, the third porous polymer 48 of the third region 38 may include a plurality of nodes 50, a plurality of fibrils 52 connecting adjacent nodes 50, and a plurality of pores 54 formed between each node 50 and fibril 52. The pores 44 of the second porous polymer 40 and / or the pores 54 of the third porous polymer 48 may be considered micropores, as further described above.

[0046] The first composite region 28, the second region 36, and the third region 38 of the sorbent polymer composite article 20 may be formed using different processes. In certain embodiments, the first composite region 28, the second region 36, and / or the third region 38 may be formed as separate layers and then bonded together. In this case, the first porous polymer 22 of the first composite region 28, the second porous polymer 40 of the second region 36, and / or the third porous polymer 48 of the third region 38 may be distinct structures. In other embodiments, the first composite region 28, the second region 36, and / or the third region 38 may be formed together and then subjected to different coating processes or surface treatments to distinguish the particular regions, as described further below. In this case, the first porous polymer 22 of the first composite region 28, the second porous polymer 40 of the second region 36, and / or the third porous polymer 48 of the third region 38 may be continuous or monolithic structures.

[0047] The first composite region 28, the second region 36, and the third region 38 of the sorbent polymer composite article 20 can have different degrees of hydrophobicity. The hydrophobicity can be altered by various methods, such as the application of coatings or surface treatments, including, but not limited to, plasma etching and the application of fine topographical features. The first composite region 28 can have a first hydrophobicity, the second region 36 can have a second hydrophobicity, and the third region 38 can have a third hydrophobicity. The first hydrophobicity is less than the second and third hydrophobicities, respectively. The second hydrophobicity can be less than, greater than, or equal to the third hydrophobicity. The greater hydrophobicity of the second and third regions 36, 38 can reduce the permeability of liquid water through the respective regions 36, 38, thus forming a barrier between the surrounding liquid water and the components of the first composite region 28. This reduces degradation of the sorbent material 24, 24' in the first composite region 28 that can be caused by liquid water, improving the life and durability of the sorbent polymer composite article 20. The increased hydrophobicity of the second region 36 and the increased hydrophobicity of the third region 38 relative to the first hydrophobicity of the first composite region 28 can be attributed to the absence of the sorbent material 24, 24' in the second and third regions 36, 38.

[0048] In some embodiments, the first composite region 28 is sealed with a coating (not shown). In particular examples, the coating is configured to be a carbon adsorbent material similar to the sorbent materials 24, 24' described above.

[0049] The second porous polymer 40 of the second region 36 and the third porous polymer 48 of the third region 38 can be at least one of polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), expanded polyethylene (ePE), or other suitable porous polymers. The second porous polymer 40 of the second region 36 may be the same or different from the third porous polymer 48 of the third region 38. Furthermore, the first porous polymer 22 of the first composite region 28, the second porous polymer 40 of the second region 36, and the third porous polymer 48 of the third region 36 may be the same or different.

[0050] In various embodiments, the thickness of second region 36 is less than the thickness of first composite region 28, and the thickness of third region 38 is less than the thickness of first composite region 28. The overall thickness of sorbent polymer composite article 20 can be from about 0.1 mm to about 5.0 mm. In certain embodiments, the thickness of first composite region 28 can comprise a majority of the overall thickness, for example, about 70%, about 80%, about 90% or more of the overall thickness.

[0051] The pore characteristics of the porous polymers 22, 40, 48 of the first composite region 28, the second region 36, and the third region 38, respectively, can be varied. In certain embodiments, the second and third regions 36, 38 can have fewer and / or smaller pores 44, 54 than the first composite region 28 to selectively limit the permeation of undesirable contaminants (e.g., water) into the first composite region 28 while allowing the permeation of desired molecules (e.g., CO) into the first composite region 28. In contrast, the first composite region 28 can have more and / or larger pores 32 than the second and third regions 36, 38 to facilitate the movement of CO through the first composite region 28 for adsorption and desorption.

[0052] Additionally, the pore characteristics can vary between different embodiments, and this variation in pore characteristics can depend on the overall thickness of the sorbent polymer composite article 20, as well as the individual thicknesses of the first composite region 28, the second region 36, and the third region 38.

[0053] FIG. 2A is a schematic elevational view of the first composite region 28 of the sorbent composite article 20 of FIG. 2. In this embodiment, the sorbent polymer composite article 20 (FIG. 2) is relatively thick, e.g., about 3 mm, with the first composite region 28 having a thickness T1 that accounts for a majority of the overall thickness of the sorbent polymer composite 20. The sorbent polymer composite article 20 can be loaded with a desired amount of sorbent material 24 (e.g., about 60% sorbent material 24) to maintain a relatively high porosity, where porosity is the relative ratio of the volume of void space in the first composite region 28 to the overall volume of the first composite region 28. In this manner, the sorbent polymer composite article 20 is structurally relatively open, providing relatively high accessibility to the sorbent material 24. Because of the thickness T1 in this embodiment, the sorbent material 24 remains accessible to gases, although the distance required for gas diffusion may be greater. As a result, the initial rate of gas adsorbing onto the sorbent material 24 may be slower compared to thinner embodiments, as described herein, but equilibrium of CO2 adsorbing onto the sorbent material 24 may be reached more quickly.

[0054] FIG. 2B is an alternative embodiment of the first composite region 28 of FIG. 2A, in which the sorbent composite article 20 (FIG. 2) has a median thickness of, for example, about 0.5 mm. In this embodiment, the first composite region 28 has a thickness T2 that accounts for a majority of the overall thickness of the sorbent polymer composite article 20. In this case, if the amount of polymer 22 (FIG. 2) and the amount of sorbent material 24 in the first composite region are constant compared to the previous embodiment, the porosity is relatively smaller than that of the first composite region 28 of FIG. 2A. Thus, the sorbent polymer composite article 20 maintains a porosity that allows gas access to the sorbent material 24 but is relatively less accessible than the sorbent material 24 of the embodiment of FIG. 2A. As a result, the initial rate of gas adsorption into the sorbent material 24 may be faster due to the shorter diffusion distance, but the time to reach equilibrium CO2 adsorption is increased compared to the embodiment of FIG. 2A.

[0055] FIG. 2C is an alternative embodiment of the first composite region 28 of FIGS. 2A and 2B, in which the sorbent polymer composite article 20 (FIG. 2) is relatively thin, e.g., about 0.1 mm. In this embodiment, the first composite region 28 has a thickness T3 that accounts for a majority of the overall thickness of the sorbent polymer composite article 20. In this case, if the amount of polymer 22 (FIG. 2) and the amount of sorbent material 24 in the first composite region 28 are constant relative to the previous two embodiments, the polymer 22 and available sorbent material 24 are more concentrated within the sorbent polymer composite article 20. The diffusion distance required for gas to pass through the article 20 is shorter due to the compressed thickness of the sorbent polymer composite article 20, but the sorbent material 24 is also less accessible to the gas. As a result, the initial rate of gas adsorption onto the sorbent material 24 is faster than in the previous embodiment, but it may take longer for the system to reach CO2 adsorption equilibrium.

[0056] 2, the pore characteristics of the sorbent polymer composite 20 can vary within each layer, but also across various embodiments as a result of varying different properties including the thickness of the sorbent polymer composite article 20, the thickness of the first composite region 28, the amount of sorbent material 24, 24′ used in the sorbent polymer composite article 20, and the amount of polymer 22. In this manner, the relationship between the diffusion length and the accessibility of the sorbent material 24, 24′ can be varied to maximize the performance of the sorbent polymer composite article 20.

[0057] Additionally, the ability to vary the hydrophobicity, thickness, pore characteristics, and other properties of the first composite region 28, second region 36, and third region 38 can increase the durability and adaptability of the sorbent polymer composite article 20. Additionally, the use of a relatively thin and flexible sorbent polymer composite article 20 may allow the sorbent polymer composite article 20 to conform to different configurations for CO2 adsorption and desorption.

[0058] 2, other useful components can be incorporated into the sorbent polymer composite articles 20, 20′ (see FIG. 4) and 20″ (see FIG. 6). Components can include fillers that can enhance thermal conductivity. For example, as shown in FIG. 2, thermally conductive powder 78 can be mixed into the mixture, or thermally conductive components (e.g., aluminum filaments and / or fabrics) can be laminated to the structure. In some instances, electrical conductors (e.g., wires, grids) may be incorporated. In some instances, adhesives incorporating thermally conductive materials can be used to bond regions of the sorbent polymer composite articles 20, 20′, 20″. One example of a useful component is a thermally and / or electrically conductive screen 25 (FIGS. 9A and 9B), which is described further below. Additionally, component materials can be selected based on thermal conductivity, electrical conductivity, flexibility, ductility, hydrophobicity, thinness, durability, UV resistance, compatibility, etc. for a particular application.

[0059] FIG. 2D is an additional elevational view of the sorbent polymer composite article of FIG. 2 , including an additional edge seal region 21. In embodiments, the sorbent polymer composite article 20 includes this edge seal region 21 to protect the components of the sorbent polymer composite article 20. For example, if the sorbent polymer composite article 20 is cut or divided in any manner, such as for production or manufacturing purposes, it may leave the first composite region 28, and thus the sorbent material 24, 24′ within the first composite region 28, exposed to external environmental elements such as water, steam, or debris that may be detrimental to the properties of the sorbent polymer composite article 20. Therefore, an embodiment with an edge seal region 21 may be desirable. As shown in FIG. 2D , the edge seal region 21 can connect the polymer 40 of the second region 36 and the polymer 48 of the third region 38 and is positioned to cover the exposed polymer 28 of the first composite region 28 on at least one side.

[0060] In the illustrated embodiment of FIG. 2D , the edge seal region 21 is formed by applying an additional layer of sealing material 47 onto the sorbent polymer composite article 20. The sealing material 47 may be the same or different from the material of the second region 36 and the third region 36. For example, the sealing material 47 may be ePTFE (shown in FIG. 2A ), ePE, a silicone elastomer, or any other suitable non-porous and / or hydrophobic material that protects the first composite region 28. In other embodiments, the edge seal region 21 may be formed by extending the second region 36 and the third region 38 and bonding (e.g., sandwiching, gluing) the regions 36, 38 together. The addition of this edge sealing step benefits the composite by protecting the sorbent retained within the composite and strengthening the leading edge of the composite (the area most susceptible to damage from airborne debris and high-velocity impacts).

[0061] 3 is a flow chart illustrating a method 100 for forming the above-described sorbent polymer composite article 20 (FIG. 2). In block 102, the method 100 includes forming a first composite region 28 including a first porous polymer 22 and a sorbent material 24, 24′ (FIG. 2). This forming step of block 102 can include coating, entraining, and / or filling the first porous polymer 22 with the sorbent material 24, 24′, as described above.

[0062] At block 104, the method includes bonding a second hydrophobic region 36 to the first side 72 of the first composite region 28, which bonding includes laminating, adhering, or otherwise attaching the second hydrophobic region 36 to the first side 72 of the first composite region 28. At block 106, the method includes bonding a third hydrophobic region 38 to the second side 74 of the first composite region 28, which bonding includes laminating, adhering, or otherwise attaching the third hydrophobic region 38 to the second side 74 of the first composite region 28. In some embodiments, the bonding of the third hydrophobic region 38 in block 106 can occur before or simultaneously with the bonding of the second hydrophobic region 36 in block 104.

[0063] FIG. 4 illustrates a second exemplary embodiment of a sorbent polymer composite article 20′ of the present disclosure. The sorbent polymer composite article 20′ is similar to the sorbent polymer composite article 20 (FIG. 2) described above, except as described below, and like reference numerals indicate like elements. The sorbent polymer composite article 20′ includes a first composite region 28, a second region 36, the second region 36 being bonded to a first side 72 of the first composite region 28, and a third region 38, the third region 38 being bonded to a second side 74 of the first composite region 28. In this embodiment, the sorbent polymer composite article 20′ includes multiple attachment points 80 (i.e., connection points) at which the second region 36 and the third region 38 are connected to one another. The distance 82 between the attachment points is variable and can be decreased or increased. In certain embodiments, an adhesive is used to form the attachment points 80. In this manner, first composite region 28 can be sandwiched between second region 36 on first side 72 and third region 38 on second side 74 in pocket-like regions between adjacent attachment points 80. The attachment points can be designed or engineered to create a uniform space between regions 36 and 38 for the sorbent and carrier to reside in, positioning and supporting the sorbent and carrier for optimal adsorption while minimizing the amount of surface area loss.

[0064] FIG. 5 is a flowchart illustrating a method 200 for forming the above-described sorbent polymer composite article 20′ (FIG. 4). In block 202, the method 200 includes forming a first composite region 28 including a porous polymer and a sorbent material. In block 204, the method 200 includes bonding a second hydrophobic region 36 to a first side 72 of the first composite region 28. In block 206, the method includes bonding a third hydrophobic region 38 to a second side 74 of the first composite region 28. In block 208, the method 200 includes connecting the second hydrophobic region 36 and the third hydrophobic region 38 at attachment points 80. In some embodiments, an adhesive is used to form the attachment points 80. The use of various attachment points 80 can maximize the available surface area, thus minimizing the amount of adhesive required and the surface area occupied by the adhesive. Stitch patterns and variations in stitching are also contemplated for attaching the layers 36 and 38 together at specific points.

[0065] FIG. 6 illustrates a third exemplary embodiment of a sorbent polymer composite article 20'' of the present disclosure. The sorbent polymer composite article 20'' is similar to the sorbent polymer composite article 20 (FIG. 2) and the sorbent polymer composite article 20' (FIG. 4) described above, except as described below, and like reference numerals identify like elements. The sorbent polymer composite article 20'' includes a first composite region 28 having a first porous polymer 22 and a sorbent material 24, 24', as described above.

[0066] The sorbent polymer composite article 20" further includes a second region 36 integrally formed with the first side 72 of the first composite region 28. In this embodiment, the first porous polymer 22 of the first composite region 28 may be continuous with the second porous polymer 40 of the second region 36. In certain embodiments, the sorbent polymer composite article 20" may further include a third region 38 having a third porous polymer 48 integrally formed with the second side 74 of the first composite region. In this embodiment, the first porous polymer 22 of the first composite region 28 may be continuous with the third porous polymer 48 of the third region 38.

[0067] In certain embodiments, the second region 36 and the third region 38 are modified surface regions of the first composite region 28 of the sorbent polymer composite article 20'', and the sorbent polymer composite article 20'' is monolithic. In these embodiments, the second region 36 and the third region 38 may be created by applying a surface treatment to the porous polymer 40, 48 so that each region 36, 38 has a hydrophobicity greater than the hydrophobicity of the first porous polymer 22 of the first composite region 28. This surface treatment may include eroding the sorbent material 24, 24' beyond the first side 72 of the first composite region 28 and beyond the second side 74 of the first composite region 28, such that the porous polymer 40, 48 of the second region 36 and the third region 38, respectively, does not include the sorbent material 24, 24'. Rather than applying the sorbent material 24, 24' and then eroding it from the second region 36 and the third region 38, the surface treatment can include masking the second region 36 and the third region 38 so that the sorbent material 24, 24' is deposited within the first composite region 28. The surface treatment can also include applying a hydrophobic coating to the second region 36 and the third region 38. More information regarding these and other surface treatments is provided below.

[0068] FIG. 7 is a flowchart illustrating a method 300 for forming the above-described sorbent polymer composite article 20″ (FIG. 6). In block 302, the method 300 includes forming a first composite region 28 comprised of a first porous polymer 22 and a sorbent material 24, 24′. In block 306, the method 300 includes applying a surface treatment to a first side 72 of the first composite region 28. The surface treatment can include eroding the sorbent material 24, 24′ beyond the first side 72. The erosion can be accomplished through the use of heat, solvents, or plasma. In other examples, the surface treatment can include applying a wash, applying a plasma treatment, or masking the region beyond the first side 72 with a hydrophobic material. In block 308, the method 300 includes applying a surface treatment to a second side 74 of the first composite region 28. The surface treatment can include eroding the sorbent material 24, 24′ beyond the second side 74. Erosion can be accomplished by the use of heat, solvents, or plasma. In other examples, surface treatment can include applying a wash, applying a plasma treatment, or masking the area beyond the second side 74 with a hydrophobic material.

[0069] FIG. 8 is a flow chart illustrating a basic method 400 of using the above-described sorbent polymer composite article 20 of FIG. 2 for adsorption, particularly DAC. In embodiments, the method of use 400 is modified to use the sorbent polymer composite article 20 of FIG. 2 in adsorption processes other than DAC, as described above. While method 400 is described with reference to the sorbent polymer composite article 20 of FIG. 2, method 400 applies equally to the sorbent 20′ and sorbent polymer composite article 20″ of FIGS. 4 and 6, respectively. At block 402, method 400 includes providing a sorbent polymer composite article 20. At block 404, method 400 includes directing a feed stream, which may be similar to the air input stream 11 of FIG. 1, containing CO2 molecules 16 across the sorbent polymer composite article 20. Other suitable input streams 11 include liquids (e.g., seawater) or other vapors. At block 406, method 400 includes adsorbing the CO2 molecules 16 onto the sorbent polymer composite article 20. At block 408, the method 400 includes desorbing the CO2 molecules 16 from the sorbent polymer composite article 20, thereby regenerating the sorbent polymer composite article 20 for further use (FIG. 1). In certain examples, this desorption step at block 408 includes applying at least one of water, steam, or heat to the sorbent polymer composite article 20. At block 410, the method 400 includes recovering the CO2 molecules 16 for a desired end use by vacuum or another suitable recovery technique.

[0070] In certain embodiments, the process of adsorbing CO2 molecules 16 onto the sorbent polymer composite article 20 at block 406, followed by desorbing CO2 16 from the sorbent polymer composite article 20 at block 408, can be repeated. Thus, the sorbent polymer composite article 20 can be efficiently and durably cycled between the adsorption and desorption stages.

[0071] FIG. 9A is an exemplary embodiment of a fourth sorbent polymer composite article 20'''. The sorbent polymer composite article 20''' includes a first region 28'' that includes a sorbent material 24 and a screen 25 (e.g., glass fiber, wire). The screen 25 can have a lattice-type configuration and can extend along the entire first side 72 and second side 74 of the first composite region 28''. The screen 25 can provide structural support to the sorbent polymer composite article 20 and the retained sorbent material 24, similar to the first porous polymer 22 described in the previous embodiment. Also, as noted above, the screen 25 can be considered a useful component, as described above, that promotes thermal and / or electrical conductivity within the sorbent polymer composite article 20'''. The sorbent polymer composite article 20'' may further include a second region 36'' of the second porous polymer 40'' and / or a third region 38'' of the third porous polymer 48'', as described above, which may immobilize the sorbent material 24 on the screen 25.

[0072] Figure 9B is an exemplary embodiment of a variation of the sorbent polymer composite article 20''' shown in Figure 9A. In this embodiment, the screen 25 can have a grid-type configuration instead of the lattice-type configuration of Figure 9A. Other variations are within the scope of this disclosure. [Example]

[0073] example Example 1 Sorptive polymer composite articles incorporating adsorbent-loaded tape were fabricated. Samples were prepared by obtaining amorphous silica powder (Syloid C 803, available from Grace Industries, Columbia, Maryland) and mixing it with PTFE resin. The blend ratio was 60% silica and 40% PTFE by weight. The components were blended using the process described in U.S. Patent No. 4,985,296 to Mortimer, Jr. This process involved mixing a blend of 60% silica and 40% PTFE by weight in an aqueous dispersion. The method then involved coagulating the filler and PTFE. The method then involved lubricating the loaded PTFE with an extrusion lubricant (Isopar K) and paste-extruding it to form a tape. The method then involved stretching and expanding the tape to form a porous PTFE tape with the filler dispersed therein, and finally compressing it to the desired thickness. The resulting loaded tape measured approximately 0.762 mm thick and 150 mm wide. The tape was cut into samples approximately 53 mm x 85 mm.

[0074] Figures 10A, 10B, 10C, and 10D are scaled SEM images taken of this sample. The SEM images are displayed with the scale indicated on each image. Figure 10A displays a surface image of tape 90 at 100x magnification, showing the surface variations with light areas 90a and dark bands 90b, with a 500 μm scale marking the image. Shown at the bottom of the image are: HV 10.00 kV, magnification 100x, WD 10.1 mm, HFW 1.49 mm, and det BSED. Figure 10B shows a higher magnification SEM at 1000x of the same surface of tape 90, with a 50 μm scale marking the image, where silica particles 92 are shown embedded in the polymer; the light areas 90a in Figure 10A are the silica particles 92, and the dark areas in Figure 10A are the polymer supporting the silica particles 92. Shown at the bottom of the image are HV 10.00 kV, 1000x magnification, WD 10.1 mm, HFW 149 μm, and det BSED. Figure 10C shows a cross-sectional image of the same tape 90 as Figure 10A at 100x magnification, showing some surface variations with light areas 90a and bands of dark areas 90b, and includes a 500 μm scale on the image. Shown at the bottom of the image are HV 10.00 kV, 100x magnification, WD 9.4 mm, HFW 1.49 mm, and det BSED. Figure 10D shows a higher magnification SEM of the same cross-section of the sorptive polymer composite article at 1000x magnification with a 50 μm scale on the image, where silica particles 92 are again evident, embedded in the polymer; the light areas 90a in Figure 10C are the silica particles 92, and the dark areas in Figure 10C are the polymer supporting the silica particles 92. Shown at the bottom of the image are HV 10.00 kV, magnification 1000x, WD 9.5 mm, HFW 149 μm, det BSED.

[0075] Example 2 Sorptive polymer composite articles were fabricated by incorporating a fiberglass screen between ePTFE membranes. The samples were prepared by first spraying two coats of polyurethane adhesive (Gorilla brand spray adhesive, Gorilla Glue Company, Cincinnati, Ohio) onto a fiberglass mesh / screen (Saint-Gobain, ADFORS, fiberglass vent screen). The adhesive was allowed to dry until no longer tacky. Expanded ePTFE was obtained, manufactured according to the teachings of U.S. Patent No. 5,814,405 to Branca et al. The ePTFE membrane was adhered to one side of the adhesive-coated screen, using localized heat from a soldering iron to reflow the polyurethane and bond it. The same silica powder described in Example 1 was then applied to the structure, filling the openings in the screen with silica. A straightedge was used to smooth the powder along the surface of the screen. Another layer of the same ePTFE membrane was used to cover the screen and powder. The structure was placed in a T-shirt press set at 150°C. The press was closed and pressure and heat were applied to the construct for 30 seconds. The sample was removed, allowed to cool, and cut with scissors. The final sample size measured approximately 53mm x 85mm.

[0076] Example 3 Sorptive polymer composite articles incorporating sorbent-loaded tape were fabricated. Samples were prepared by obtaining amorphous silica powder (Syloid C 803, available from Grace Industries, Columbia, MD) and mixing it with PTFE resin. The blend proportions were 60% silica and 40% PTFE by weight. The mixture was then processed into tape as described in Example 1. The resulting tape was approximately 0.762 mm thick and 150 mm wide.

[0077] Expanded ePTFE membranes were obtained, manufactured according to the teachings of U.S. Patent No. 5,814,405 to Branca et al. An ePTFE membrane was placed on both sides of the sample. The sample was then placed in a Carver hydraulic press and compressed between aluminum shims. The pressure compressed the sample to approximately one-third of its original thickness. The sample was removed and trimmed to approximately 53 mm x 85 mm.

[0078] The sorbent polymer composite articles of Examples 1, 2, and 3 were then analyzed for several properties. One of the properties tested was the hydrophobicity of the sorbent polymer composite articles. Hydrophobicity testing revealed that the hydrophobicity of the sorbent polymer composites was not altered by the coating. Although PEI is hydrophilic, studies found that the hydrophobicity of the ePTFE layer was maintained in the sorbent polymer composite articles after the coating process. The results also showed that the critical size of the HO droplets determined whether the water droplets would run off the sorbent polymer composite article or remain on the surface. However, shaking the sorbent polymer composite article removed the HO droplets remaining on the sorbent polymer composite article. This is an advantage of creating a conformable sorbent polymer composite article.

[0079] Additionally, temperature swing sorption was replicated by exposing the sorptive polymer composite articles of Examples 1, 2, and 3 to elevated temperatures. The samples were able to withstand five cycles of temperature swing sorption while maintaining adequate functionality.

[0080] Example 4 Sorptive polymer composite articles were fabricated incorporating loaded tape containing Dowex particles. Dowex Marathon A in the chloride form was obtained from Lenntech USA, South Miami, Florida. The resin was then freeze-ground to an average size of approximately 50 microns. The Dowex resin powder was then mixed with PTFE resin in a ratio of 60% Dowex and 40% PTFE by weight. The mixture was then processed into tape as described in Example 1. The resulting tape measured approximately 0.762 mm thick and 150 mm wide. The tape was cut into samples approximately 53 mm x 85 mm and labeled for testing.

[0081] Figures 11A, 11B, 11C, and 11D are SEM images taken from this sample. The SEM images are displayed with a scale marked on each image. Figure 11A displays a surface image of the Dowex tape at 50x magnification, including a scale marking a length of 1.00 mm on the image (so that the distance between two consecutive vertical markers represents 0.1 mm), showing the polymer 94 supporting the filler particles 96 and the presence of a PTFE skin 95 over the surface of many of the particles 96. Shown at the bottom of the image is a 2.0 kV 10.8 mm x 50 LM (UL) 6 / 25 / 2020. Figure 11B displays a higher magnification SEM of the same surface of the Dowex tape at 200x magnification, including a scale marking a length of 200 μm on the image (so that the distance between two consecutive vertical markers represents 20 μm), again showing the polymer 94 supporting the filler particles 96 and the presence of a PTFE skin 95 over the surface of many of the particles 96. Shown at the bottom of the image is: 2.0 kV 10.8 mm x 200 LM (UL) 6 / 25 / 2020. Figure 11C displays a cross-sectional image of the same Dowex tape as Figure 11A at 50x magnification, including a scale marking a length of 1.00 mm on the image (so that the distance between two consecutive vertical markers represents 0.1 mm), showing that polymer 94 forms a layer supporting filler particles 96. Shown at the bottom of the image is: 2.0 kV 11.1 mm x 50 LM (UL) 6 / 25 / 2020. Figure 11D shows a higher magnification SEM of the same cross-section of Dowex tape at 200x magnification, including a scale marking a length of 200 μm on the image (so that the distance between two consecutive vertical markers represents 20 μm), again showing that polymer 94 forms a layer supporting filler particles 96. Shown at the bottom of the image is a 2.0 kV 11.1 mm x 200 LM (UL) 6 / 25 / 2020. In both Figures 11A and 11B, the Dowex particles are not clearly visible because they are embedded below the surface of the polymer 94. In Figures 11C and 11D, cross sections show Dowex particles 96 embedded within the polymer 94.

[0082] Example 5a Process 1 (Drying) Sorptive polymer composite articles were fabricated by incorporating a fiberglass screen between ePTFE membranes. The samples were prepared by first spraying two coats of polyurethane adhesive (Gorilla brand spray adhesive, Gorilla Glue Company, Cincinnati, Ohio) onto a fiberglass mesh / screen (Saint-Gobain, ADFORS, Fiberglass Vent Screen). The adhesive was allowed to dry until tack-free. Expanded ePTFE was obtained, manufactured according to the teachings of U.S. Patent No. 5,814,405 to Branca et al. An ePTFE membrane was adhered to one side of the adhesive-coated screen using localized heat from a soldering iron to reflow the polyurethane and create adhesion. The same Dowex resin described in Example 4 was then applied to the structure, and the openings in the screen were filled with resin. A straightedge was used to smooth the powder along the surface of the screen. Another layer of the same ePTFE membrane was used to cover the screen and resin. The structure was placed in a T-shirt press set at 125°C. The press was closed and the construction was subjected to pressure and heat for 30 seconds. The sample was removed, allowed to cool and cut with scissors to approximately 53mm x 85mm.

[0083] Example 5b Process 2 (wet) Sorptive polymer composite articles were fabricated by incorporating a fiberglass screen between ePTFE membranes. The samples were prepared by first spraying two coats of polyurethane adhesive (Gorilla brand spray adhesive, Gorilla Glue Company, Cincinnati, Ohio) onto a fiberglass mesh / screen (Saint-Gobain, ADFORS, Fiberglass Vent Screen). The adhesive was allowed to dry until tack-free. Expanded ePTFE membranes were obtained, manufactured according to the teachings of U.S. Patent No. 5,814,405 to Branca et al. The polyurethane was reflowed using localized heat from a soldering iron to create adhesion, and the ePTFE membrane was attached to one side of the adhesive-coated screen. The same Dowex resin described in Example 5a was then mixed with 70% IPA until a thin slurry consistency was achieved. It was then applied to the structure, filling the openings in the screen with the resin slurry. A straightedge was used to even out the slurry along the screen surface. Another layer of the same ePTFE membrane was used to cover the screen and resin. The construction was allowed to dry for 30 minutes and then placed in a T-shirt press set at 125°C. The press was closed and pressure and heat were applied to the construction for 30 seconds. The sample was removed, cooled, and cut to approximately 53mm x 85mm with scissors.

[0084] Those skilled in the art will recognize that other porous materials can be readily substituted in the foregoing examples. It will be understood that nonwoven materials such as nanospun, meltblown, spunbond, and porous cast film can be used in place of the fiberglass mesh / screen in Examples 5a and 5b.

[0085] Example 6 Sorptive polymer composite articles were fabricated incorporating layers of SnowPure laminated to ePTFE sheets on both sides. A polypropylene-based membrane containing Dowex Marathon A resin, available from SnowPure, LLC, San Clemente, California, was obtained. Expanded ePTFE membranes manufactured according to the teachings of U.S. Patent No. 5,814,405 to Branca et al. were obtained. An ePTFE membrane was placed on each surface of the SnowPure material and secured in place using localized heat from a soldering iron tip. The heat from the soldering iron partially melted the polypropylene substrate of the SnowPure membrane, creating adhesion to the ePTFE. Samples were then cut / trimmed to approximately 53 mm x 85 mm.

[0086] Samples from Examples 5a, 5b and 6 were analyzed for performance when subjected to moisture swing adsorption compared to a competitive product (SnowPure only) as a baseline.

[0087] 12 shows the amount of CO2 (µmol / g) adsorbed by the sorbent polymer composite articles when a 30-minute humidity swing adsorption cycle was used. The results show that the sorbent polymer composite article formed according to Example 5a (Process 1) achieved the highest CO2 adsorption of the sorbent polymer composite articles tested, while the sorbent polymer composite article formed according to Example 4 achieved the lowest CO2 adsorption. The baseline sorbent polymer composite article and the sorbent polymer composite article made according to Example 6 performed better than that of Example 4, but not as well as Examples 5a or 5b.

[0088] Figure 13 is similar to Figure 12, but shows the kinetic results as the amount of CO2 (µmol / g / min) adsorbed by the sorbent polymer composite article over time during a 30-minute humidity swing adsorption cycle. Similar to the results in Figure 12, the best performing sample was the sample from Example 5a (Process 1), followed by the sample from Example 5b (Process 2). The least desirable performing sorbent polymer composite article was again that from Example 4. The baseline sample and the sample from Example 6 did not perform as well as the samples from Examples 5a and 5b, but performed better than the sample from Example 4.

[0089] Both the CO2 adsorption and adsorption kinetics results suggest the benefits of using a composite of Dowex and ePTFE sorbent polymer composite articles formed according to Examples 5a and 5b.

[0090] Various modifications and additions can be made to the described exemplary embodiments without departing from the scope of the present disclosure. For example, while the above embodiments refer to particular features, the scope of the present disclosure also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present disclosure is intended to encompass all such alternatives, modifications, and variations that fall within the scope of the claims, together with all equivalents thereof. (Aspect) (Aspect 1) a first composite region comprising a first porous polymer and a sorbent material; and a second region of a second porous polymer disposed adjacent to a first side of the first composite region; Including, the first complex region has a first hydrophobicity; the second region has a second hydrophobicity that is greater than the first hydrophobicity; Sorptive polymer composite article. (Aspect 2) The sorbent polymer composite article of embodiment 1, further comprising a third region of a third porous polymer positioned adjacent to a second side of the first composite region, the third region having a third hydrophobicity greater than the first hydrophobicity. (Aspect 3) 3. The sorbent polymer composite article of embodiment 2, wherein the first porous polymer, the second porous polymer, and the third porous polymer are the same. (Aspect 4) 3. The sorbent polymer composite article of claim 2, wherein the greater hydrophobicity of both the second region and the third region compared to the first composite region is determined by the absence of the sorbent material within the second region and the third region. (Aspect 5) 2. The sorbent polymer composite article of embodiment 1, wherein the first porous polymer of the first composite region is continuous with the second porous polymer of the second region. (Aspect 6) 3. The sorbent polymer composite article of embodiment 2, wherein the first porous polymer of the first composite region is continuous with the third porous polymer of the third region. (Aspect 7) 2. The sorbent polymer composite article of embodiment 1, wherein the sorbent material is a carbon dioxide sorbent material. (Aspect 8) 2. The sorptive polymer composite article of embodiment 1, wherein the sorptive material is an ion exchange resin, a zeolite, an activated carbon, an alumina, a metal organic framework, or polyethyleneimine (PEI). (Aspect 9) 2. The sorbent polymer composite article of embodiment 1, wherein the first porous polymer of the first sorbent composite region is expanded polytetrafluoroethylene, polytetrafluoroethylene, or expanded polyethylene. (Aspect 10) 3. The sorbent polymer composite article of claim 2, wherein the second region has a thickness less than the thickness of the first composite region, and the third region has a thickness less than the thickness of the first composite region. (Aspect 11) 2. The sorbent polymer composite article of embodiment 1, wherein the thickness of the sorbent polymer composite article is from about 0.1 mm to about 5.0 mm. (Aspect 12) 2. The sorbent polymer composite article of embodiment 1, wherein the first composite region further comprises a carrier. (Aspect 13) 13. The sorptive polymer composite article of claim 12, wherein the sorbent is configured to coat the carrier of a first composite layer and not coat the porous polymer of the first composite layer. (Aspect 14) 13. The sorbent polymer composite article of embodiment 12, wherein the carrier is silica or ceramic. (Aspect 15) 2. The sorbent polymer composite article of claim 1, wherein the second porous polymer of the second region is at least one of polytetrafluoroethylene, expanded polytetrafluoroethylene, and expanded polyethylene. (Aspect 16) 3. The sorbent polymer composite article of claim 2, wherein the third porous polymer of the third region is at least one of polytetrafluoroethylene, expanded polytetrafluoroethylene, and expanded polyethylene. (Aspect 17) 3. The sorbent polymer composite article of embodiment 2, wherein the second porous polymer of the second region and the third porous polymer of the third region are the same. (Aspect 18) 3. The sorbent polymer composite article of embodiment 2, wherein the first composite region has larger pores than the second and third regions. (Aspect 19) 10. The sorbent polymer composite article of embodiment 1, further comprising at least one useful component selected from an electrically conductive material, a thermal conductor material, or a hydrophobic material. (Aspect 20) 1. A method of forming a sorbent polymer composite article, comprising: forming a first composite region comprising a first porous polymer and a sorbent material; and forming a second hydrophobic region comprising a second porous polymer on a first side of the first composite region; A method comprising the steps of: (Aspect 21) 21. The method of embodiment 20, wherein the second hydrophobic region is a distinct layer from the first complex region. (Aspect 22) 22. The method of embodiment 21, wherein forming the second hydrophobic region on the first side of the first composite layer comprises bonding the second porous polymer of the second hydrophobic layer to the first side of the porous polymer of the first composite layer. (Aspect 23) 21. The method of embodiment 20, wherein the method further comprises forming a third hydrophobic region on a second side of the first composite layer, the third hydrophobic region comprising a third porous polymer. (Aspect 24) 24. The method of embodiment 23, wherein the third hydrophobic region is a distinct layer from the first complex region. (Aspect 25) 25. The method of embodiment 24, wherein the step of forming the third hydrophobic region on the second side of the first composite region further comprises bonding the third porous polymer of the third hydrophobic region to the second side of the first porous polymer of the first composite region. (Aspect 26) 23. The method of embodiment 22, wherein the bonding step comprises laminating the second hydrophobic region to the first side of the first composite region. (Aspect 27) 26. The method of embodiment 25, wherein the bonding step comprises laminating the third hydrophobic region to the second side of the first composite region. (Aspect 28) 26. The method of embodiment 25, further comprising connecting the second hydrophobic region to the third hydrophobic region by creating attachment points along the length of the sorbent polymer composite article such that the first composite region is sandwiched between the second hydrophobic region and the third hydrophobic region between adjacent attachment points. (Aspect 29) 30. The method of embodiment 28, wherein the connecting step comprises using an adhesive material. (Aspect 30) 30. The method of embodiment 28, wherein the distance between adjacent attachment points along the sorbent polymer composite article is varied. (Aspect 31) 21. The method of embodiment 20, wherein forming the first composite region comprising the first porous polymer and the sorbent material further comprises coating the first porous polymer with a sorbent coating, and forming the second hydrophobic region on the first side of the first composite region further comprises applying a surface treatment over the first side of the first composite region. (Aspect 32) 24. The method of embodiment 23, wherein forming the first composite region comprising the first porous polymer and the sorbent material further comprises coating the first porous polymer with a sorbent coating, and wherein forming the third hydrophobic region on the second side of the first composite region further comprises applying a surface treatment over the second side of the first composite region. (Aspect 33) 33. The method of embodiment 32, wherein the sorptive coating is polyethyleneimine (PEI). (Aspect 34) 1. A method of using a sorbent polymer composite article for adsorption, comprising: providing a sorptive polymer composite article comprising a first composite region comprising a first porous polymer and a sorbent, the first composite region having a first hydrophobicity, and a second region disposed adjacent a first side of the first region and having a second hydrophobicity greater than the first hydrophobicity; directing a feed stream comprising carbon dioxide across the sorbent polymer composite article; and adsorbing carbon dioxide into said sorbent polymer composite article; A method comprising: (Aspect 35) The method of embodiment 34, wherein the step of providing the sorbent polymer composite article further comprises forming a third region of a third porous polymer on a second side of the first region, the third region having a third hydrophobicity greater than the first hydrophobicity. (Aspect 36) 35. The method of embodiment 34, further comprising desorbing carbon dioxide by applying at least one of water and heat to the sorbent polymer composite article. (Aspect 37) 35. The method of embodiment 34, further comprising recovering the desorbed carbon dioxide using a vacuum. (Aspect 38) a first region having a sorbent material and a screen; a second region disposed adjacent to the first region, the second region comprising a second polymer; and a third region disposed adjacent to the first region, the third region comprising a third polymer; 1. A sorbent polymer composite article comprising: (Aspect 39) 39. The sorbent polymer composite article of claim 38, wherein the second polymer of the second region and the third polymer of the third region are at least one of expanded polytetrafluoroethylene and expanded polyethylene. (Aspect 40) 39. The sorbent polymer composite article of embodiment 38, wherein the screen is electrically conductive or thermally conductive. (Aspect 41) 39. The sorbent polymer composite article of embodiment 38, wherein the screen comprises glass fiber or wire. (Aspect 42) a first composite region comprising a first porous polymer and a sorbent material; a second region of a second porous polymer disposed adjacent to a first side of the first composite region; a third region of a third porous polymer disposed adjacent to a second side of the first composite region; and an edge seal region disposed between the second region and the third region so as to surround an edge of the first composite region; Including, the first complex region has a first hydrophobicity; the second region has a second hydrophobicity that is greater than the first hydrophobicity; the third region has a third hydrophobicity greater than the first hydrophobicity; Sorptive polymer composite article. (Aspect 43) 43. The sorbent polymer composite article of claim 42, wherein the edge seal region is formed by sandwiching the second region and the third region together. (Aspect 44) 43. The sorptive polymer composite article of embodiment 42, wherein the edge seal region is an additional layer of sealing material disposed on the sorptive polymer composite article. (Aspect 45) 45. The sorbent polymer composite article of embodiment 44, wherein the sealing material is the same as the porous polymer of the second region or the porous polymer of the third region.

Claims

1. a first composite region comprising a first porous polymer and a sorbent material; and a second region of a second porous polymer disposed adjacent to a first side of the first composite region; Including, the first complex region has a first hydrophobicity; the second region has a second hydrophobicity that is greater than the first hydrophobicity; the sorbent material is a coating, packing, or entrained particle of the first porous polymer; the first porous polymer of the first composite region is continuous with the second porous polymer of the second region; Sorptive polymer composite article.

2. The sorbent polymer composite article of claim 1, further comprising a third region of a third porous polymer positioned adjacent to a second side of the first composite region, the third region having a third hydrophobicity greater than the first hydrophobicity.

3. The sorbent polymer composite article of claim 2 , wherein said first porous polymer, said second porous polymer, and said third porous polymer are the same.

4. The sorbent polymer composite article of claim 2, wherein the greater hydrophobicity of both the second and third regions compared to the first composite region is determined by the absence of the sorbent material within the second and third regions.

5. The sorbent polymer composite article of claim 2 , wherein said first porous polymer of said first composite region is continuous with said third porous polymer of said third region.

6. The sorbent polymer composite article of claim 1 , wherein said sorbent material is a carbon dioxide sorbent material.

7. The sorptive polymer composite article of claim 1 , wherein the sorptive material is an ion exchange resin, a zeolite, activated carbon, alumina, a metal organic framework, or polyethyleneimine (PEI).

8. The sorbent polymer composite article of claim 1 , wherein said first porous polymer of said first composite region is expanded polytetrafluoroethylene, polytetrafluoroethylene, or expanded polyethylene.

9. The sorbent polymer composite article of claim 2 , wherein the thickness of the second region is less than the thickness of the first composite region, and the thickness of the third region is less than the thickness of the first composite region.

10. The sorbent polymer composite article of claim 1, wherein the thickness of said sorbent polymer composite article is from 0.1 mm to 5.0 mm.

11. the first conjugate region further comprises a carrier; The sorptive polymer composite article of claim 1 , wherein the carrier is silica, ceramic, polystyrene beads, porous polymer beds or spheres, or an oxide support.

12. The sorbent polymer composite article of claim 11 , wherein the sorbent material is configured to coat the carrier in a first composite region and not coat the porous polymer in the first composite region.

13. The sorbent polymer composite article of claim 11 , wherein the carrier is silica or ceramic.

14. The sorbent polymer composite article of claim 1 , wherein said second porous polymer of said second region is at least one of polytetrafluoroethylene, expanded polytetrafluoroethylene, and expanded polyethylene.

15. The sorbent polymer composite article of claim 2 , wherein said third porous polymer of said third region is at least one of polytetrafluoroethylene, expanded polytetrafluoroethylene, and expanded polyethylene.

16. The sorbent polymer composite article of claim 2 , wherein said second porous polymer of said second region and said third porous polymer of said third region are the same.

17. The sorbent polymer composite article of claim 2 , wherein said first composite region has larger pores than said second and third regions.

18. The sorbent polymer composite article of claim 1 further comprising at least one useful component selected from an electrically conductive material, a thermally conductive material, or a hydrophobic material.

19. 1. A method of forming a sorbent polymer composite article, comprising: forming a first composite region comprising a first porous polymer and a sorbent material; and forming a second hydrophobic region comprising a second porous polymer on a first side of the first composite region; The process includes the steps of: the first complex region has a first hydrophobicity; the second hydrophobic region has a second hydrophobicity greater than the first hydrophobicity; the sorbent material is a coating, packing, or entrained particle of the first porous polymer; the first porous polymer of the first composite region is continuous with the second porous polymer of the second hydrophobic region; method.

20. 20. The method of claim 19, further comprising forming a third hydrophobic region comprising a third porous polymer on a second side of the first composite region.

21. 21. The method of claim 20, wherein the third hydrophobic region is a distinct layer from the first composite region.

22. 22. The method of claim 21, wherein the step of forming the third hydrophobic region on the second side of the first composite region further comprises bonding the third porous polymer of the third hydrophobic region to the second side of the first porous polymer of the first composite region.

23. 23. The method of claim 22, wherein the bonding step comprises laminating the third hydrophobic region to the second side of the first composite region.

24. 23. The method of claim 22, further comprising connecting the first composite region to the third porous polymer of the third hydrophobic region by creating attachment points along the length of the sorbent polymer composite article such that the first composite region is sandwiched between the second hydrophobic region and the third hydrophobic region between adjacent attachment points.

25. 25. The method of claim 24, wherein the connecting step includes using an adhesive material.

26. 25. The method of claim 24, wherein the distance between adjacent attachment points along the sorbent polymer composite article is varied.

27. 20. The method of claim 19, wherein forming the first composite region comprising the first porous polymer and the sorbent material further comprises coating the first porous polymer with a sorbent coating, and forming the second hydrophobic region on the first side of the first composite region further comprises applying a surface treatment over the first side of the first composite region.

28. 21. The method of claim 20, wherein forming the first composite region comprising the first porous polymer and the sorbent material further comprises coating the first porous polymer with a sorbent coating, and forming the third hydrophobic region on the second side of the first composite region further comprises applying a surface treatment over the second side of the first composite region.

29. 29. The method of claim 28, wherein the sorptive coating is polyethyleneimine (PEI).

30. 1. A method of using a sorbent polymer composite article for adsorption, comprising: providing a sorbent polymer composite article comprising a first composite region comprising a first porous polymer and a sorbent material and having a first hydrophobicity, and a second region disposed adjacent a first side of said first composite region and comprising a second porous polymer and having a second hydrophobicity greater than said first hydrophobicity; directing a feed stream comprising carbon dioxide across the sorbent polymer composite article; and adsorbing carbon dioxide into said sorbent polymer composite article; Including, the sorbent material is a coating, packing, or entrained particle of the first porous polymer; the first porous polymer of the first composite region is continuous with the second porous polymer of the second region; method.

31. The method of claim 30, wherein the step of providing the sorbent polymer composite article further comprises forming a third region of a third porous polymer on a second side of the first composite region, the third region having a third hydrophobicity greater than the first hydrophobicity.

32. 31. The method of claim 30, further comprising desorbing carbon dioxide by applying at least one of water and heat to the sorbent polymer composite article.

33. 31. The method of claim 30, further comprising recovering the desorbed carbon dioxide using a vacuum.

34. The sorbent polymer composite article of claim 1 , further comprising a screen and a third region disposed adjacent said first composite region, said third region comprising a third polymer.

35. 35. The sorbent polymer composite article of claim 34, wherein the second polymer of the second region and the third polymer of the third region are at least one of expanded polytetrafluoroethylene and expanded polyethylene.

36. 35. The sorbent polymer composite article of claim 34, wherein said screen is electrically conductive or thermally conductive.

37. 35. The sorbent polymer composite article of claim 34, wherein said screen comprises fiberglass or wire.

38. an edge seal region disposed between the second region and the third region so as to surround an edge of the first composite region; The sorbent polymer composite article of claim 2 further comprising:

39. 40. The sorbent polymer composite article of claim 38, wherein said edge seal region is formed by sandwiching said second region and said third region together.

40. 40. The sorptive polymer composite article of claim 38, wherein said edge seal region is an additional layer of sealing material disposed on said sorptive polymer composite article.

41. 41. The sorbent polymer composite article of claim 40, wherein said sealing material is the same as the porous polymer of said second region or the porous polymer of said third region.

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