Fluid capturing apparatus and method of making

Abstract

A fluid capturing apparatus includes a substrate and an adsorbing composition incorporated with the substrate where the adsorbing composition includes a solid organic sorbent and an elastomeric binder dispersed in a protic polar solvent prior to being incorporated with the substrate.

Description

FLUID CAPTURING PPARATUS AND METHOD OF MAKINGCROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority under 35 U.S.C. §119 of U.S. Provisional Application Serial No. 63 / 672,469 filed on July 17, 2024, the content of which is relied upon and incorporated herein by reference in its entirety their entireties.Field

[0002] The present disclosure relates generally to a fluid capturing apparatus and method of making the same and more particularly to a fluid capturing apparatus incorporating a solid organic sorbent.Background

[0003] Efforts to address the effects of climate change include fluid capture technology, such as carbon dioxide capture technology, which includes flowing a carbon dioxide containing gas, such as ambient air, over or through a sorbent material capable of adsorbing at least a portion of the carbon dioxide. The sorbent material can then be regenerated by heating or flowing a vapor containing fluid (e.g., steam) thereover or therethrough, thereby removing captured carbon dioxide from the sorbent material. Suitable sorbent materials for this purpose can be inorganic or organic, which can be formulated as pelletized beds, in the form of a laminate structure, or coated onto a monolithic substrate. When incorporating a sorbent material with a substrate, several criteria must be simultaneously considered, including, but not limited to, adherence of the material to the substrate over operating cycles, mechanical integrity of the material over operating cycles, and maintenance of adsorption capacity of the sorbent over operating cycles. Accordingly, it is desirable to address one or more of these factors.SUMMARY

[0004] Embodiments disclosed herein include a fluid capturing apparatus. The fluid capturing apparatus includes a solid substrate and an adsorbing composition incorporatedwith the substrate. The adsorbing composition includes a solid organic sorbent and an elastomeric binder, the elastomeric binder being dispersed in a protic polar solvent prior to being incorporated with the substrate.

[0005] Embodiments disclosed herein also include a method of making a fluid capturing apparatus. The method includes incorporating an adsorbing composition with a solid substrate. The adsorbing composition includes a solid organic sorbent, a protic polar solvent, and an elastomeric binder dispersed in the protic polar solvent.

[0006] Additional features and advantages of the embodiments disclosed herein will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the disclosed embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.

[0007] It is to be understood that both the foregoing general description and the following detailed description present embodiments intended to provide an overview or framework for understanding the nature and character of the claimed embodiments. The accompanying drawings are included to provide further understanding and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the disclosure, and together with the description serve to explain the principles and operations thereof.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1A is a schematic end view of an example porous substrate in accordance with embodiments disclosed herein;

[0009] FIG. IB is a schematic side cutaway view of the example porous substrate of FIG. 1A;

[0010] FIG. 2A is an exploded schematic end view of a portion of the example porous substrate of FIGS. 1A-1B;

[0011] FIG. 2B is an exploded schematic end view of a portion of the example porous substrate of FIGS. 1A-1B with a coating composition comprising a solid organic sorbent deposited thereon;

[0012] FIGS. 3A-3C are exploded schematic end views of a process of applying a coating composition to the example porous substrate of FIGS 1A-1B;

[0013] FIGS. 4A-4D are exploded schematic end views of various coating compositions applied to the example porous substrate of FIGS. 1A-1B before and after a drying step;

[0014] FIG. 5 is a chart showing carbon dioxide adsorption of various sorbent containing coatings as compared to a control sample; and

[0015] FIG. 6 is a chart showing carbon dioxide adsorption of various sorbent containing coated substrates and sorbent coatings as compared to a control sample.DETAILED DESCRIPTION

[0016] Reference will now be made in detail to the present preferred embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts. However, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

[0017] Ranges can be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, for example by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0018] Directional terms as used herein - for example up, down, right, left, front, back, top, bottom - are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

[0019] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order, nor that with any apparatus specific orientations be required. Accordingly, where a method claim does not actually recite an order to be followed by its steps, or that any apparatus claim does not actually recite an order or orientation to individual components, or it is not otherwisespecifically stated in the claims or description that the steps are to be limited to a specific order, or that a specific order or orientation to components of an apparatus is not recited, it is in no way intended that an order or orientation be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps, operational flow, order of components, or orientation of components; plain meaning derived from grammatical organization or punctuation, and; the number or type of embodiments described in the specification.

[0020] As used herein, the singular forms "a," "an" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a” component includes aspects having two or more such components, unless the context clearly indicates otherwise.

[0021] As used herein, the term “fluid capture” refers to not only carbon dioxide capture or adsorption but also capture or adsorption of other fluids such as acidic and / or aldehyde effluents.

[0022] As used herein, the terms “incorporated with” or “incorporating” or “incorporates” refer to a relationship between a first referenced composition and a second referenced composition, structure, or material wherein the first referenced composition deposited on (e.g., coated on) or present within the second referenced composition, structure, or material. For example, the recitation “adsorbing composition incorporated with the substrate” includes situations where the adsorbing composition is not only deposited on (e.g., coated on) a substrate but also situations where the adsorbing composition is present within the substrate material (e.g., within the pores of the material, etc.).

[0023] As used herein, the term “elastomeric binder” refers to a binder that is capable of recovering to its original shape upon deformation or stretching.

[0024] As used herein the term “protic polar solvent” refers to a polar solvents that have at least one hydrogen that is connected directly to a particular electronegative atom (e.g., O-H, N-H, etc.) and are capable of forming hydrogen bonds with the solute. An exemplary protic polar solvent is water.

[0025] As used herein, the term “bare solid organic sorbent” refers to an amount of solid organic sorbent that has not been incorporated with an adsorbing composition or a substrate.For example, a bare solid organic sorbent includes an isolated sample of solid organic sorbent, such as beads or ground particles of the solid organic sorbent.

[0026] As used herein, the term “median particle size” refers to the particle size of a referenced material wherein half of the particles of that material have a larger particle size than the median particle size and half of the particles have a smaller particle size than the median particle size.

[0027] Embodiments disclosed herein include a fluid capturing apparatus, such as a carbon dioxide capturing apparatus, that includes a solid substrate and an adsorbing composition that comprises a solid organic sorbent that is incorporated with the substrate. Such embodiments include, for example, a fluid capturing apparatus, such as a carbon dioxide capturing apparatus, that includes a solid substrate and an adsorbing composition comprising a coating composition that comprises a solid organic sorbent that is deposited on the substrate. The coating composition may, for example, be deposited on the substrate by first depositing a slurry containing the solid organic sorbent on the substrate and then drying the slurry to form the coating composition.

[0028] Embodiments disclosed herein include those in which the adsorbing composition comprises an elastomeric binder that is dispersed in a protic polar solvent. Such dispersion may, for example, include emulsification of an elastomeric binder in the protic polar solvent wherein the elastomeric binder is insoluble in the protic polar solvent. The protic polar solvent may, for example, comprise or consist essentially of water.

[0029] In certain exemplary embodiments, the solid substrate comprises or consists essentially of a ceramic substrate, a glass substrate, a metal substrate, a carbon-based substrate, a polymeric substrate, or a glass-ceramic substrate. In certain exemplary embodiments, the solid substrate comprises or consists essentially of at least one of cordierite, amorphous silica, aluminum titanate, silicon carbide, diatomaceous earth, or hollow glass microspheres. In certain exemplary embodiments, the solid substrate comprises a porous substrate. In certain exemplary embodiments, the solid substrate comprises a plurality of channels extending therethrough and the adsorbing composition is deposited on and / or within walls of the plurality of channels.

[0030] FIGS. 1A and IB show respective schematic end and side cutaway views of an example porous substrate 100 in accordance with embodiments disclosed herein. Poroussubstrate 100 includes a plurality of channels 102 extending therethrough. Specifically, porous substrate 100 comprises a honeycomb structure, wherein a MxN matrix of parallel channels 102 extend therethrough. And while FIGS. 1A and IB show a porous substrate having a rectangular cross section with rectangular channels, embodiments disclosed herein include other geometries, such as porous substrates having other polygonal-shaped crosssections (e.g., triangular, pentagonal, hexagonal, etc.) or porous substrates having circular or elliptical cross-sections (e.g., cylindrical-shaped substrates), as well as any such substrates having channels with other polygonal-shaped cross-sections (e.g., triangular, pentagonal, hexagonal, etc.) or channels with circular or elliptical cross-sections (e.g., cylindrical-shaped channels).

[0031] In certain exemplary embodiments, the M*N matrix of parallel channels 102 extending through substrate comprises from 50 to 500 cells per square inch, such as from 100 to 400 cells per square inch, wherein “cells per square inch” refers to the number of channels per square inch as viewed from an end face (e.g., perspective of FIG. 1A) of substrate. In certain exemplary embodiments, walls of parallel channels 102 may have a thickness ranges from 2 mils to 10 mils, such as from 4 mils to 7 mils.

[0032] In certain exemplary embodiments, porous substrate 100 comprises a ceramic substrate, a glass substrate, a metal substrate, a carbon-based substrate, a polymeric substrate, a glass-ceramic substrate, or combinations thereof. For example, porous substrate 100 may comprise or consist essentially of at least one of cordierite, amorphous silica, aluminum titanate, silicon carbide, diatomaceous earth, or hollow glass microspheres.

[0033] In certain exemplary embodiments, porous substrate 100 may have a porosity (i.e., total volume of pores in substrate relative to the total substrate volume) ranging from about 30% to about 85%, such as from about 40% to about 80%, and further such as from about 50% to about 75%. In certain exemplary embodiments, porous substrate 100 may have a median pore size (PoreD50) ranging from about 5 microns to about 30 microns, such as from about 10 microns to about 20 microns, and further such as from about 12 microns to about 18 microns.

[0034] In certain exemplary embodiments, porous substrate 100 may have a porosity ranging from about 30% to 45% and a PoreD50 ranging from about 5 microns to about 15 microns. In certain exemplary embodiments, porous substrate 100 may have a porosityranging from about 45% to about 55% and a PoreD50 ranging from about 10 microns to about 20 microns. In certain exemplary embodiments, porous substrate 100 may have a porosity ranging from about 55% to about 70% and a PoreD50 ranging from about 15 microns to about 30 microns.

[0035] FIG. 2A shows an exploded schematic end view of a portion of the example porous substrate 100 of FIGS. 1A-1B and FIG. 2B shows an exploded schematic end view of a portion of the example porous substrate 100 of FIGS. 1A-1B with a coating composition 104 comprising a solid organic sorbent deposited thereon. Specifically, coating composition 104 comprising a solid organic sorbent is deposited on channels 102 of porous substrate 100.

[0036] Coating composition 104 can be applied to porous substrate 100 by first depositing a slurry comprising the solid organic sorbent on channels 102. This can, for example, be accomplished by at least one of wash coating, dip coating, piston coating, vacuum coating, spray -coating, or spin-coating coating processes as known to persons having ordinary skill in the art. Such coating deposition may, for example, be done in a slurry viscosity ranging from lOcP to 500cP, such as from 50cP to lOOcP and may include one or more slurry deposition steps.

[0037] For example, embodiments disclosed herein include those in which substrate 100 is first exposed to in an aqueous solution, such as water, which can be done up to saturation via, for example, via water dipping, which could be done by immersion, under vacuum, by vapor exposure, and / or using ultrasound to mitigate bubble formation. Next, substrate 100 may be subjected to an aspiration step or air blowing to remove excess water. The substrate 100 is then exposed to the slurry comprising a solid organic sorbent using any of the methods described above for atime sufficient to coat channels 102 with slurry. Following deposition, excess slurry may be removed (e.g., mechanically). Substrate 100 may then again be subjected to an aspiration step or air blowing to remove excess slurry. Following this step, the slurry may be dried to form a coating composition 104 comprising a solid organic sorbent on channels 102.

[0038] Embodiments disclosed herein do not require a calcination step. Instead, deposited coating may be simply dried to remove water, allowing for binder coalescence and film forming. Such drying may be done at temperatures below 100°C, such as from 20°C to 80°C, including room temperature (e.g., 25°C), or at temperatures below 100°C but above roomtemperature, such as from 40°C to 80°C, which can include flowing air in these temperature ranges over and / or through substrate 100.

[0039] Embodiments disclosed herein include those in which the adsorbing composition comprises an elastomeric binder, which, in certain exemplary embodiments may be water insoluble, including embodiments in which the elastomeric binder is hydrophobic or at least comprises hydrophobic moieties. The elastomeric binder may, for example, be dried into a solid from a dispersion at a temperature of less than 100°C, such as a temperature of from 0°C to 100°C, and further such as from 10°C to about 80°C, and yet further such as from 20°C to 60°C, and still yet further from 20°C to 30°C, including about 25°C.

[0040] In certain exemplary embodiments, the elastomeric binder has a glass transition temperature (Tg) of less than about 0°C.

[0041] Embodiments disclosed herein include an elastomeric binder that is dispersed in a protic polar solvent prior to drying. For example, the elastomeric binder may be dispersed in water prior to drying. Such embodiments include those in which the elastomeric binder is water insoluble and / or emulsified in water, including those in which the elastomeric binder is hydrophobic or at least comprises hydrophobic moieties.

[0042] In certain exemplary embodiments, the elastomeric binder comprises at least one of an acrylic polymer, a styrene acrylic copolymer, an acrylate polymer, and / or a polyvinyl butyral copolymer. In certain exemplary embodiments, the elastomeric binder comprises an emulsion of a polystyrene-acrylic polymer and / or an emulsion of an elastomer with polyvinyl alcohol. In certain exemplary embodiments, the elastomeric binder comprises poly(vinyl alcohol) stabilized vinyl acetate-ethylene (VAE) copolymer dispersion.

[0043] Embodiments disclosed herein include those in which, subsequent to drying, the elastomeric binder is water insoluble. Such embodiments also include those in which, subsequent to drying, the elastomeric binder resists thermal and / or aqueous degradation, such as resistance to water and / or steam at temperatures up to at least 160°C and / or resistance to degradation in sub-freezing temperatures, such as temperatures down to or below -40°C.

[0044] In certain exemplary embodiments, the elastomeric binder comprises from 5wt% to 30wt%, such as from 10wt% to 20wt% of the total dry weight of the coating composition. In certain exemplary embodiments, the elastomeric binder is substantially free of plasticizers.

[0045] In certain exemplary embodiments, the adsorbing composition comprises at least one of a viscosity modifier, a rheology modifier, a stabilizer, a pH modifier, and / or a dispersing agent. For example, one or more of such materials may be used to stabilize the dispersion of sorbent particles and decrease viscosity to facilitate processing. Such materials may, for example, be steric or electrostatic so as to stabilize the dispersion through physicochemical interaction between particles. Non-limiting examples of such materials include those comprising polypropylene glycol polymers, such as Tego Dispers 761 W available from Evonik, and / or those based on modified polyurethanes, such as Disperbyk 185 (BYK 185) available from BYK. In certain exemplary embodiments, such materials may be present in a slurry of the adsorbing composition in an amount ranging from 0. lwt% to I0wt%, such as from lwt% to 5wt% of the total dry weight of the coating composition.

[0046] In addition, the adsorbing composition may comprise at least one defoaming agent, which can improve homogeneity, decrease viscosity, and / or facilitate processing. Nonlimiting examples of defoaming agents include hydrophobic solids, foam destroying fat derivatives, polyamide particles, and / or highly branched polymers. In certain exemplary embodiments, the at least one defoaming agent comprises a mixture of hydrophobic solids and foam destroying fat derivatives. In certain exemplary embodiments, the at least one defoaming agent may be present in a slurry of the adsorbing composition in an amount ranging from 0. lwt% to I0wt%, such as from lwt% to 5wt% of the total dry weight of the coating composition.

[0047] The solid organic sorbent may comprise a porous or nonporous material. When porous, the solid organic sorbent may have a total porous volume ranging from 10vol% to 60vol%, such as from 20vol%to 40vol%.

[0048] In certain exemplary embodiments, the solid organic sorbent comprises a polymeric resin. In certain exemplary embodiments, the solid organic sorbent comprises a material designed as an ion exchange resin. In certain exemplary embodiments, the solid organic sorbent comprises a crosslinked polystyrene resin, such as a crosslinked polystyrene resin with amine functional groups. Non-limiting examples of solid organic sorbents include Lewatit VPOC 65 available from Lanxess, Purolite Al 10 available from Purolite, or Diaion WA21J available from Diaion.

[0049] In certain exemplary embodiments, the solid organic sorbent can absorb water when exposed to steam or liquid water. For example, after exposure to steam or liquid water, from 1% to 50wt%, such as from 10% to 25% of the weight of a coating composition comprising the solid organic sorbent may be water. In addition, a volume of the coating composition comprising the solid organic sorbent may increase upon exposure to steam or liquid water. For example, embodiments disclosed herein include those in which a volume of the coating composition increases by 5% to 20%, such as by 10% to 15%, upon exposure of the fluid capturing apparatus to 120°C steam flowed over the fluid capturing apparatus at a rate of 2 meters per second.

[0050] Embodiments disclosed herein include those in which the solid organic sorbent is rigid or deformable and may or may not absorb water when exposed to steam or liquid water. The sorbent may be in the form of beads, pellets, extrudates, or other solid forms, which may be ground into particles having the particle size distribution(s) described herein.

[0051] In certain exemplary embodiments, the slurry of the adsorbing composition comprises from about 55wt% to about 80wt% water, from about 15wt%to about 40wt% solid organic sorbent, and from about lwt% to about 10wt% elastomeric binder.

[0052] Embodiments disclosed herein include those in which the solid organic sorbent comprises a first group of particles having a first median particle size (PartD50i) and a second group of particles having a second median particle size (PartD502), wherein PartD50i is less than PoreD50 and PartD502 is greater than PoreD50. In certain exemplary embodiments, PartD50i ranges from about 1 micron to about 10 microns, such as from about 2 microns to about 4 microns, PartD502 ranges from about 20 microns to about 250 microns, such as from about 50 microns to about 200 microns, and PoreD50 ranges from about 5 microns to about 30 microns, such as from about 10 microns to about 20 microns.

[0053] In certain exemplary embodiments, PoreD50 / PartD50i ranges from about 3: 1 to about 6: 1, such as from about 4 : 1 to about 5: 1. In certain exemplary embodiments, PoreD50 / PartD50Pre ranges from about 3: 1 to about 6: 1, such as from about 4: 1 to about 5: 1. In certain exemplary embodiments, PartD502 / PoreD50 ranges from about 5: 1 to about 15: 1, such as from about 8: 1 to about 12: 1.

[0054] FIGS. 3A-3C show exploded schematic end views of a process of applying a coating composition 104 to the example porous substrate 100 of FIGS. 1A-1B. In thisprocess, a precursor slurry comprising a solid organic sorbent is first deposited on channels 102 of porous substrate 100 of FIG. 3A. The solid organic sorbent comprises a group of particles having a precursor particle size (PartD50pre), wherein PartD50pre is less than PoreD50. Due to PartD50prebeing less than PoreD50, particles of precursor slurry penetrate into pores of porous substrate 100 as indicated by darkened channel walls of FIG. 3B. Next, as shown in FIG. 3C, a slurry comprising a solid organic sorbent is deposited on channels 102 of porous substrate 10, wherein the solid organic sorbent comprises a first group of particles having a first median particle size (PartD50i) and a second group of particles having a second median particle size (PartD502), wherein PartD50i is less than PoreD50 and PartD502 is greater than PoreD50.

[0055] In certain exemplary embodiments, PartD50preranges from about 1 micron to about 10 microns and PoreD50 ranges from about 5 microns to about 30 microns.

[0056] FIGS. 4A-4D show exploded schematic end views of various coating compositions applied to the example porous substrate 100 of FIGS. 1A-1B before and after a drying step. Specifically, FIGS. 4A and 4B show exploded schematic end views of a coating composition applied to porous substrate 100 before and after a drying step, wherein the coating composition has a solid organic sorbent having a first group of particles having a first median particle size (PartD50i) and a second group of particles having a second median particle size (PartD502), wherein PartD50i is less than PoreD50 and PartD502 is greater than PoreD50. FIGS. 4C and 4D show exploded schematic end views of a coating composition applied to porous substrate 100 before and after a drying step, wherein a precursor slurry is first applied to porous substrate 100 and includes a solid organic sorbent having a precursor particle size (PartD50Pre), wherein PartD50preis less than PoreD50. Next, a slurry comprising a solid organic sorbent having a first group of particles having a first median particle size (PartD50i) and a second group of particles having a second median particle size (PartD502) is applied to porous substrate 100, wherein PartD50i is less than PoreD50 and PartD502 is greater than PoreD50.

[0057] FIGS. 4C-4D show a more darkened porous substrate 100 than FIGS. 4A-4B, indicating greater penetration of solid organic sorbent within the walls of porous substrate 100 for the embodiments shown in FIGS. 4C-4D as compared to those shown in FIG. 4A-4B.

[0058] In certain exemplary embodiments, a ratio of coating mass to substrate volume ranges from 10 grams of coating to 300 grams of coating per liter of substrate, such as from 50 grams to 275 grams of coating per liter of substrate, and further such as from 100 grams to 250 grams of coating per liter of substrate.

[0059] Embodiments disclosed herein include those in which the coating exhibits good mechanical integrity and adheres to the substrate upon exposure to a variety of conditions such as, for example, heat, cold liquid water, hot liquid water, freezing, air flow and / or steam flow. Such conditions may include, for example, immersion in liquid water at 20°C for at least one week, immersion in liquid water at 90°C for at least three days, immersion in boiling water for at least one hour, exposure to temperatures at or below -20°C for at least one week, exposure to 120°C steam flow at a rate of 2 meters per second for at least one hour, and / or cyclic exposure between 25°C air flow at a rate of 2 meters per second for at least one hour and 120°C steam flow at a rate of 2 meters per second for at least one hour.

[0060] In certain exemplary embodiments, less than lwt%, such as less than 0.5wt%, of the sorbent is removed from the substrate upon exposure of the fluid capturing apparatus to 120°C steam flowed over the fluid capturing apparatus at a rate of 2 meters per second for a period of one hour.

[0061] Embodiments disclosed herein also include those in which the substrate comprises a plurality of channels extending therethrough that comprise, are coated with, and / or impregnated with the adsorbing composition while still exhibiting a low pressure drop upon exposure to a gaseous flow. For example, embodiments disclosed herein include those in which the plurality of channels have a length of at least 50 millimeters and a pressure drop along the plurality of channels is less than 1000 pascals, such as less than 750 pascals, and further such as less than 500 pascals, such as from 100 pascals to 1000 pascals, upon exposure to an airflow of up to 5 meters per second through the plurality of channels.

[0062] Such embodiments include those in which the fluid capturing apparatus has high carbon dioxide adsorption efficiency. For example, embodiments disclosed herein include those in which a carbon dioxide adsorption capacity of the solid organic sorbent incorporated with the substrate is at least 80%, such as at least 90%, and further such as at least 95%, and yet further such as at least 99% of a carbon dioxide adsorption capacity of the bare solid organic sorbent. In addition, embodiments disclosed herein include those in which the fluidcapturing apparatus adsorbs at least 1 mmol of carbon dioxide, such as at least 2 mmol of carbon dioxide, per gram of solid organic sorbent incorporated with the substrate upon exposure to carbon dioxide having a partial pressure of at least 50 at a temperature of 25°C.

[0063] Examples

[0064] Embodiments disclosed herein are further illustrated by the following non-limiting examples.

[0065] Example 1 :

[0066] Four different aqueous slurries were prepared as set forth below in Table 1, wherein the listed ingredients are shown as weight percentages of the formulations. Each slurry contained Lewatit VP OC 65 as a sorbent and Vinnapas EP7000 as a binder. Once prepared, each slurry was dried into a solid coating material using a rotary evaporator. The carbon dioxide adsorbing capacity of each coating material was then measured at 25 °C various partial carbon dioxide pressures by a volumetric method using an ASAP 2020 from Micromeritics. The adsorbed amount for each sample was normalized by the amount of sorbent it contained and compared to a control sample of Lewatit VP OC 65 beads with the results shown in FIG. 5. As can be seen from FIG. 5, Formulas 1 and 2, which did not contain acetic acid, achieve similar adsorption performance as the control sample.

[0067] Table 1:

[0068] Example 2:

[0069] Porous cordierite ceramic substrates (Coming® DuraTrap® GC HP 1.2 filter substrates) comprising a plurality of channels extending therethrough were coated with an aqueous slurry corresponding to Formula 4 of Example 1 by first dipping the substrate into water and then aspirating the substrate to remove excess water. The substrates were then dipped into the slurry at different loading levels after which the substrate was again aspiratedto remove excess slurry. Next, the substrate was placed in at oven at 70°C for 1 hour to dry the slurry in order to form a coated substrate, wherein at a first loading level, the coated substrate comprised 74 grams of coating per liter of substrate and at a second loading level, the coated substrate comprised 178 grams of coating per liter of substrate. The carbon dioxide adsorbing capacity of each coated substrate was then measured as described in Example 1 and compared to the dried coating materials Formulas 1 and 4 of Example 1 (i.e., coating materials not placed on a substrate) as well as the control sample of Example 1 (Lewatit VP OC 65 beads) with the results shown in FIG. 6. As can be seen from FIG. 6, depositing the coating onto a substrate had no negative impact on adsoprtion capability.

[0070] It will be apparent to those skilled in the art that various modifications and variations can be made to embodiment of the present disclosure without departing from the spirit and scope of the disclosure. Thus, it is intended that the present disclosure cover such modifications and variations provided they come within the scope of the appended claims and their equivalents.

Claims

What is claimed is:

1. A fluid capturing apparatus, comprising: a solid substrate; and an adsorbing composition incorporated with the solid substrate, the adsorbing composition comprising: a solid organic sorbent; and an elastomeric binder, the elastomeric binder being dispersed in a protic polar solvent prior to being deposited on the solid substrate.

2. The fluid capturing apparatus of claim 1, wherein the adsorbing composition comprises a coating composition deposited on the solid substrate.

3. The fluid capturing apparatus of claim 1, wherein the elastomeric binder is water insoluble.

4. The fluid capturing apparatus of claim 3, wherein a glass transition temperature (Tg) of the elastomeric binder is less than 0°C.

5. The fluid capturing apparatus of claim 4, wherein the elastomeric binder comprises a poly(vinyl alcohol) stabilized vinyl acetate-ethylene (VAE) copolymer.

6. The fluid capturing apparatus of any one of claims 1 to 5, wherein the protic polar solvent comprises water.

7. The fluid capturing apparatus of any one of claims 1 to 6, wherein the fluid is carbon dioxide and a carbon dioxide adsorption capacity of the solid organic sorbent incorporated with the solid substrate is at least 80% of a carbon dioxide adsorption capacity of a bare solid organic sorbent.

8. The fluid capturing apparatus of claim 7, wherein the carbon dioxide adsorption capacity of the solid organic sorbent incorporated with the solid substrate is at least 90% of a carbon dioxide adsorption capacity of the bare solid organic sorbent.

9. The fluid capturing apparatus of any one of claims 1 to 8, wherein the solid substrate comprises a plurality of channels extending therethrough and the adsorbing composition comprises, is deposited on, and / or within walls of the plurality of channels.

10. The fluid capturing apparatus of claim 9, wherein the solid substrate comprises 50 to 500 cells per square inch and the plurality of channels comprise a wall thickness of 2 mils to 10 mils.

11. The fluid capturing apparatus of claims 9 or 10, wherein the plurality of channels have a length of at least 50 millimeters and a pressure drop along the plurality of channels is less than about 1000 pascals upon exposure of the fluid capturing apparatus to an airflow of up to 5 meters per second through the plurality of channels.

12. The fluid capturing apparatus of any one of claims 1 to 11, wherein less than 1 wt% of the sorbent is removed from the solid substrate upon exposure of the fluid capturing apparatus to 120°C steam flowed over the fluid capturing apparatus at a rate of 2 meters per second for a time of at least one hour.

13. The fluid capturing apparatus of any one of claims 1 to 11, wherein the solid substrate comprises a porous substrate having a medium pore size (PoreD50).

14. The fluid capturing apparatus of claim 13, wherein the solid substrate comprises a ceramic substrate, a glass substrate, a metal substrate, a carbon-based substrate, a polymeric substrate, or a glass-ceramic substrate.

15. The fluid capturing apparatus of claim 14, wherein the solid substrate comprises at least one of cordierite, amorphous silica, aluminum titanate, silicon carbide, diatomaceous earth, or hollow glass microspheres.

16. The fluid capturing apparatus of any one of claims 13 to 15, wherein the solid organic sorbent comprises a first group of particles having a first median particle size (PartD50i) and a second group of particles having a second medium particle size (PartDSCh), wherein PartDSCh is greater than PartD50i.

17. The fluid capturing apparatus of claim 16, wherein PoreD50 is greater than PartD50i and less than PartDSCh.

18. The fluid capturing apparatus of claim 17, wherein PartD50i ranges from 1 micron to 10 microns, PartD502 ranges from 20 microns to 250 microns, and PoreD50 ranges from 5 microns to 30 microns.

19. The fluid capturing apparatus of any one of claims 1 to 18, wherein the solid organic sorbent comprises a crosslinked polystyrene resin.

20. The fluid capturing apparatus of claim 19, wherein the crosslinked polystyrene resin comprises amine functional groups.

21. The fluid capturing apparatus of any one of claims 1 to 20, wherein the solid organic sorbent comprises a total porous volume ranging from 10 vol% to 60 vol%.

22. The fluid capturing apparatus of any one of claims 1 to 21, wherein a ratio of adsorbing composition mass to solid substrate volume ranges from 10 grams of the adsorbing composition to 300 grams of the adsorbing composition per liter of the solid substrate.

23. A method of making a fluid capturing apparatus comprising:incorporating an adsorbing composition with a solid substrate, the adsorbing composition comprising a solid organic sorbent, a protic polar solvent, and an elastomeric binder dispersed in the protic polar solvent.

24. The method of claim 23, wherein the incorporating comprises depositing a slurry comprising the adsorbing composition on the solid substrate and drying the slurry to form a coating composition on the solid substrate.

25. The method of claim 24, wherein the method comprises dipping the solid substrate in water prior to depositing the slurry.

26. The method of any one of claims 23 to 25, wherein the elastomeric binder is water insoluble.

27. The method of claim 26, wherein a glass transition temperature (Tg) of the elastomeric binder is less than 0°C.

28. The method of claim 27, wherein the elastomeric binder comprises a poly(vinyl alcohol) stabilized vinyl acetate-ethylene (VAE) copolymer.

29. The method of any one of claims 23 to 28, wherein the protic polar solvent comprises water.

30. The method of any one of claims 23 to 29, wherein the adsorbing composition is dried at a temperature less than 100°C.

31. The method of claim 30, wherein the adsorbing composition is dried at a temperature between 20°C and 30°C.

32. The method of claims 24 or 25, wherein the slurry comprises from about 55 wt% to about 80 wt% water, from about 15 wt%to about 40 wt% solid organic sorbent, and from about 1 wt% to about 10 wt% elastomeric binder.

33. The method of any one of claims 23 to 32, wherein the solid substrate comprises a plurality of channels extending therethrough and the method comprises incorporating the adsorbing composition on and / or within walls of the plurality of channels.

34. The method of any one of claims 23 to 33, wherein the solid substrate comprises a porous substrate having a medium pore size (PoreD50).

35. The method of claim 34, wherein the solid substrate comprises a ceramic substrate, a glass substrate, a metal substrate, a carbon-based substrate, a polymeric substrate, or a glassceramic substrate.

36. The method of claim 35, wherein the solid substrate comprises at least one of cordierite, amorphous silica, aluminum titanate, silicon carbide, diatomaceous earth, or hollow glass microspheres.

37. The method of any one of claims 34 to 36, wherein the solid organic sorbent comprises a first group of particles having a first median particle size (PartD50i) and a second group of particles having a second medium particle size (PartDSCh), wherein Part D5 (h is greater than PartD50i.

38. The method of claim 37, wherein PoreD50 is greater than PartD50i and less than PartD5Ch.

39. The method of claim 38, wherein PartD50i ranges from 1 micron to 10 microns, PartD502 ranges from 20 microns to 250 microns, and PoreD50 ranges from 5 microns to 30 microns.

40. The method of any one of claims 34 to 39, wherein, prior to incorporating the adsorbing composition with the solid substrate, the method comprises depositing a precursor slurry onto the solid substrate, the precursor slurry comprising a solid organic sorbent comprising a group of particles having precursor particle size (PartD50pre), wherein PartD50pre is less than PoreD50.

41. The method of claim 40, wherein PartD50preranges from about 1 micron to about 10 microns and PoreD50 ranges from about 5 microns to about 30 microns.

42. The method of any one of claims 23 to 41, wherein the solid organic sorbent comprises a crosslinked polystyrene resin.

43. The method of claim 42, wherein the crosslinked polystyrene resin comprises amine functional groups.

44. The method of any one of claims 23 to 43, wherein the adsorbing composition comprises at least one of a viscosity modifier, a rheology modifier, a stabilizer, a pH modifier, a dispersing agent, or a defoaming agent.

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