Acid reactive materials and methods for making and using the same

Abstract

Acid reactive materials and methods for making and using the same are disclosed. The material includes a binder polymer that includes amide groups, and acid reactive salt dispersed throughout the binder polymer. The material may include support particles dispersed throughout the binder polymer. The support particles may be impregnated with the acid reactive salt. The material may be used to form a coating on a substrate. The substrate may be a porous substrate, such as a foam. The material may be used to form articles by casting, molding, or extruding. When exposed to an acid, the binder polymer may gradually degrade, making additional acid reactive salt available to react with the acid.

Description

ACID REACTIVE MATERIALS AND METHODS FOR MAKING AND USING THE SAMECROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 673,878, filed July 22, 2024 which is incorporated herein by reference in its entirety.FIELD

[0002] The present disclosure relates to a material, methods of making the material, and methods of using the material, for example to sequester an acid with the material. The present disclosure relates to a material that includes an acid reactive salt capable of reacting with an acid. In particular, the present disclosure relates to a material that exhibits a gradual exposure of acid reactive salt when the material is used to react with the acid.SUMMARY

[0003] Acid reactive materials and methods for making and using the same are disclosed. According to an embodiment, the material includes a binder polymer, the binder polymer including amide groups and acid reactive salt dispersed throughout the binder polymer. The binder polymer may include, for example, a polyamide, a polyacrylamide, a polyimide, a polyurethane, or a combination thereof. The binder polymer may be soluble in one or more of organic alcohols, alkanes, alkenes, alkynes aldehydes, ketones, or cyclic hydrocarbons (benzene, toluene, xylene), chloroform, dichloromethane, dimethylformamide (DMF), or N-Methyl-2- pyrrolidone (NMP). The binder polymer may be insoluble in water. The binder polymer may be capable of reacting with the same acid as the acid reactive salt. The binder polymer may be degradable by the acid.

[0004] The acid reactive salt may include LiCCh, LiHCCh, RbCCh, RbHCCh, CsCCh, CsHCCh, K2CO3, KHCO3, Na2CO3, NaOH, Ca(OH)2, NaHCC , CaO, MgO, BeO, SrO, BaO, or a combination of two or more thereof. The acid reactive salt may be insoluble in at least one solvent that the binder polymer is soluble in. The material may include 1 wt-% or greater of the acid reactive salt relative to combined weight of the binder polymer and the acid reactive salt.

[0005] The material may include support particles dispersed throughout the binder polymer. The support particles may be reactive or non-reactive to acids. The support particles may include activated carbon, metal-organic frameworks (MOFs), covalent organic frameworks (COFs),zeolites, silica (amorphous or crystalline), graphene, graphite, MXenes, metal oxides, reduced metals, alumina (amorphous or crystalline), or a combination of two or more thereof. The support particles may be impregnated with the acid reactive salt. The support particles may also contain functionalities capable of reacting with acidic species, such as metallic centers, hydroxyl groups, or aminated functionalities.

[0006] The material may be used to form a coating on a substrate. The substrate may be a porous substrate, such as a foam, or nonporous such as a ceramic honeycomb. The material may be used to form articles by casting, molding, jet-spraying, injection molding, or extruding.

[0007] A method of making the material may include dissolving the binder polymer in a first solvent to form a first solution and dispersing the acid reactive salt in the same solution to form a mixture, where the acid reactive salt is not soluble in the polymer-dissolving solvent. The method may further include the acid reactive salt in a second solvent to form a second solution, and dispersing a plurality of support particles in the second solvent, to form impregnated support particles that include the plurality of support particles impregnated with the acid reactive salt. Dispersing the acid reactive salt in the first solution may include dispersing the impregnated support particles in the first solution. The method may include removing at least some, substantially all, or all of the second solvent from the second solution prior to dispersing the impregnated support particles in the first solution. An article may be coated with the material by immersing the article first in the first solution, followed by heating the article to extract the carrier solvent. An article may be formed by molding or casting the mixture. The method may further include removing at least some of the first solvent from the mixture. The solvent may be removed before or after using the mixture to coat or form an article. In some embodiments, the method includes removing at least some of the first solvent to form an intermediate mixture, and extruding, molding, or casting the intermediate mixture to form an article.

[0008] A method of using the material includes exposing at least a portion of the material to the acid, thereby causing at least a portion of the acid to react with the binder polymer, the acid reactive salt, the support particles, or any combination thereof. A method of sequestering an acid with the material includes exposing at least a portion of the material to the acid, thereby causing at least a portion of the acid to react with the binder polymer, the acid reactive salt, the support particles, or any combination thereof. The reaction of the acid with the binder polymer may cause the binder polymer to partially or completely degrade into acidified salt constituents,causing more of the acid reactive salt and / or support particles to become available for reaction with the acid. A breakthrough curve of the acid through the material may exhibit a decrease in contaminant breakthrough concentration of the acid over time. The binder polymer may be temporally degraded by the acid. Temporal degradation of the binder polymer reveals previously covered acid reactive particles. The increased accessibility of the acid reactive particles may lead to a temporal or stepwise enhancement in adsorption capacity towards acid gases.

[0009] The above summary is not intended to describe each embodiment or every implementation. Rather, a more complete understanding of illustrative embodiments will become apparent and appreciated by reference to the following Detailed Description and claims in view of the accompanying figures.BRIEF DESCRIPTION OF DRAWINGS

[0010] FIG. 1 is a schematic representation of an illustrative of a material coated on a substrate according to an embodiment.

[0011] FIG. 2 is a schematic representation of an illustrative of a material being exposed to an acidic compound according to an embodiment.

[0012] FIGS. 3A and 3B are graphical representations of data from Example 1 A.

[0013] FIGS. 4A and 4B are graphical representations of data from Example IB.

[0014] FIGS. 5A to 5D are SEM micrographs of coated materials prepared according to an embodiment in Example IB.

[0015] FIG. 6 is a graphical representation of data from Example 2.

[0016] FIGS. 7A to 7D are SIM micrographs of nylon fibers before and after exposure to acid according to Example 2.

[0017] FIG. 8 is a graphical representation of data from Example 3.

[0018] The figures are rendered primarily for clarity and, as a result, are not necessarily drawn to scale. Moreover, various structure / components, including but not limited to liners, support structures, housing, fluid lines, pumps, pre-filters, and the like, may have been omitted where inclusion of such structures / components is not necessary to an understanding of the various exemplary embodiments described herein. The lack of illustration / description of such structures / components in a particular figure is, however, not to be interpreted as limiting the scope of the various embodiments in any way. Still further, “Figure x” and “FIG. x” may be used interchangeably herein to refer to the figure numbered “x.”DEFINITIONS

[0019] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are to facilitate understanding of certain terms used frequently herein and are not meant to limit the scope of the present disclosure.

[0020] The term “polymer” and “polymeric material” include, but are not limited to homopolymers, copolymers, blends of two or more homopolymers, blends of two or more copolymers, blends of one or more homopolymers and one or more copolymers that have any geometric configuration such as a linear configuration, branched configuration, graft configuration, star configuration, isotactic symmetry, syndiotactic symmetry, atactic symmetry, or any combination thereof. Copolymers are polymers polymerized from two or more monomers and include block copolymers, alternating copolymers, periodic copolymers, statistical copolymers, stereoblock copolymers, gradient copolymers, and the like. Polymers are polymerized from one or more monomers. A polymer polymerized from a particular monomer may be described as “monomer name” polymer or poly(monomer name). For example, a polymer polymerized from n-butyl acrylate monomers, may be described as an n-butyl acrylate polymer or poly(n-butyl acrylate).

[0021] The term “conformal” is used here to refer to a coating that follows the surface contours of the underlying material so that the coating is present on the whole surface irrespective of surface roughness or defects. The term “non-conformal” refers to a coating that does not follow the surface contours of the underlying material and may be absent from some parts of the surface, for examples due to surface roughness or defects.

[0022] The terms “upstream” and “downstream” are used herein to describe respective positions within a fluid flow (e.g., gas flow or airflow). For example, if body A is upstream of body B, then the airflow will encounter A before B. In such an example, body B would be downstream of body A.

[0023] The term “substantially” as used here has the same meaning as “significantly,” and can be understood to modify the term that follows by at least about 90 %, at least about 95 %, or at least about 98 %.

[0024] The term “not substantially” as used here has the same meaning as “not significantly,” and can be understood to have the inverse meaning of “substantially,” i.e., modifying the termthat follows by not more than 25 %, not more than 10 %, not more than 5 %, or not more than 2

[0025] The term “about” is used here in conjunction with numeric values to include normal variations in measurements as expected by persons skilled in the art, and is understood to have the same meaning as “approximately” and to cover a typical margin of error, such as ±5 % of the stated value.

[0026] Terms such as “a,” “an,” and “the” are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration.

[0027] The terms “a,” “an,” and “the” are used interchangeably with the term “at least one.” The phrases “at least one of’ and “comprises at least one of’ followed by a list refers to any one of the items in the list and any combination of two or more items in the list.

[0028] As used here, the term “or” is generally employed in its usual sense including “and / or” unless the content clearly dictates otherwise. The term “and / or” means one or all of the listed elements or a combination of any two or more of the listed elements.

[0029] The recitations of numerical ranges by endpoints include all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc. or 10 or less includes 10, 9.4, 7.6, 5, 4.3, 2.9, 1.62, 0.3, etc.). Where a range of values is “up to” or “at least” a particular value, that value is included within the range.

[0030] As used here, “have,” “having,” “include,” “including,” “comprise,” “comprising,” or the like are used in their open-ended sense, and generally mean “including, but not limited to.” It will be understood that “consisting essentially of,” “consisting of,” and the like are subsumed in “comprising” and the like. As used herein, “consisting essentially of,” as it relates to a composition, product, method, or the like, means that the components of the composition, product, method, or the like are limited to the enumerated components and any other components that do not materially affect the basic and novel character! stic(s) of the composition, product, method, or the like.

[0031] The words “preferred” and “preferably” refer to embodiments that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, including the claims.

[0032] Any direction referred to here, such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” and other directions and orientations are described herein for clarity in reference to the figures and are not to be limiting of an actual device or system or use of the device or system. Devices or systems as described herein may be used in a number of directions and orientations.

[0033] In this description, particular embodiments may be described in isolation for clarity. Reference throughout this specification to “one embodiment,” “an embodiment,” “certain embodiments,” “one or more embodiments,” or “some embodiments,” etc., means that a particular feature, configuration, composition, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. Thus, the appearances of such phrases in various places throughout this specification are not necessarily referring to the same embodiment of the disclosure. Furthermore, the particular features, configurations, compositions, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, features described in the context of one embodiment may be combined with features described in the context of a different embodiment except where the features are necessarily mutually exclusive.

[0034] In several places throughout the following description, guidance is provided through lists of examples, which examples can be used in various combinations. In each instance, the recited list serves only as a representative group and should not be interpreted as an exclusive list.DETAILED DESCRIPTION

[0035] The present disclosure relates to a material, methods of making the material, and methods of using the material, for example to sequester an acid with the material. The present disclosure relates to a material that includes an acid reactive salt capable of sequestering an acid. In particular, the present disclosure relates to a material that exhibits a gradual exposure of acid reactive salt when used to sequester the acid. The material includes a binder polymer and acid reactive salt dispersed throughout the binder polymer. The binder polymer includes amide groups. The material may optionally include support particles. The support particles may be dispersed throughout the binder polymer.

[0036] According to an embodiment, the material includes a binder polymer and acid reactive salt supported on a support particle and dispersed throughout the binder polymer. The acid reactive salt is capable of reacting with (e.g., sequestering) an acid. The binder polymer may be arranged to enable a gradual exposure of the acid reactive salt to the acid.

[0037] As the material is contacted with the acid, the binder polymer in the material provides a gradual exposure of the acid reactive salt. The binder polymer may include chemical groups that also react with the acid, thus gradually degrading the binder polymer. Such chemical groups may include amide groups. Gradual exposure of the acid reactive salt means that more of the acid reactive salt becomes available to react with the acid over time. When the material is in contact with the acid, the material reacts, adsorbs, and / or absorbs at least some of the acid. The reacting, absorbing, and / or adsorbing of the acid may be collectively referred to here as reacting. In some cases, the reaction, adsorption, or absorption of the acid may be referred to as sequestering of the acid.

[0038] In order to provide a material having an extended lifetime and capable of continued reaction, it is desirable to provide a material with a gradual exposure of acid reactive salt. It is desirable to provide a material having an extended reaction period with acid. It is further desirable to provide a material that is capable of reacting with an acid for at least 60 hours at an acid exposure rate of 0.09 mmol acid / minute over a coated foam substrate weighing 50 g and having an active material content of 38 g.

[0039] An exemplary embodiment of an article 100 including the material 110 coated onto a substrate 150 is shown in FIG. 1. The material 110 includes a binder polymer 112. The binder polymer 112 may bind together or support the various other components of the material. The material 110 further includes acid reactive salt 114 dispersed throughout the binder polymer 112. The acid reactive salt 114 may be present as particles, clusters, or aggregates 116. The material 110 may also include support particles 118 dispersed throughout the binder polymer 112. The support particles 118 may act as a support for the acid reactive salt 114. In some embodiments, the acid reactive salt 114 is impregnated into the support particles 118. The acid reactive salt 114 may be present within pores of the support particles 118. The acid reactive salt 114 may be present as aggregates 116 within pores of the support particles 118.

[0040] The binder polymer may be used as a sacrificial polymer binder in the material. When the binder polymer is used as a sacrificial polymer binder, the material enables a gradual exposure of the acid reactive salt. This process is schematically shown in FIG. 2. The binder polymer 112 may be etched away when it comes in contact with the acid 70 over time. The acid reactive salt particles 120 (e.g., support particles impregnated with acid reactive salt) are dispersed throughout the binder polymer 112. Some of the acid reactive salt particles are embeddedparticles 121 and not yet available to react with the acid 70, while others are available particles 122 on the surface of the binder polymer 112. As the binder polymer 112 is etched away, it enables additional acid reactive salt particles 120 to become available particles 122 and to react with the acid. In doing so, the binder polymer enables a multi-step capture of the acid. When the active sites of acid reactive salt become inactive after reacting with the acid, the etching away of the binder polymer enables new active sites of acid reactive salt to become available. The active sites refer to the acid reactive salt before any chemical reaction with the acid. The process may repeat itself over time until no more binder polymer and / or acid reactive salt is left in the material.

[0041] According to an embodiment, the material is capable of reacting with, adsorbing, and / or absorbing compounds in or from fluids. Such fluids may include a basic fluid, an acidic fluid, an organic compound, an inorganic compound, and combinations thereof. The fluid may be a gas or a liquid. The material may be particularly useful for reacting with, adsorbing, and / or absorbing compounds that are acidic. That is, the compounds may be acids or may convert into acids (be acid precursors), for example, in contact with water. The fluid may include acidic compounds (e g., mixed in with other compounds) or may itself be acidic. In some embodiments, the fluid is an acidic gas. Examples of acidic compounds in the fluid include carbon dioxide; carbon monoxide; perfluorocarbons; volatile organic compounds; sulfur oxides; nitrogen oxides; hydrogen sulfide; ammonia (basic fluid); and combinations of two or more thereof. The compounds may be considered contaminants or impurities in the fluid. The compounds may be reactants, provided for a chemical reaction with the acid reactive salt.

[0042] According to an embodiment, the material may optionally include support particles. The support particles may be configured to support the binder polymer and the acid reactive salt but may also serve another purpose, such as adsorbing and / or absorbing a fluid, such as a basic fluid, an acidic fluid, an organic compound, an inorganic compound, or combinations thereof. For example, the support particles may be capable of adsorbing and / or absorbing acidic gases.

[0043] According to an embodiment, the material may be used for gas filtration. The material may be used to making filter media. As such, in some embodiments, a filter may include a filter media made of the material. In some embodiments, the material may be added onto filter media. As such, in some embodiments, a filter may include the material disposed on (e.g., coated onto) the filter media.

[0044] In some embodiments, the material may be used in a fuel cell air-intake filter. A fuel cell is an electrochemical cell that produces energy useful for powering various appliances, cars, tools, or other equipment. Reagents that participate in the reactions of a fuel cell may supplied from a source external to the cell. Reagents are commonly supplied to a fuel cell in the form of purified hydrogen (on the cathode side) and oxygen in the form of ambient air (on the anode side). The fuel cell may be exposed to contaminants in the feedstock. For example, ambient air may include various contaminants such as sulfur oxides (SOx), nitrogen oxides (NOx), siloxanes, ammonia, hydrogen sulfide, acidic compounds, siloxanes, and volatile organic compounds. These contaminants react with the metal catalyst sites in the fuel cell cathode which irreversibly diminishes its lifetime energetic output. For example, a fuel cell system exposed to 10 parts per billion (ppb) of airborne contaminants can have reduced energetic throughput by over 50 % after only 4 hours. In many cases, it may be desirable to provide media capable of filtering, removing (e.g., sequestering), or at least partially removing, contaminants from a fluid (e.g., a gas), such as the fuel cell reagent supply. Filtration and / or removal of a contaminant from a gas may be accomplished through, for example, sorption (absorption and / or adsorption) of the contaminant to a sorbent material and / or the chemical transformation of a contaminant into a different compound. In some embodiments, the material is used as a fuel cell air-intake filter to filter and / or remove (e.g., sequester) acidic contaminants from the fuel cell reagent supply.

[0045] When used for gas filtration, the material may enable capture of contaminants or impurities in the gas. Examples of the gas being filtered may include a basic gas, an acidic gas, an organic gas, an inorganic gas, and combinations thereof. The material may be particularly useful for removing acidic contaminants from gases. The acidic contaminants may be acids or may convert into acids in contact with water. Examples of the contaminants or impurities in the fluid or compound may include carbon dioxide; carbon monoxide; perfluorocarbons; volatile organic compounds; sulfur oxides; nitrogen oxides; hydrogen sulfide; ammonia (basic fluid); and combinations of two or more thereof.

[0046] In some embodiments, the material may be used as a platform for chemical reactions to facilitate a reaction between an acid and the acid reactive salt.

[0047] The material may be provided as articles having varying form factors. According to an embodiment, the material may be used to form a coating or it may be the bulk material of an article (e.g., the material may form the body of an article, as opposed to only a coating on itssurface). The material may be used to form a molded article or a cast shape. According to an embodiment, the material may be used as a coating on a substrate. The material may be used as a coating on a porous substrate. The material may be used as a coating on fdter media. In some embodiments, the coating may be a conformal coating. In some other embodiments, the coating may be a non-conformal coating.

[0048] When the material used to form a coating, the coated substrate may be porous or non- porous. In some embodiments, at least a portion of the substrate is covered by the material. In some embodiments, all or substantially all surfaces of the substrate are covered by the material.

[0049] When the substrate with the coated material is exposed to an acid, some acid reactive salt may be exposed on the surface of the material and is available to react with the acid (e.g., may be used to sequester the acid). Also while exposed to the acid, the binder polymer provides reactive sites for fluid sorption by way of acidified attack on its amide groups. Specifically, gradually at least a portion of the binder polymer is etched away by the acid over time. As the binder polymer is etched away, it enables more active sites of acid reactive salt to become available and to react with the acid. When the active sites of acid reactive salt become inactive after reaction with the acid, the etching away of the binder polymer enables new active sites of acid reactive salt to become exposed to the acid. The process may repeat itself over time until no more binder polymer and / or acid reactive salt is left in the coating.

[0050] Depending on the working conditions and the chemical composition and structure of the material, the acid may be sequestered by the material by chemical reaction, adsorption, absorption, or a combination thereof. Different parts or compounds of the material may serve different functions and may act as chemical reactants, adsorbents, or absorbents. The parts or compounds of the material may serve different functions sequentially or simultaneously. Each of the different parts or compounds of the material may itself serve different functions sequentially or simultaneously. For example, the acid reactive salt may act as a chemical reactant, adsorbent, or absorbent, or a combination thereof. The binder polymer may act as a chemical reactant, adsorbent, or absorbent, or a combination thereof. The support particles may act as a chemical reactant, adsorbent, or absorbent, or a combination thereof. If the material is applied onto a substrate, the substrate may act as a chemical reactant, adsorbent, or absorbent, or a combination thereof. The substrate and / or the material may also act as a physical filter. In some embodiments, or at certain times throughout the use of the material, some of the parts or compounds of thematerial may not act as a chemical reactant, adsorbent, or absorbent. For example, in some embodiments, the substrate is not reactive and / or does not act as an adsorbent or absorbent. In some embodiments, the support particles are not reactive and / or do not act as adsorbent and / or absorbent.

[0051] If the acid is sequestered by a compound by adsorption or absorption, the compound may be characterized as an adsorbent or absorbent. An adsorbent is a material capable of adsorbing a chemical; that is, the material is capable of isolating a chemical on at least a portion of its surface area. An adsorbent may be a chemisorbent, a physisorbent, or a chemisorbent-physisorbent hybrid. A physisorbent is an adsorbent that isolates a chemical through the formation of weak interactions (e.g., van der Waals and / or electrostatic forces) between the physisorbent and the chemical being adsorbed. A chemisorbent is an adsorbent that isolates a chemical through the formation of an ionic or covalent bond between the chemisorbent and the chemical being adsorbed. Chemisorbent-physisorbent hybrids include grafted hybrids and impregnated hybrids. A grafted hybrid is a chemisorbent grafted onto a physisorbent or a physisorbent grafted onto a chemisorbent. An impregnated hybrid is a physisorbent impregnated with a chemisorbent or a chemisorbent impregnated with a physisorbent. Grafted hybrids are characterized as a chemisorbent being covalently linked to the physisorbent. Impregnated hybrids are characterized as the chemisorbent being located within the pores of a physisorbent. In impregnated hybrids the chemisorbent is held in the pore via non-covalent interactions (e.g., van der Waals forces). In some embodiments, a graft hybrid or an impregnated hybrid includes one or more of the following physisorbents, activated carbon, a zeolite, a silicate, a metal-organic framework (MOFs), or a mesoporous transition metal oxide. The type of adsorbent may be selected based on the intended use of the material.

[0052] Adsorbents that are capable of adsorbing a basic fluid, an acidic fluid, a gaseous organic compound, a gaseous inorganic compound, or combinations thereof, may be included in the material. As used herein, the term “gaseous organic compound” refers to a compound that includes at least one carbon-hydrogen covalent bond that is in the gas phase, vapor phase, or both. Examples of gaseous organic compounds that adsorbents can adsorb include aromatic hydrocarbons such as toluene, benzene, xylene, and ethylbenzene; polycyclic aromatic hydrocarbons such as the 16 polycyclic aromatic hydrocarbons classified as priority pollutants by the United States Environmental Protection Agency in 2005 (i.e., naphthalene, acenaphthylene,acenaphthene, fluorene, phenanthrene, anthracene, fluoranthene, pyrene, benz(a)anthracene, chrysene, benzo(b)fluoranthene, benzo(k)fluoranthene, benzo(a)fluoranthene, dibenz(a,h)anthracene, benzo(ghi)perylene, and indeno(l,2,3-cd)pyrene); n-alkanes such as methane, ethane, and n-propane, n-butane, n-pentane, and n-hexane; n-alkenes such as methylene, ethylene, propylene; various alcohols; aldehydes such as formaldehyde; siloxanes; and combinations thereof.

[0053] As used herein, the term “gaseous inorganic compound” refers to a compound that does not have at least one carbon-hydrogen bond that is in the gas phase, vapor phase, or both. Examples of inorganic compounds that adsorbents can adsorb include carbon dioxide; carbon monoxide; water; perfluorocarbons such as tetrafluoromethane and hexafluoroethane; sulfur hexafluoride; ozone; and combinations thereof. Examples of adsorbents capable of adsorbing one or more inorganic compounds include activated carbon, zeolites (e g., zeolite X, zeolite A, zeolite Y, zeolite P, and zeolite ZsM-5), silicates, metal-organic frameworks (MOFs), mesoporous transition metal oxides, and combinations thereof. Zeolite physisorbents are an example of an adsorbent capable of adsorbing ozone.

[0054] An acidic gas is a gas that when mixed with water at a pH of 7, acidifies the water such that the pH of the resultant solution is below 7. Acidic gases may be gaseous inorganic compounds or gaseous organic compounds. Examples of acidic gases that adsorbents can adsorb include sulfur dioxide, nitrogen dioxide, hydrogen sulfide, sulfur trioxide, nitric oxide, and combinations thereof. Examples of adsorbents capable of adsorbing an acidic gas include chemisorbents that include a group I metal (Li, Na, K, Rb, Cs, Fr) carbonate; a metal oxide; a group I (Li, Na, K, Rb, Cs, Fr) metal hydroxide; a group II metal (Be, Mg, Ca, Sr, Ba, Ra) hydroxide; a group II metal (Be, Mg, Ca, Sr, Ba, Ra) oxide; an N-containing compound such as an amine (e.g., tetraethylenepentamine, ethylenediamine and 3-aminopropyltriethoxysilane), an imine (e.g., polyethyleneimine), and an ammonium salt (e.g., ammonium persulfate); and combinations thereof. In some embodiments, the selected chemisorbent may be grafted onto a physisorbent, or impregnated within a physisorbent such as activated carbon; a zeolite; a silicate; or combinations thereof.

[0055] A basic gas is a gas that when mixed with water at a pH of 7, basifies the water such that the pH of the resultant solution is above 7. Basic gases may be gaseous inorganic compounds or gaseous organic compounds. Examples of basic gases that adsorbents can adsorb includeammonia and nitrogen trifluoride. Examples of adsorbents capable of adsorbing a basic gas include physisorbents such as activated carbon, zeolites, silicates, and combinations thereof. Additional examples of adsorbents capable of adsorbing a basic gas include chemisorbents that have a carboxylic acid (COOH) functional group. Examples of chemisorbent compounds that have a carboxylic acid functional group include citric acid, terephthalic acid, trimesic acid, tartaric acid, maleic acid, benzoic acid, oxalic acid, and combinations thereof. Chemisorbents capable of adsorbing a basic gas include inorganic acids such as boric acid, nitric acid, sulfuric acid, hydrochloric acid, and combinations thereof. Such chemisorbents may be grafted onto or impregnated within a physisorbent such as activated carbon, a zeolite, a silicate, or combinations thereof.

[0056] Examples of adsorbents that may be used in the material include carbon such as activated carbon, zeolites (e.g., zeolite X, zeolite A, zeolite Y, zeolite 0, and zeolite ZSM-5); silicates; metal-organic frameworks; covalent-organic frameworks; porous organic cages; graphite; mesoporous transition metal oxides; group I metal (Li, Na, K, Rb, Cs, Fr) carbonates; group I metal (Li, Na, K, Rb, Cs, Fr) hydroxide; group II metal (Be, Mg, Ca, Sr, Ba, Ra) hydroxide; group II metal (Be, Mg, Ca, Sr, Ba, Ra) oxide; nitrogen containing compounds such as amines, imines, and / or ammonia; chemisorbents that have a carboxylic acid (COOH) functional group such as citric acid, terephthalic acid, trimesic acid, tartaric acid, maleic acid, benzoic acid, oxalic acid, and combinations thereof; chemisorbents that have been modified or impregnated by strong- or weak- acids such as hydrogen fluoride, hydrogen chloride, hydrogen bromide, sulfuric acid, phosphoric acid, nitric acid, perchloric acid, periodic acid, and any combination thereof; and any combination thereof.

[0057] In some embodiments, the adsorbent or absorbent is capable of adsorbing or absorbing a gas. Adsorbents and / or absorbents that are able to remove or prevent and / or reduce the emission of harmful gasses into the atmosphere may be of particular interest. For example, the material may include an adsorbent and / or absorbent capable of adsorbing and / or adsorbing carbon dioxide; carbon monoxide; perfluorocarbons; volatile organic compounds; sulfur oxides; nitrogen oxides; hydrogen sulfide; ammonia (basic fluid); or any combination thereof.Binder Polymer

[0058] The binder polymer may be configured to secure (e.g., hold in place) the acid reactive salt, the support particles, or both. The binder polymer may be configured to secure the acidreactive salt, the support particles, or both to a substrate. The binder polymer may be a sacrificial binder polymer. A sacrificial polymer means that the polymer degrades during use and is sacrificed in pursuit of another function or material. In this case, the sacrificial polymer is allowed to degrade during use by passing the fluid containing an acid through or onto it, thus making available more acid reactive salt that is dispersed within the sacrificial polymer. The fluid may be any fluid as described here above. In some embodiments, the binder polymer is degradable by an acid. In some embodiments, the binder polymer etched away by exposing to an acid. The acid maybe an acid or an acid precursor. The acid may include SO2, H2S, NO, NO2, HC1, H2SO4, H3PO4, HNO3, acetic acid, or a combination of two or more thereof.

[0059] Without wishing to be bound by theory, the binder polymer reacts with an acidic compound in the fluid, such as acid gases, and is etched away by the acidic compound in the fluid. As the binder polymer is degradable by an acid, the acid reactive salt dispersed in deeper layers of the material becomes accessible and therefore rendering additional active sites available to the fluid and the acidic compound.

[0060] The binder polymer includes one or more types of chemical groups that are capable of reacting with the acid. Such chemical groups may include amide groups. The chemical groups may be pendant groups or may be part of the backbone of the polymer, as long as the groups are capable of reacting with the acid. The binder polymer may be a homopolymer, copolymer, or a blend of two or more polymers. Examples of suitable binder polymers include aromatic polyamides, linear polyamides, polyacrylamides, polyimides, polyurethanes, and blends and copolymers thereof. In some embodiments, the binder polymer is or includes a polyamide. In some embodiments, the binder polymer is or includes a polyurethane. Many types of polyamides are useful as the binder polymer. One class of suitable polyamide condensation polymers are nylon materials. The term “nylon” is a generic name for all long chain synthetic polyamides. Typically, nylon nomenclature includes a series of numbers such as in nylon-6, 6 which indicates that the starting materials are a C6 diamine and a C6 diacid (the first digit indicating a C6 diamine and the second digit indicating a C6 dicarboxylic acid compound). Another nylon can be made by the polycondensation of s (epsilon)-caprolactam in the presence of a small amount of water. This reaction forms a nylon-6 (made from a cyclic lactam, also known as s-aminocaproic acid) that is a linear polyamide. Further, nylon copolymers are also contemplated. Exemplary nylon materials include nylon-6, nylon-6, 6, nylon-6, 10, and blends and copolymers thereof.

[0061] Any suitable molecular weight of the binder polymer may be used. In some embodiments, the binder polymer has a molecular weight of 10 kg / mol or greater, 20 kg / mol or greater, 50 kg / mol or greater, 100 kg / mol or greater, 200 kg / mol or greater, 500 kg / mol or greater, or 1000 kg / mol or greater. In some embodiments, the binder polymer has a molecular weight of 2000 kg / mol or less, 1500 kg / mol or less, 1000 kg / mol or less, 750 kg / mol or less, 500 kg / mol or less, 200 kg / mol or less, or 100 kg / mol or less. In some embodiments, the binder polymer has a molecular weight in a range of 10 kg / mol to 2000 kg / mol, 20 kg / mol to 1500 kg / mol, or 50 kg / mol to 1000 kg / mol.

[0062] The binder polymer may have any suitable base number. In some embodiments, the binder polymer has a base number of 10 kg / mol or greater, 20 kg / mol or greater, 50 kg / mol or greater, 100 kg / mol or greater, 200 kg / mol or greater, 500 kg / mol or greater, or 1000 kg / mol or greater. In some embodiments, the binder polymer has a base number of 2000 kg / mol or less, 1500 kg / mol or less, 1000 kg / mol or less, 750 kg / mol or less, 500 kg / mol or less, 200 kg / mol or less, or 100 kg / mol or less. In some embodiments, the binder polymer has a base number in a range of 10 kg / mol to 2000 kg / mol, 20 kg / mol to 1500 kg / mol, or 50 kg / mol to 1000 kg / mol.

[0063] The binder polymer may have any suitable amide group density. In some embodiments, the binder polymer has an amide group density of 5 wt-% or greater, 10 wt-% or greater, 15 wt- % or greater, 20 wt-% or greater, 25 wt-% or greater, or 30 wt-% or greater. In some embodiments, the binder polymer has an amide group density of 60 wt-% or less, 50 wt-% or less, 40 wt-% or less, 30 wt-% or less, or 25 wt-% or less. In some embodiments, the binder polymer has an amide group density in a range of 5 wt-% to 60 wt-% nitrogen moieties via thermal CHN analysis or some equivalent analytical technique.

[0064] The binder polymer is soluble in one or more of solvents. Examples of solvents the binder polymer may be soluble in include organic alcohols, alkanes, alkenes, alkynes aldehydes, ketones, cyclic hydrocarbons (benzene, toluene, xylene), chloroform, dichloromethane, dimethylformamide (DMF), N-methyl-2-pyrrolidone (NMP), and combinations thereof. In some embodiments, the binder polymer is insoluble in water.Acid Reactive Salt

[0065] The acid reactive salt may be selected such that it reacts with, adsorbs, and / or absorbs target impurities in the fluid. In some embodiments, the acid reactive salt is selected such that it chemically reacts with acidic target compounds, such as a target impurity. The primary intendedfunction of the acid reactive salt may be to chemically react with acidic compounds or acidic impurities. However, the acid reactive salt may additionally have adsorbent and / or absorbent qualities. In some embodiments, the acid reactive salt may not be capable of adsorbing and / or absorbing the acidic compounds or acidic impurities. The fluid may include one or more acidic compounds. The fluid may include one or more acidic impurities. The acidic compounds or acidic impurities may include an acid gas or a mixture of acid gases. According to an embodiment, the acid reactive salt is capable of reacting with the acidic compounds or acidic impurities in the fluid. Examples of the acidic compounds or acidic impurities include carbon dioxide; carbon monoxide; perfluorocarbons; volatile organic compounds; sulfur oxides; nitrogen oxides; hydrogen sulfide; ammonia (basic fluid); and combinations of two or more thereof.

[0066] The acid reactive salt is capable of reacting with an acid and is insoluble in at least one solvent that the binder polymer is soluble in. The acid reactive salt may be soluble in water and / or other solvents that the binder polymer is not soluble in. Examples of solvents the acid reactive salt is insoluble in include those that are consistent with any solvent described here. Examples of suitable acid reactive salts include LiCCh, LiHCCh, RbCCh, RbHCCh, CsCCh, CsHCOa, K2CO3, KHCO3, Na2CO3, NaOH, Ca(OH)2, NaHCC , CaO, MgO, BeO, SrO, BaO, and combinations of two or more thereof. In some embodiments, both the binder polymer and the acid reactive salt are capable of reacting with at least some of the same acidic compounds or acidic impurities. In some other embodiments, only the binder polymer is capable of reacting with the acid. According to such embodiments, the acid reactive salt is capable of adsorbing and / or absorbing the acid without chemical reaction.

[0067] The acid reactive salt may be present in the material as particles or aggregates. The acid reactive salt may be present as particles or aggregates that are porous. The acid reactive salt may be chemisorbent, physisorbent, or chemisorbent-physisorbent hybrid. The acid reactive salt may be capable of adsorbing gaseous inorganic compounds. The acid reactive salt may be capable of adsorbing acidic gases. The acid reactive salt may be capable of adsorbing basic gases.

[0068] The acid reactive salt may be included in the material at any desired concentration. For example, the material may include 1 wt-% or greater of the acid reactive salt relative to the combined weight of the binder polymer and the acid reactive salt. In some embodiments, the material includes 1 wt-% or greater, 10 wt-% or greater, 20 wt-% or greater, 30 wt-% or greater,40 wt-% or greater, 50 wt-% or greater, 60 wt-% or greater, 70 wt-% or greater, 80 wt-% or greater, or 90 wt-% or greater of the acid reactive salt relative to a combined weight of the binder polymer and the acid reactive salt. The material may include 95 wt-% or less of the acid reactive salt relative to a combined weight of the binder polymer and the acid reactive salt. In some embodiments, the material includes 90 wt-% or less, 80 wt-% or less, 70 wt-% or less, 60 wt-% or less, 50 wt-% or less, 40 wt-% or less, 30 wt-% or less, 20 wt-% or less, or 10 wt-% or less of the acid reactive salt relative to a combined weight of the binder polymer and the acid reactive salt. In some embodiments, the material includes 1 wt-% to 95 wt-%, 10 wt-% to 90 wt-%, 20 wt-% to 90 wt-%, 30 wt-% to 90 wt-%, or 40 wt-% to 80 wt-% of the acid reactive salt relative to a combined weight of the binder polymer and the acid reactive salt.

[0069] According to an embodiment, at least some of the acid reactive salt is present as salt aggregates. The salt aggregates may be formed by a single type of acid reactive salt. In some embodiments, the salt aggregates may be formed by multiple different acid reactive salts. The acid reactive salt including salt aggregates may exhibit enhanced wettability. The salt aggregates may exhibit the same properties as described here above. The salt aggregates may be configured to react with, adsorb, and / or absorb the acidic compounds or acidic impurities in the fluid. In some embodiments, the salt aggregates are capable of chemically reacting with the acidic compounds or acidic impurities in the fluid but not capable of adsorb or absorbing them. The salt aggregates may have the same chemical composition as described here above. The salt aggregates may include LiCC , LiHCCh, RbCCh, RbHCCh, CsCC , CsHCCh, K2CO3, KHCO3, Na2CO3, NaOH, Ca(OH)2, NaHCCh, CaO, MgO, BeO, SrO, BaO, or a combination of two or more thereof. The salt aggregates are insoluble in at least one solvent that the binder polymer is soluble in. Examples of solvents are consistent with any solvent described above. In some embodiments, both the binder polymer and the salt aggregates are capable of reacting with at least some of the same acidic compounds or acidic impurities. Examples of the acidic compounds or acidic impurities are consistent with any acidic compounds or acidic impurities described above.

[0070] The material may include 1 wt-% or greater of the salt aggregates relative to a combined weight of the binder polymer and the acid reactive salt. In some embodiments, the material includes 1 wt-% or greater, 10 wt-% or greater, 20 wt-% or greater, 30 wt-% or greater, 40 wt-% or greater, 50 wt-% or greater, 60 wt-% or greater, 70 wt-% or greater, 80 wt-% or greater, or 90wt-% or greater of the salt aggregates relative to a combined weight of the binder polymer and the acid reactive salt. The material may include 95 wt-% or less of the salt aggregates relative to combined weight of the binder polymer and the acid reactive salt. In some embodiments, the material includes 90 wt-% or less, 80 wt-% or less, 70 wt-% or less, 60 wt-% or less, 50 wt-% or less, 40 wt-% or less, 30 wt-% or less, 20 wt-% or less, or 10 wt-% or less of the salt aggregates relative to a combined weight of the binder polymer and the acid reactive salt. In some embodiments, the material includes 1 wt-% to 95 wt-%, 10 wt-% to 90 wt-%, 20 wt-% to 90 wt- %, 30 wt-% to 90 wt-%, or 40 wt-% to 80 wt-% of the salt aggregates relative to a combined weight of the binder polymer and the acid reactive salt.

[0071] The salt aggregates have a particle size. The particle size may be defined as the greatest distance across an aggregate. The particle size may be a geometric average, measured using microscopy techniques including scanning electron microscopy (SEM), whereby the average widths of thirty particles across an 1 lOOx magnification area of interest is collected. The salt aggregates may have an average particle size of 2 nanometers (nm) or smaller, 1.8 nm or smaller, 1.6 nm or smaller, 1.4 nm or smaller, 1.2 nm or smaller, 1 nm or smaller, or 0.8 nm or smaller. The salt aggregates may have an average particle size of 0.1 nm or greater. The salt aggregates may be present inside pores of the support particles. In such embodiments, the particle size of the salt aggregates may not be able to be measured directly. However, the pore size of the support particles may be determined, for example, using N2 physisorption and the Barrett- Joy ner- Halenda (BJH) method. The pore size of the support particles may be 2 nm or smaller, 1.8 nm or smaller, 1.6 nm or smaller, 1.4 nm or smaller, 1.2 nm or smaller, 1 nm or smaller, or 0.8 nm or smaller. By extension, the particle size of the salt particles generally lies within this range since the salt particles are disposed within the pores.

[0072] In embodiments where the acid reactive salt is impregnated into support particles, the amount of acid reactive salt may be expressed as an impregnation level, i.e., the relative amount of acid reactive salt included in the support particles, based on total impregnated weight of the particles. The acid reactive salt may be impregnated into the support particles at an impregnation level of 1 wt-% or greater, 10 wt-% or greater, 20 wt-% or greater, 30 wt-% or greater, 40 wt-% or greater, 50 wt-% or greater, 60 wt-% or greater, 70 wt-% or greater, or 80 wt-% or greater, by weight of the impregnated particles. The acid reactive salt may be impregnated into the support particles at an impregnation level of 90 wt-% or less, 80 wt-% or less, 70 wt-% or less, 60 wt-%or less, 50 wt-% or less, 40 wt-% or less, 30 wt-% or less, 20 wt-% or less, or 10 wt-% or less, by weight of the impregnated particles.

[0073] In some embodiments, the acid reactive salt is not present as aggregates, i.e., the material may be free or substantially free of salt aggregates. When the acid reactive salt is free or substantially free of salt aggregates, it does not change the function or other properties of the material as described here.Support Particles

[0074] In some embodiments, the material includes support particles. The material may include support particles dispersed throughout the binder polymer. The support particles may be configured to support the binder polymer and the acid reactive salt. The support particles may also serve other functions, such as being capable of adsorbing and / or absorbing one or more compounds in the fluid. For example, the support particles may be capable of adsorbing and / or absorbing basic compounds, acidic compounds, organic compounds, inorganic compounds, or a combination of two or more thereof. For example, the support particles may be capable of adsorbing and / or absorbing acid gases.

[0075] The support particles may be absorbent. The support particles may be chemisorbent, physisorbent, or chemisorbent-physisorbent hybrids. The support particles may be capable of adsorbing a gaseous inorganic compounds. The support particles may be capable of adsorbing an acidic gases. The support particles may be capable of adsorbing basic gases. The support particles may include one or more phy si sorbents, such as activated carbon, zeolites (e.g., zeolite X, zeolite A, zeolite Y, zeolite P, and zeolite ZsM-5), silicates, metal-organic frameworks (MOFs), mesoporous transition metal oxides, or a combination of two or more thereof. The support particles may include chemisorbents capable of adsorbing an acidic gas, such as a group I metal (Li, Na, K, Rb, Cs, Fr) carbonate; a metal oxide; a group I (Li, Na, K, Rb, Cs, Fr) metal hydroxide; a group II metal (Be, Mg, Ca, Sr, Ba, Ra) hydroxide; a group II metal (Be, Mg, Ca, Sr, Ba, Ra) oxide; an N-containing compound such as an amine (e.g., tetraethylenepentamine, ethylenediamine and 3 -aminopropyltri ethoxy silane), an imine (e.g., polyethyleneimine), and an ammonium salt (e.g., ammonium persulfate) , or a combination of two or more thereof.

[0076] The support particles may include a chemisorbent capable of adsorbing a basic gas, such as a chemisorbent that has a carboxylic acid (COOH) functional group. Examples of chemisorbent compounds that have a carboxylic acid functional group include citric acid,terephthalic acid, trimesic acid, tartaric acid, maleic acid, benzoic acid, oxalic acid, and combinations thereof. Chemisorbents capable of adsorbing a basic gas include inorganic acids such as boric acid, nitric acid, sulfuric acid, hydrochloric acid, and combinations thereof. Such chemisorbents may be grafted onto or impregnated within a physisorbent such as activated carbon, a zeolite, a silicate, or combinations thereof.

[0077] The support particles may include a metal-organic framework (MOF). MOFs may be an adsorbent (e.g., physisorbent, chemisorbent, or both), a catalyst, or both.

[0078] In some embodiments, the support particles are non-reactive to acids. That is, the support particles may be non-reactive to acids such that the acidic compounds in the fluid do not break down the support particles. In some embodiments, the support particles are reactive to acids. The support particles may include activated carbon, a covalent organic framework (COF), zeolite, silica (amorphous or crystalline), graphene, graphite, MXene (a carbide or nitride of a transition metal), alumina (amorphous or crystalline), or a combination of two or more thereof. The support particles may also contain functionalities capable of reacting with acidic species, such as metallic centers, hydroxyl groups, or aminated functionalities. In some embodiments, the support particles include carbon. The carbon may be activated carbon.

[0079] According to an embodiment, the support particles are porous, having a pore size. The pore size may be measured using N2 physisorption and the Barrett-Joyner-Halenda (BJH) method. The pore size may be 0.1 nm or greater, 0.2 nm or greater, 0.4 nm or greater, 0.8 nm or greater, 1 nm or greater, 1.2 nm or greater, or 1.6 nm or greater. The pore size may be 2 nm or less, 1.5 nm or less, 1 nm or less, or 0.5 nm or less.

[0080] The support particles have a particle size. The particle size is defined as the greatest distance across a particle. The particle size of the support particles may be a geometric average, measured using SEM. Specifically, the particle size of the support particles may be measured by averaging the particle widths at the widest points across thirty particles in an image area of 1100X magnification. The particle size of the support particles may be 0.1 pm or greater, 0.5 pm or greater, 1 pm or greater, 5 pm or greater, or 10 pm or greater. The particle size of the support particles may be 100 pm or less, 80 pm or less, 60 pm or less, 50 pm or less, 40 pm or less, 30 pm or less, 20 pm or less, or 10 pm or less. The particle size of the support particles may be in a range of 0.1 pm to 100 pm, 0.5 pm to 80 pm, or 1 pm to 50 pm.

[0081] The support particles may be configured to support the binder polymer and the acid reactive salt. In some embodiments, the support particles are impregnated with the acid reactive salt. In some embodiments, the acid reactive salt is grafted onto the support particles. In some embodiments, the material may not include support particles.

[0082] The support particles may be included in the material at any suitable concentration. The material may include 1 wt-% or more, 5 wt-% or more, 10 wt-% or more, 15 wt-% or more, 20 wt-% or more, or 25 wt-% or more of the support particles by weight of the coating. The material may include 99 wt-% or less, 95 wt-% or less, 90 wt-% or less, 85 wt-% or less, 80 wt-% or less, 75 wt-% or less, 70 wt-% or less, 60 wt-% or less, or 50 wt-% or less of the support particles by weight of the coating. The material may include 1 wt-% to 99 wt-%, 5 wt-% to 95 wt-%, 10 wt- % to 90 wt-%, 15 wt-% to 85 wt-%, or 20 wt-% to 80 wt-% of the support particles by weight of the coating. In some embodiments, the material includes 25 wt-% to 80 wt-% of the support particles by weight of the coating.Methods of Making

[0083] In one embodiment, the method of making the material includes dissolving the binder polymer in a first solvent to form a first solution. The acid reactive salt may be dispersed in the first solvent. The acid reactive salt may be dispersed in the first solution that contains the dissolved binder polymer. According to an embodiment, the acid reactive salt is not soluble in the first solvent. Dispersing the acid reactive salt in the first solution forms a mixture. At least some of the first solvent may then be removed from the mixture. Examples of solvents suitable for dissolving the binder polymer (e.g., suitable for use as the first solvent) include organic alcohols, alkanes, alkenes, alkynes aldehydes, ketones, or cyclic hydrocarbons (benzene, toluene, xylene), chloroform, dichloromethane, dimethylformamide (DMF), or N-Methyl-2-pyrrolidone (NMP).

[0084] In some embodiments where support particles are used to support the acid reactive salt, the dispersing of the acid reactive salt includes dispersing support particles impregnated with the acid reactive salt in the first solution. The support particles may be porous particles. At least some of the acid reactive salt may enter the pores of the support particles, thus impregnating the support particles. The support particles may be impregnated by mixing the support particles and the acid reactive salt in a second solvent in which the acid reactive salt is soluble. This may include first dissolving the acid reactive salt in the second solvent and then mixing in the supportparticles, or first dispersing the support particles in the second solvent and then dissolving the acid reactive salt in the second solvent. The second solvent may be any solvent in which the acid reactive salt is soluble. Conveniently, the second solvent may be or may include water. The binder polymer and the acid reactive may be selected such that at least one pair of solvents can be identified that satisfies the condition that (1) the binder polymer is soluble in the first solvent; (2) the acid reactive salt is soluble in the second solvent; and (3) the acid reactive salt is insoluble in the first solvent. One example of such a combination is polyamide as the binder polymer, ethanol (or another alcohol) as the first solvent, K2CO3 as the acid reactive salt, and water as the second solvent. Many other combinations selected from the polymers, solvents, and salts disclosed herein may be used.

[0085] The method may further include using the material to form a coating or to form an article. The coating may be performed by preparing the mixture as described above, and immersing a substrate or an article in the mixture. The coating may include dip coating the substrate in the mixture. The method may further include molding, casting, injection molding, jet spraying, or extruding an article from the mixture of the first solution and the second solution.

[0086] The method may further include drying the mixture at an elevated temperature to remove at least a portion of the first solvent. For example, after coating with or preparing from the mixture, the article may be dried to remove at least a portion of the solvents. In some embodiments, removing at least some of the first solvent from the mixture includes removing all or substantially all of the first solvent. Depending on the use of the material, the solvent may be removed before, after, or during using the mixture to form or coat an article. For example, the mixture may be used to coat a substrate or an article, and after coating the substrate or article, the solvent (e.g., all or substantially all of the solvent) may be removed. In some embodiments, removing at least some of the first solvent from the mixture includes removing only some of the solvent, forming an intermediate mixture. The intermediate mixture may then be used to form an article. The remaining first solvent may be removed during or after forming or the article. Drying may be accomplished, for example, by air drying, vacuum drying, contacting the article with an absorbent material (e.g., cotton; cellulose; a sponge including polyester, polyurethane, vegetal cellulose, melamine, or combinations thereof; anhydrous calcium chloride; anhydrous magnesium sulfate; and sodium polyacrylate), exposing the article to an elevated temperature, or any combination thereof. The elevated temperature may be below the melting temperature of thebinder polymer so the binder polymer is not melted or deformed when drying at the elevated temperature. According to an embodiment, the elevated temperature may be 10 °C or higher, 20 °C or higher, 30 °C or higher, 50 °C or higher, 100 °C or higher, 150 °C or higher, 200 °C or higher, or 250 °C or higher. The elevated temperature may be 500 °C or below, 400 °C or below, 350 °C or below, 300 °C or below, 250 °C or below, 200 °C or below, or 100 °C or below. In some embodiments, the elevated temperature is in a range of 30 °C to 400 °C.

[0087] In some embodiments, an intermediate mixture is formed by removing at least a portion of the first solvent and extruding, molding, or casting the intermediate mixture to form an article. The intermediate mixture means the mixture has at least a portion of the solvent still present in the mixture. The intermediate mixture is not the final product after the drying. The intermediate mixture may be extruded, molded, or cast to form an article such as a honeycomb, sphere, trilobe, quadrilobe, or cylinder. The elevated temperature may be consistent with any elevated temperature as described here.Coating on Substrate

[0088] In some embodiments, the material forms a coating on a substrate. The coating may be a conformal coating. A coating with a suitable thickness may be prepared that provides the desired reaction capacity. If the coating is applied onto a porous substrate, it may be desirable for the coating to have a thickness that does not clog the pores of the porous substrate. The coating may have a thickness of 10 pm or greater, 20 pm or greater, 50 pm or greater, 100 pm or greater, 200 pm or greater, or 500 pm or greater. The coating may have a thickness of 2 mm or less, 1.5 mm or less, 1.2 mm or less, 1 mm or less, 800 pm or less, 500 pm or less, 250 pm or less, 200 pm or less, or 100 pm or less. The coating may have a thickness of 10 pm to 2 mm, 50 pm to 1.5 mm, or 100 pm to 1.2 mm.

[0089] In some embodiments, the coating is applied onto a porous substrate. The porous substrate may be a foam. The porous substrate may be a reticulated foam. The term reticulated foam is typically used to refer to open-cell foams that form a net or a mesh shape (as opposed to closed-cell foams that form bubble or cell shapes). The majority of pores in a reticulated foam may be open pores and / or through pores. Reticulated foams typically are very porous and have a low density. For example, reticulated foams (prior to coating) may have a porosity of 60 % or greater, 90 % or greater or 95 % or greater as measured by three-dimensional topographical scans. Reticulated foams may be polymer-based; metal-, metal oxide-, or metal carbide-based;carbon-based; or any combination thereof. Examples of polymer-based reticulated foams include reticulated polyester, reticulated polyether, reticulated polyurethane, reticulated polyurethane without heat treatment, reticulated cellulose, and reticulated melamine. Examples of carbonbased reticulated foams include reticulated activated carbon, reticulated vitreous carbon, and reticulated graphene. Examples of metal-based reticulated foams include reticulated foams made from reduced metals (i.e., zero-valent metals) such as titanium, lead, iron, copper, zinc, chromium, cobalt, nickel, manganese, gold, silver, platinum, palladium, rhodium, tungsten, molybdenum, vanadium, zirconium, silicon, ruthenium, and any combination thereof. Examples of metal oxide-based reticulated foams include reticulated silicon oxide. Examples of metal carbide-based reticulated foams include reticulated silicon carbide. Examples of alumina-based reticulated foams include reticulated foams made of aluminum oxide. The reticulated foam may be made of a combination of two or more of any of the materials listed here.

[0090] In some embodiments, the coating is applied to a non-porous substrate. An example of a non-porous substrate is a ceramic honeycomb.

[0091] The porous substrate may be a reticulated foam having any suitable number of pores per inch (PPI) defined using three-dimensional scans of the surface coupled with assessment of the average pore size via scanning electron microscopy. For example, the reticulated foam may 3 PPI or greater, 10 PPI or greater, 20 PPI or greater, 30 PPI or greater, 40 PPI or greater, 50 PPI or greater, 60 PPI or greater, 70 PPI or greater, 80 PPI or greater, 90 PPI or greater or 100 PPI or less, 90 PPI or less, 80 PPI or less, 70 PPI or less, 60 PPI or less, 50 PPI or less, 40 PPI or less, 30 PPI or less, 20 PPI or less, or 10 PPI or less.

[0092] Coating a foam with the material may include disposing the material on a surface of the foam, impregnating the foam with the material, embedding the material within the foam, or a combination of two or more thereof. As such, in some embodiments, the material including the binder polymer and the acid reactive salt, is disposed on a surface of the foam; the foam is impregnated with the material; the foam has the material embedded within; or any combination thereof. A material that impregnates a foam is disposed on at least a portion of a pore surface of the foam.

[0093] In some embodiments a foam (e.g., a reticulated foam) is coated with the material. For example, a foam may be contacted with the material. For a purpose of coating, the material may be provided as a mixture of the binder polymer, the acid reactive salt and one or more solvents.Examples of solvents include organic alcohols, alkanes, alkenes, alkynes aldehydes, ketones, or cyclic hydrocarbons (benzene, toluene, xylene), chloroform, dichloromethane, dimethylformamide (DMF), or N-Methyl-2-pyrrolidone (NMP). The coating material may further include a surfactant.

[0094] In some embodiments when the foam is a wettable porous substrate, the foam may be contacted with a wetting mixture prior to and / or after contacting the substrate with the coating mixture. The wetting mixture may expose collapsible pores in which the support particles and / or the polymer may become embedded. The wetting mixture may include any liquid capable of wetting the substrate; that is, swelling the substrate to expose collapsible pores in the solid portion of the substrate. Depending on the foam, the wetting liquid may be an organic solvent such as ethanol, methanol, acetone, or acetonitrile. In some embodiments, the wetting mixture includes at least a portion of the acid reactive salt and / or support particles. In some such embodiments, the wetting liquid may be chosen such that at least one component of the acid reactive salt and / or support particles is not soluble therein. In other embodiments, the wetting liquid may be chosen such that at least one component of the acid reactive salt and / or support particles is soluble (and dissolves) in the wetting liquid. In other embodiments, the liquid carrier of the coating mixture is a wetting liquid. In some embodiments, the foam may be exposed to two wetting mixtures. The two wetting mixtures may include a first wetting mixture lacking a solid particulate and a second wetting mixture containing a solid particulate.

[0095] The porous substrate may have any suitable configuration. In some embodiments, the porous substrate may be a porous membrane with any desired pore size. Porous membranes such as microfiltration membranes, ultrafiltration membranes, and / or nanofiltration membranes find many uses including, for example, sterilization, water treatment, plasma fractionalization, virus removal, dewaxing, and protein concentration. The physical and / or chemical properties of a porous membrane are often balanced depending on the intended application of the porous membrane. In some embodiments, the porous membrane may be a polymeric porous membrane. The polymeric porous membranes include and / or are made of one or more polymers. Polymeric porous membranes may include, for example, one or more of the following polymers: poly(vinylidene fluoride); poly(ether ketone); sulfonated poly(ether ketone); poly(benzimidazole); poly(sulfone); poly(ether sulfone); cellulose acetate; regenerated cellulose; poly(acrylonitrile); poly(methyl acrylate); sulfonated poly(benzimidazole); poly(imide);poly(lactic acid); poly(vinyl alcohol); poly(vinyl chloride); poly(methyl methacrylate); ethylene vinyl alcohol copolymer; poly(L-lactide); poly(DL-lactide); poly(ether ether ketone); sulfonated poly(ether ether ketone); oligodimethylsiloxane-grafted aromatic poly(amide-imide) copolymer; perfluorosulfonated poly(arylene ether sulfone) multiblock copolymer; and cyclodextrin polymer. In some embodiments, the polymeric porous membrane includes and / or is made of poly (vinylidene fluoride). In some embodiments, the polymeric porous membrane includes and / or is made of poly(ether sulfone).

[0096] In some embodiments, the porous substrate may include fibrous filter media. Typically, fibrous filter media includes fibers made of one or more materials, such as polymers, glass, carbon, cellulosic materials, and the like. Polymer fibers may include, for example, fibers made of polyester, polyaramid, polyimide, polyolefin (for example, polyethylene such as high density polyethylene, low density polyethylene, and / or linear low density polyethylene), ethylene-vinyl acetate, polyacrylamide, polylactic acid, polypropylene, halogenated polymers (for example, polyethylene terephthalate), acrylics, polyphenylene oxide, polyphenylene sulfide, thermoplastic elastomers (for example, thermoplastic polyurethane), polymethyl pentene, and combinations thereof. In some embodiments, the fibrous filter media is free or substantially free of polymers that may be degraded by acidic compounds, such as polymers containing amide groups.

[0097] The substrate may have a honeycomb structure. In some embodiments, the substrate may include a plurality of pellets. The substrate may have a spherical structure.

[0098] In some embodiments, the material is used as a coating material on the substrate. In other embodiments, the material is not applied as a coating but rather, may be form a bulk material of a molded article or a cast article.Method of Using

[0099] The material of the present disclosure may be used to capture (e.g., sequester) an acidic compound, such as an acidic impurity or contaminant. The acidic compound (e.g., an acidic impurity or contaminant) may be present in a fluid. The fluid may be an acidic fluid or a basic fluid. In many embodiments, the fluid is an acidic fluid. The fluid may be a gas or a liquid. The method may include exposing at least a portion of the material to the fluid including the acidic compound. For example, the material may be placed in a stream of fluid, causing the fluid to flow onto, over, or through the material. The acidic compound in the fluid may react with the binder polymer and any acid reactive salt available to come into contact with the acidiccompound. The acidic compound in the fluid may also react with the support particles. Exposing the material causes etching of the binder polymer, thus exposing more acid reactive salt to the acidic compound. The binder polymer may be etched by the acidic compound gradually, extending the lifetime of the material (e.g., extending how long the material is capable of reacting with the acidic compound). The etching of the binder polymer may also increase the capacity of the material to react with the acidic compound. The reaction of the acid with the binder polymer may cause the binder polymer to partially or completely degrade into acidified salt constituents, causing more of the acid reactive salt and / or support particles to become available for reaction with the acid.

[0100] The acidic compound (e.g., an acidic impurity or contaminant) may include SO2, H2S, NO, NO2, HC1, H2SO4, H3PO4, HNO3, acetic acid, or a combination of two or more thereof. In some embodiments, the acidic compound has a concentration in a range of 1 pg / L or greater in the fluid prior to being contacted with the material. The concentration of the acidic compound is not particularly limited but in practice, the concentration of the acidic compound may be 10 g / L or less. However, it has been found that the material (including the binder polymer) is capable of reacting with acids at very low concentrations, including at 10 pg / L or lower, or 100 pg / L or lower.

[0101] When a fluid containing an acidic compound is flown through (or onto) the material, the capability of the material to sequester the acidic compound can be monitored by monitoring the breakthrough of the acidic compound. That is, the amount of the acidic compound that is not captured by the material (i.e., breaks through) can be monitored. Alternatively, a reaction product of the acidic compound and the acid reactive salt may be monitored. Typical filtration materials exhibit an amount of breakthrough known as bypass at approximately 50 % saturation. This can be observed as an increase known as a “knee” in the breakthrough curve. Once a knee is observed, the amount of breakthrough typically does not decrease but continues to increase until the capacity of the material has been exhausted. However, it has surprisingly been observed that the materials of the present application exhibit multiple knees in the breakthrough curve and a reduction in breakthrough after each knee. It is hypothesized that this is due to the increased availability of the acid reactive salt as the polymeric binder is etched away. The materials of the present application also exhibit a longer lifetime and greater capacity than would typically be expected.

[0102] The material of the present disclosure may be capable of reacting with an acid for at least 40 hours, at least 50 hours, at least 60 hours, at least 70 hours, or at least 80 hours at an acid exposure rate of 0.09 mmol acid / minute over a coated foam substrate weighing 50 g with an active material content of 38 g.EMBODIMENTS

[0103] The following is a list of exemplary embodiments according to the present disclosure.

[0104] Embodiment 1 is a material including a binder polymer. The binder polymer includes amide groups and acid reactive salt dispersed throughout the binder polymer.

[0105] Embodiment 2 is the material of embodiment 1, wherein the binder polymer includes one or more of aromatic polyamide, linear polyamide, polyacrylamide, polyimide, or polyurethane, preferably wherein the binder polymer includes polyamide.

[0106] Embodiment 3 is the material of embodiment 1 or 2, wherein the binder polymer has a molecular weight in a range of 10 kg / mol to 2000 kg / mol. The binder polymer may have a molecular weight of 10 kg / mol or greater. The binder polymer may have a molecular weight of 20 kg / mol or greater. The binder polymer may have a molecular weight of 50 kg / mol or greater. The binder polymer may have a molecular weight of 100 kg / mol or greater. The binder polymer may have a molecular weight of 200 kg / mol or greater. The binder polymer may have a molecular weight of 500 kg / mol or greater. The binder polymer may have a molecular weight of 1000 kg / mol or greater. The binder polymer may have a molecular weight of 2000 kg / mol or less. The binder polymer may have a molecular weight of 1500 kg / mol or less. The binder polymer may have a molecular weight of 1000 kg / mol or less. The binder polymer may have a molecular weight of 750 kg / mol or less. The binder polymer may have a molecular weight of 500 kg / mol or less. The binder polymer may have a molecular weight of 200 kg / mol or less. The binder polymer may have a molecular weight of 100 kg / mol or less. The binder polymer may have a molecular weight in a range of 10 kg / mol to 2000 kg / mol, 20 kg / mol to 1500 kg / mol, or 50 kg / mol to 1000 kg / mol.

[0107] Embodiment 4 is the material of any one of embodiments 1 to 3, wherein the binder polymer has a base number in a range of 10 kg / mol to 2000 kg / mol. The binder polymer may have a base number of 10 kg / mol or greater. The binder polymer may have a base number of 20 kg / mol or greater. The binder polymer may have a base number of 50 kg / mol or greater. The binder polymer may have a base number of 100 kg / mol or greater. The binder polymer may havea base number of 200 kg / mol or greater. The binder polymer may have a base number of 500 kg / mol or greater. The binder polymer may have a base number of 1000 kg / mol or greater. The binder polymer may have a base number of 2000 kg / mol or less. The binder polymer may have a base number of 1500 kg / mol or less. The binder polymer may have a base number of 1000 kg / mol or less. The binder polymer may have a base number of 750 kg / mol or less. The binder polymer may have a base number of 500 kg / mol or less. The binder polymer may have a base number of 200 kg / mol or less. The binder polymer may have a base number of 100 kg / mol or less. The binder polymer may have a base number in a range of 10 kg / mol to 2000 kg / mol, 20 kg / mol to 1500 kg / mol, or 50 kg / mol to 1000 kg / mol.

[0108] Embodiment 5 is the material of any one of embodiments 1 to 4, wherein the binder polymer includes polyamide and has an amide group density in a range of 5 wt-% to 60 wt-% nitrogen moi eties. The binder polymer may have an amide group density of 5 wt-% or greater. The binder polymer may have an amide group density of 10 wt-% or greater. The binder polymer may have an amide group density of 15 wt-% or greater. The binder polymer may have an amide group density of 20 wt-% or greater. The binder polymer may have an amide group density of 25 wt-% or greater. The binder polymer may have an amide group density of 30 wt-% or greater. The binder polymer may have an amide group density of 60 wt-% or less. The binder polymer may have an amide group density of 50 wt-% or less. The binder polymer may have an amide group density of 40 wt-% or less, 30 wt-% or less. The binder polymer may have an amide group density of 25 wt-% or less. The binder polymer may have an amide group density in a range of 5 wt-% to 60 wt-% nitrogen moieties via thermal CHN analysis or some equivalent analytical technique.

[0109] Embodiment 6 is the material of any one of embodiments 1 to 5, wherein the binder polymer is soluble in one or more of organic alcohols, alkanes, alkenes, alkynes aldehydes, ketones, or cyclic hydrocarbons (benzene, toluene, xylene), chloroform, dichloromethane, dimethylformamide (DMF), or N-Methyl-2 -pyrrolidone (NMP).

[0110] Embodiment 7 is the material of any one of embodiments 1 to 6, wherein both the binder polymer and the acid reactive salt are capable of reacting with the same acid.

[0111] Embodiment 8 is the material of any one of embodiments 1 to 7, wherein the binder polymer is degradable by an acid.

[0112] Embodiment 9 is the material of embodiment 8, wherein the acid is an acid or an acid precursor and includes SO2, H2S, NO, NO2, HC1, H2SO4, H3PO4, HNO3, acetic acid, or a combination of two or more thereof, optionally wherein the acid includes SO2, H2S, or H2SO4.

[0113] Embodiment 10 is the material of any one of embodiments 1 to 9, wherein the acid reactive salt includes LiCO3, LiHCO3, RbCO3, RbHCO3, CsCO3, CsHCO3, K2CO3, KHCO3, Na2COs, NaOH, Ca(OH)2, NaHCOs, CaO, MgO, BeO, SrO, BaO, or a combination of two or more thereof, optionally wherein the acid reactive salt includes K2CO3.

[0114] Embodiment 11 is the material of any one of embodiments 1 to 10, wherein the acid reactive salt is present as salt aggregates, optionally wherein the salt aggregates have a particle size of 2 nm or smaller.

[0115] Embodiment 12 is the material of any one of embodiments 1 to 11, wherein the acid reactive salt is insoluble in at least one solvent that the binder polymer is soluble in.

[0116] Embodiment 13 is the material of any one of embodiments 1 to 12, wherein the material includes 1 wt-% or greater of the acid reactive salt relative to combined weight of the binder polymer and the acid reactive salt. In some embodiments, the material includes 1 wt-% or greater. In some embodiments, the material includes 10 wt-% or greater. In some embodiments, the material includes 20 wt-% or greater. In some embodiments, the material includes 30 wt-% or greater. In some embodiments, the material includes 40 wt-% or greater. In some embodiments, the material includes 50 wt-% or greater. In some embodiments, the material includes 60 wt-% or greater. In some embodiments, the material includes 70 wt-% or greater. In some embodiments, the material includes 80 wt-% or greater. In some embodiments, the material includes or 90 wt-% or greater of the acid reactive salt relative to a combined weight of the binder polymer and the acid reactive salt.

[0117] Embodiment 14 is the material of any one of embodiments 1 to 13, wherein the material includes 95 wt-% or less of the acid reactive salt relative to combined weight of the binder polymer and the acid reactive salt. In some embodiments, the material includes 90 wt-% or less. In some embodiments, the material includes 80 wt-% or less. In some embodiments, the material includes 70 wt-% or less. In some embodiments, the material includes 60 wt-% or less. In some embodiments, the material includes 50 wt-% or less. In some embodiments, the material includes 40 wt-% or less. In some embodiments, the material includes 30 wt-% or less. In some embodiments, the material includes 20 wt-% or less. In some embodiments, the material includes10 wt-% or less of the acid reactive salt relative to a combined weight of the binder polymer and the acid reactive salt. In some embodiments, the material includes 1 wt-% to 95 wt-%, 10 wt-% to 90 wt-%, 20 wt-% to 90 wt-%, 30 wt-% to 90 wt-%, or 40 wt-% to 80 wt-% of the acid reactive salt relative to a combined weight of the binder polymer and the acid reactive salt.

[0118] Embodiment 15 is the material of any one of embodiments 1 to 14, wherein the material includes support particles dispersed throughout the binder polymer.

[0119] Embodiment 16 is the material of embodiment 15, wherein the support particles are non- reactive to acids or wherein acids do not break down the support particles.

[0120] Embodiment 17 is the material of embodiment 15 or 16, wherein the support particles include activated carbon, metal-organic frameworks (MOFs), covalent organic frameworks (COFs), zeolites, silica (amorphous or crystalline), graphene, graphite, MXenes, metal oxides, reduced metals, alumina (amorphous or crystalline), or a combination of two or more thereof, optionally wherein the support particles include activated carbon or zeolite, optionally wherein the support particles include activated carbon.

[0121] Embodiment 18 is the material of any one of embodiments 15 to 17, wherein the support particles have a particle size in a range of 0.1 nm to 100 pm. The support particles may have a particle size of 0.1 pm or greater. The support particles may have a particle size of 0.5 pm or greater. The support particles may have a particle size of 1 pm or greater. The support particles may have a particle size of 5 pm or greater. The support particles may have a particle size of or 10 pm or greater. . The support particles may have a particle size of 100 pm or less. The support particles may have a particle size of 80 pm or less. The support particles may have a particle size of 60 pm or less. The support particles may have a particle size of 50 pm or less. The support particles may have a particle size of 40 pm or less. The support particles may have a particle size of 30 pm or less. The support particles may have a particle size of 20 pm or less. The support particles may have a particle size of or 10 pm or less. The particle size of the support particles may be in a range of 0.1 pm to 100 pm, 0.5 pm to 80 pm, or 1 pm to 50 pm.

[0122] Embodiment 19 is the material of any one of embodiments 15 to 18, wherein the support particles are impregnated with the acid reactive salt.

[0123] Embodiment 20 is the material of any one of embodiments 15 to 19, wherein the acid reactive salt is grafted onto the support particles.

[0124] Embodiment 21 is the material of any one of embodiments 15 to 20, wherein the material includes 25 wt-% to 80 wt-% of the support particles. The material may include 1 wt-% or more of the support particles. The material may include 5 wt-% or more of the support particles. The material may include 10 wt-% or more of the support particles. The material may include 15 wt- % or more of the support particles. The material may include 20 wt-% or more of the support particles. The material may include or 25 wt-% or more of the support particles by weight of the coating. The material may include 99 wt-% or less of the support particles. The material may include 95 wt-% or less of the support particles. The material may include 90 wt-% or less of the support particles. The material may include 85 wt-% or less, 80 wt-% or less of the support particles. The material may include 75 wt-% or less of the support particles. The material may include 70 wt-% or less of the support particles. The material may include 60 wt-% or less of the support particles. The material may include or 50 wt-% or less of the support particles by weight of the coating. The material may include 1 wt-% to 99 wt-%, 5 wt-% to 95 wt-%, 10 wt-% to 90 wt-%, 15 wt-% to 85 wt-%, 20 wt-% to 80 wt-%, or 25 wt-% to 80 wt-% of the support particles by weight of the coating.

[0125] Embodiment 22 is the material of any one of embodiments 1 to 21, wherein the material forms a coating on a substrate.

[0126] Embodiment 23 is the material of embodiment 22, wherein the coating has a thickness of 10 pm to 2 mm. The coating may have a thickness of 10 pm or greater. The coating may have a thickness of 20 pm or greater. The coating may have a thickness of 50 pm or greater. The coating may have a thickness of 100 pm or greater. The coating may have a thickness of 200 pm or greater. The coating may have a thickness of or 500 pm or greater. The coating may have a thickness of 2 mm or less. The coating may have a thickness of 1.5 mm or less. The coating may have a thickness of 1.2 mm or less. The coating may have a thickness of 1 mm or less. The coating may have a thickness of 800 pm or less. The coating may have a thickness of 500 pm or less. The coating may have a thickness of 250 pm or less. The coating may have a thickness of 200 pm or less. The coating may have a thickness of 100 pm or less. The coating may have a thickness of 10 pm to 2 mm, 50 pm to 1.5 mm, or 100 pm to 1.2 mm.

[0127] Embodiment 24 is the material of embodiment 22 or 23, wherein the coating is disposed on a porous substrate.

[0128] Embodiment 25 is the material of any one of embodiments 22 to 24, wherein the substrate includes a foam, a honeycomb structure, a spherical structure, or pellets.

[0129] Embodiment 26 is the material of any one of embodiments 1 to 21, wherein the material defines a bulk material of a molded article, a cast article, an extruded article, or an injection molded article.

[0130] Embodiment 27 is the material of any one of embodiments 1 to 26, wherein a breakthrough curve of a reactive acid through the material exhibits a decrease in breakthrough of the reactive acid over time.

[0131] Embodiment 28 is an article that includes the material of any one of embodiments 1 to 27.

[0132] Embodiment 29 is a method of making a material, the material including a binder polymer that includes amide groups and acid reactive salt dispersed throughout the binder polymer. The method includes dissolving the binder polymer in a first solvent to form a first solution. The method includes dispersing the acid reactive salt in the first solution to form a mixture, wherein the acid reactive salt is not soluble in the first solvent. The method includes removing at least some of the first solvent from the mixture to form the material.

[0133] Embodiment 30 is the method of embodiment 29, the method including dissolving the acid reactive salt in a second solvent to form a second solution, and dispersing a plurality of support particles in the second solvent, to form impregnated support particles that include the plurality of support particles impregnated with the acid reactive salt, wherein the dispersing the acid reactive salt in the first solution includes dispersing the impregnated support particles in the first solution.

[0134] Embodiment 31 is the method of embodiment 29 or 30, further including removing at least some of the second solvent from the second solution prior to dispersing the impregnated support particles in the first solution.

[0135] Embodiment 32 is the method of any one of embodiments 29 to 31, wherein the acid reactive salt forms salt aggregates in pores of the support particles, optionally wherein the salt aggregates have a particle size of 2 nm or smaller.

[0136] Embodiment 33 is the method of any one of embodiments 29 to 32, wherein the support particles are non-reactive to acids or wherein acids do not break down the support particles.

[0137] Embodiment 34 is the method of any one of embodiments 29 to 33, wherein the support particles include activated carbon, metal-organic frameworks (MOFs), covalent organic frameworks (COFs), zeolites, silica (amorphous or crystalline), graphene, graphite, MXenes, metal oxides, reduced metals, alumina (amorphous or crystalline), or a combination of two or more thereof, optionally wherein the support particles include activated carbon or zeolite, optionally wherein the support particles include activated carbon.

[0138] Embodiment 35 is the method of any one of embodiments 29 to 34, wherein the support particles have a particle size in a range of 0.1 nm to 100 pm. The support particles may have a particle size of 0.1 pm or greater. The support particles may have a particle size of 0.5 pm or greater. The support particles may have a particle size of 1 pm or greater. The support particles may have a particle size of 5 pm or greater. The support particles may have a particle size of or 10 pm or greater. . The support particles may have a particle size of 100 pm or less. The support particles may have a particle size of 80 pm or less. The support particles may have a particle size of 60 pm or less. The support particles may have a particle size of 50 pm or less. The support particles may have a particle size of 40 pm or less. The support particles may have a particle size of 30 pm or less. The support particles may have a particle size of 20 pm or less. The support particles may have a particle size of or 10 pm or less. The particle size of the support particles may be in a range of 0.1 pm to 100 pm, 0.5 pm to 80 pm, or 1 pm to 50 pm.

[0139] Embodiment 36 is the method of any one of embodiments 29 to 35, wherein the material includes 25 wt-% to 80 wt-% of the support particles. The material may include 1 wt-% or more of the support particles. The material may include 5 wt-% or more of the support particles. The material may include 10 wt-% or more of the support particles. The material may include 15 wt- % or more of the support particles. The material may include 20 wt-% or more of the support particles. The material may include or 25 wt-% or more of the support particles by weight of the coating. The material may include 99 wt-% or less of the support particles. The material may include 95 wt-% or less of the support particles. The material may include 90 wt-% or less of the support particles. The material may include 85 wt-% or less, 80 wt-% or less of the support particles. The material may include 75 wt-% or less of the support particles. The material may include 70 wt-% or less of the support particles. The material may include 60 wt-% or less of the support particles. The material may include or 50 wt-% or less of the support particles by weight of the coating. The material may include 1 wt-% to 99 wt-%, 5 wt-% to 95 wt-%, 10 wt-% to 90wt-%, 15 wt-% to 85 wt-%, 20 wt-% to 80 wt-%, or 25 wt-% to 80 wt-% of the support particles by weight of the coating.

[0140] Embodiment 37 is the method of any one of embodiments 29 to 36, the method includes immersing an article in the mixture to coat the article with the material.

[0141] Embodiment 38 is the method of any one of embodiments 29 to 37, the method includes molding, casting, jet-spraying, injection molding, or extruding the mixture to form an article from the material.

[0142] Embodiment 39 is the method of any one of embodiments 29 to 38, the method includes drying the mixture at an elevated temperature to remove at least a portion of the first solvent to form an intermediate mixture, and extruding, molding, or casting the intermediate mixture to form an article.

[0143] Embodiment 40 is the method of any one of embodiments 29 to 39, wherein the binder polymer includes one or more of aromatic polyamide, linear polyamide, polyacrylamide, polyimide, or polyurethane, preferably wherein the binder polymer includes polyamide.

[0144] Embodiment 41 is the method of any one of embodiments 29 to 49, wherein the binder polymer has a molecular weight in a range of 10 kg / mol to 2000 kg / mol. The binder polymer may have a molecular weight of 10 kg / mol or greater. The binder polymer may have a molecular weight of 20 kg / mol or greater. The binder polymer may have a molecular weight of 50 kg / mol or greater. The binder polymer may have a molecular weight of 100 kg / mol or greater. The binder polymer may have a molecular weight of 200 kg / mol or greater. The binder polymer may have a molecular weight of 500 kg / mol or greater. The binder polymer may have a molecular weight of 1000 kg / mol or greater. The binder polymer may have a molecular weight of 2000 kg / mol or less. The binder polymer may have a molecular weight of 1500 kg / mol or less. The binder polymer may have a molecular weight of 1000 kg / mol or less. The binder polymer may have a molecular weight of 750 kg / mol or less. The binder polymer may have a molecular weight of 500 kg / mol or less. The binder polymer may have a molecular weight of 200 kg / mol or less. The binder polymer may have a molecular weight of 100 kg / mol or less. The binder polymer may have a molecular weight in a range of 10 kg / mol to 2000 kg / mol, 20 kg / mol to 1500 kg / mol, or 50 kg / mol to 1000 kg / mol.

[0145] Embodiment 42 is the method of any one of embodiments 29 to 41, wherein the binder polymer has a base number in a range of 10 kg / mol to 2000 kg / mol. The binder polymer mayhave a base number of 10 kg / mol or greater. The binder polymer may have a base number of 20 kg / mol or greater. The binder polymer may have a base number of 50 kg / mol or greater. The binder polymer may have a base number of 100 kg / mol or greater. The binder polymer may have a base number of 200 kg / mol or greater. The binder polymer may have a base number of 500 kg / mol or greater. The binder polymer may have a base number of 1000 kg / mol or greater. The binder polymer may have a base number of 2000 kg / mol or less. The binder polymer may have a base number of 1500 kg / mol or less. The binder polymer may have a base number of 1000 kg / mol or less. The binder polymer may have a base number of 750 kg / mol or less. The binder polymer may have a base number of 500 kg / mol or less. The binder polymer may have a base number of 200 kg / mol or less. The binder polymer may have a base number of 100 kg / mol or less. The binder polymer may have a base number in a range of 10 kg / mol to 2000 kg / mol, 20 kg / mol to 1500 kg / mol, or 50 kg / mol to 1000 kg / mol.

[0146] Embodiment 43 is the method of any one of embodiments 29 to 42, wherein the binder polymer includes polyamide and has an amide group density in a range of 5 wt-% to 60 wt-% nitrogen moieties. The binder polymer may have an amide group density of 5 wt-% or greater. The binder polymer may have an amide group density of 10 wt-% or greater. The binder polymer may have an amide group density of 15 wt-% or greater. The binder polymer may have an amide group density of 20 wt-% or greater. The binder polymer may have an amide group density of 25 wt-% or greater. The binder polymer may have an amide group density of 30 wt-% or greater. The binder polymer may have an amide group density of 60 wt-% or less. The binder polymer may have an amide group density of 50 wt-% or less. The binder polymer may have an amide group density of 40 wt-% or less, 30 wt-% or less. The binder polymer may have an amide group density of 25 wt-% or less. The binder polymer may have an amide group density in a range of 5 wt-% to 60 wt-% nitrogen moieties via thermal CHN analysis or some equivalent analytical technique.

[0147] Embodiment 44 is the method of any one of embodiments 29 to 43, wherein the binder polymer is soluble in one or more of organic alcohols, alkanes, alkenes, alkynes aldehydes, ketones, or cyclic hydrocarbons (benzene, toluene, xylene), chloroform, dichloromethane, dimethylformamide (DMF), or N-Methyl-2 -pyrrolidone (NMP).

[0148] Embodiment 45 is the method of any one of embodiments 29 to 44, wherein both the binder polymer and the acid reactive salt are capable of reacting with the same acid.

[0149] Embodiment 46 is the method of any one of embodiments 29 to 45, wherein the binder polymer is degradable by an acid.

[0150] Embodiment 47 is the method of embodiment 46, wherein the acid is an acid or an acid precursor and includes SO2, H2S, NO, NO2, HC1, H2SO4, H3PO4, HNO3, acetic acid, or a combination of two or more thereof, optionally wherein the acid includes SO2, H2S, or H2SO4.

[0151] Embodiment 48 is the method of any one of embodiments 29 to 47, wherein the acid reactive salt includes LiCO3, LiHCO3, RbCO3, RbHCO3, CsCOs, CsHCO3, K2CO3, KHCO3, Na2COs, NaOH, Ca(OH)2, NaHCO.i, CaO, MgO, BeO, SrO, BaO, or a combination of two or more thereof, optionally wherein the acid reactive salt includes K2CO3.

[0152] Embodiment 49 is the method of any one of embodiments 29 to 48, wherein the material includes 1 wt-% or greater of the acid reactive salt relative to combined weight of the binder polymer and the acid reactive salt.

[0153] Embodiment 50 is the method of any one of embodiments 29 to 49, wherein the material includes 95 wt-% or less of the acid reactive salt relative to combined weight of the binder polymer and the acid reactive salt.

[0154] Embodiment 51 is the method of any one of embodiments 29 to 50, wherein the method includes forming a coating of the material on a substrate.

[0155] Embodiment 52 is the method of embodiment 51, wherein the coating has a thickness of 10 pm to 2 mm. The coating may have a thickness of 10 pm or greater. The coating may have a thickness of 20 pm or greater. The coating may have a thickness of 50 pm or greater. The coating may have a thickness of 100 pm or greater. The coating may have a thickness of 200 pm or greater. The coating may have a thickness of or 500 pm or greater. The coating may have a thickness of 2 mm or less. The coating may have a thickness of 1.5 mm or less. The coating may have a thickness of 1.2 mm or less. The coating may have a thickness of 1 mm or less. The coating may have a thickness of 800 pm or less. The coating may have a thickness of 500 pm or less. The coating may have a thickness of 250 pm or less. The coating may have a thickness of 200 pm or less. The coating may have a thickness of 100 pm or less. The coating may have a thickness of 10 pm to 2 mm, 50 pm to 1.5 mm, or 100 pm to 1.2 mm.

[0156] Embodiment 53 is the method of embodiment 51 or 52, wherein the coating is disposed on a porous substrate.

[0157] Embodiment 54 is the method of embodiment 53, wherein the substrate includes a foam, a honeycomb structure, a spherical structure, or pellets.

[0158] Embodiment 55 is the method of any one of embodiments 29 to 54, wherein a breakthrough curve of a reactive acid through the material exhibits a decrease in breakthrough of the reactive acid over time.

[0159] Embodiment 56 is a method of sequestering an acid with a material. The material includes a binder polymer that includes amide groups and acid reactive salt dispersed throughout the binder polymer. The material may be any material of embodiments 1 to 27. The method includes exposing at least a portion of the material to the acid, thereby causing at least a portion of the acid to react with the binder polymer, the acid reactive salt, or both.

[0160] Embodiment 57 is the method of embodiment 56, wherein a breakthrough curve of the acid through the material exhibits a decrease in contaminant breakthrough concentration of the acid over time.

[0161] Embodiment 58 is the method of embodiment 56 or 57, wherein the acid is gaseous or liquid.

[0162] Embodiment 59 is the method of any one of embodiments 56 to 58, wherein the acid is an acid or an acid precursor and includes SO2, H2S, NO, NO2, HC1, H2SO4, H3PO4, HNO3, acetic acid, or a combination of two or more thereof, optionally wherein the acid includes SO2, H2S, or H2SO4.

[0163] Embodiment 60 is the method of any one of embodiments 56 to 59, wherein the binder polymer is temporally degraded by the acid.

[0164] Embodiment 61 is the method of embodiment 60, wherein the temporal degradation of the binder polymer reveals previously covered acid reactive particles.

[0165] Embodiment 62 is the method of embodiment 61, wherein increased accessibility of the acid reactive particles leads to a temporal enhancement in adsorption capacity towards acid gases.

[0166] Embodiment 63 is the method of any one of embodiments 56 to 62, wherein the acid has a concentration in a range of 1 pg / L or greater. The concentration of the acid may be 10 g / L or less.

[0167] Embodiment 64 is the method of any one of embodiments 56 to 63, wherein the binder polymer includes one or more of aromatic polyamide, linear polyamide, polyacrylamide, polyimide, or polyurethane, preferably wherein the binder polymer includes polyamide.

[0168] Embodiment 65 is the method of any one of embodiments 56 to 64, wherein the binder polymer has a molecular weight in a range of 10 kg / mol to 2000 kg / mol. The binder polymer may have a molecular weight of 10 kg / mol or greater. The binder polymer may have a molecular weight of 20 kg / mol or greater. The binder polymer may have a molecular weight of 50 kg / mol or greater. The binder polymer may have a molecular weight of 100 kg / mol or greater. The binder polymer may have a molecular weight of 200 kg / mol or greater. The binder polymer may have a molecular weight of 500 kg / mol or greater. The binder polymer may have a molecular weight of 1000 kg / mol or greater. The binder polymer may have a molecular weight of 2000 kg / mol or less. The binder polymer may have a molecular weight of 1500 kg / mol or less. The binder polymer may have a molecular weight of 1000 kg / mol or less. The binder polymer may have a molecular weight of 750 kg / mol or less. The binder polymer may have a molecular weight of 500 kg / mol or less. The binder polymer may have a molecular weight of 200 kg / mol or less. The binder polymer may have a molecular weight of 100 kg / mol or less. The binder polymer may have a molecular weight in a range of 10 kg / mol to 2000 kg / mol, 20 kg / mol to 1500 kg / mol, or 50 kg / mol to 1000 kg / mol.

[0169] Embodiment 66 is the method of any one of embodiments 56 to 65, wherein the binder polymer has a base number in a range of 10 kg / mol to 2000 kg / mol. The binder polymer may have a base number of 10 kg / mol or greater. The binder polymer may have a base number of 20 kg / mol or greater. The binder polymer may have a base number of 50 kg / mol or greater. The binder polymer may have a base number of 100 kg / mol or greater. The binder polymer may have a base number of 200 kg / mol or greater. The binder polymer may have a base number of 500 kg / mol or greater. The binder polymer may have a base number of 1000 kg / mol or greater. The binder polymer may have a base number of 2000 kg / mol or less. The binder polymer may have a base number of 1500 kg / mol or less. The binder polymer may have a base number of 1000 kg / mol or less. The binder polymer may have a base number of 750 kg / mol or less. The binder polymer may have a base number of 500 kg / mol or less. The binder polymer may have a base number of 200 kg / mol or less. The binder polymer may have a base number of 100 kg / mol orless. The binder polymer may have a base number in a range of 10 kg / mol to 2000 kg / mol, 20 kg / mol to 1500 kg / mol, or 50 kg / mol to 1000 kg / mol.

[0170] Embodiment 67 is the method of any one of embodiments 56 to 66, wherein the binder polymer includes polyamide and has an amide group density in a range of 5 wt-% to 60 wt-% nitrogen moieties. The binder polymer may have an amide group density of 5 wt-% or greater. The binder polymer may have an amide group density of 10 wt-% or greater. The binder polymer may have an amide group density of 15 wt-% or greater. The binder polymer may have an amide group density of 20 wt-% or greater. The binder polymer may have an amide group density of 25 wt-% or greater. The binder polymer may have an amide group density of 30 wt-% or greater. The binder polymer may have an amide group density of 60 wt-% or less. The binder polymer may have an amide group density of 50 wt-% or less. The binder polymer may have an amide group density of 40 wt-% or less, 30 wt-% or less. The binder polymer may have an amide group density of 25 wt-% or less. The binder polymer may have an amide group density in a range of 5 wt-% to 60 wt-% nitrogen moieties via thermal CHN analysis or some equivalent analytical technique.

[0171] Embodiment 68 is the method of any one of embodiments 56 to 67, wherein the binder polymer is soluble in one or more of organic alcohols, alkanes, alkenes, alkynes aldehydes, ketones, or cyclic hydrocarbons (benzene, toluene, xylene), chloroform, dichloromethane, dimethylformamide (DMF), or N-Methyl-2-pyrrolidone (NMP).

[0172] Embodiment 69 is the method of any one of embodiments 56 to 68, wherein both the binder polymer and the acid reactive salt are capable of reacting with the same acid.

[0173] Embodiment 70 is the method of any one of embodiments 56 to 69, wherein the acid reactive salt includes LiCCh, LiHCCh, RbCCh, RbHCC , CsCCh, CsHCC , K2CO3, KHCO3, Na2CO3, NaOH, Ca(OH)2, NaHCCh, CaO, MgO, BeO, SrO, BaO, or a combination of two or more thereof, optionally wherein the acid reactive salt includes K2CO3.

[0174] Embodiment 71 is the method of any one of embodiments 56 to 70, wherein the acid reactive salt forms salt aggregates in pores of the support particles, optionally wherein the salt aggregates have a particle size of 2 nm or smaller.

[0175] Embodiment 72 is the method of any one of embodiments 56 to 71, wherein the acid reactive salt is insoluble in at least one solvent that the binder polymer is soluble in.

[0176] Embodiment 73 is the method of any one of embodiments 56 to 72, wherein the material includes 1 wt-% or greater of the acid reactive salt relative to combined weight of the binder polymer and the acid reactive salt.

[0177] Embodiment 74 is the method of any one of embodiments 56 to 73, wherein the material includes 95 wt-% or less of the acid reactive salt relative to combined weight of the binder polymer and the acid reactive salt.

[0178] Embodiment 75 is the method of any one of embodiments 56 to 74, wherein the material includes support particles dispersed throughout the binder polymer.

[0179] Embodiment 76 is the method of embodiment 75, wherein the support particles are non- reactive to acids or wherein acids do not break down the support particles.

[0180] Embodiment 77 is the method of embodiment 75 or 76, wherein the support particles include activated carbon, metal-organic frameworks (MOFs), covalent organic frameworks (COFs), zeolites, silica (amorphous or crystalline), graphene, graphite, MXenes, metal oxides, reduced metals, alumina (amorphous or crystalline), or a combination of two or more thereof, optionally wherein the support particles include activated carbon or zeolite, optionally wherein the support particles include activated carbon.

[0181] Embodiment 78 is the method of any one of embodiments 75 to 77, wherein the support particles have a particle size in a range of 0.1 nm to 100 pm. The support particles may have a particle size of 0.1 pm or greater. The support particles may have a particle size of 0.5 pm or greater. The support particles may have a particle size of 1 pm or greater. The support particles may have a particle size of 5 pm or greater. The support particles may have a particle size of or 10 pm or greater. . The support particles may have a particle size of 100 pm or less. The support particles may have a particle size of 80 pm or less. The support particles may have a particle size of 60 pm or less. The support particles may have a particle size of 50 pm or less. The support particles may have a particle size of 40 pm or less. The support particles may have a particle size of 30 pm or less. The support particles may have a particle size of 20 pm or less. The support particles may have a particle size of or 10 pm or less. The particle size of the support particles may be in a range of 0.1 pm to 100 pm, 0.5 pm to 80 pm, or 1 pm to 50 pm.

[0182] Embodiment 79 is the method of any one of embodiments 75 to 78, wherein the support particles are impregnated with the acid reactive salt.

[0183] Embodiment 80 is the method of any one of embodiments 75 to 78, wherein the acid reactive salt is grafted onto the support particles.

[0184] Embodiment 81 is the method of any one of embodiments 75 to 80, wherein the material includes 25 wt-% to 80 wt-% of the support particles. The material may include 1 wt-% or more of the support particles. The material may include 5 wt-% or more of the support particles. The material may include 10 wt-% or more of the support particles. The material may include 15 wt- % or more of the support particles. The material may include 20 wt-% or more of the support particles. The material may include or 25 wt-% or more of the support particles by weight of the coating. The material may include 99 wt-% or less of the support particles. The material may include 95 wt-% or less of the support particles. The material may include 90 wt-% or less of the support particles. The material may include 85 wt-% or less, 80 wt-% or less of the support particles. The material may include 75 wt-% or less of the support particles. The material may include 70 wt-% or less of the support particles. The material may include 60 wt-% or less of the support particles. The material may include or 50 wt-% or less of the support particles by weight of the coating. The material may include 1 wt-% to 99 wt-%, 5 wt-% to 95 wt-%, 10 wt-% to 90 wt-%, 15 wt-% to 85 wt-%, 20 wt-% to 80 wt-%, or 25 wt-% to 80 wt-% of the support particles by weight of the coating.

[0185] Embodiment 82 is the method of any one of embodiments 56 to 81, wherein the material forms a coating on a substrate.

[0186] Embodiment 83 is the method of embodiment 82, wherein the coating has a thickness of 10 pm to 2 mm. The coating may have a thickness of 10 pm or greater. The coating may have a thickness of 20 pm or greater. The coating may have a thickness of 50 pm or greater. The coating may have a thickness of 100 pm or greater. The coating may have a thickness of 200 pm or greater. The coating may have a thickness of or 500 pm or greater. The coating may have a thickness of 2 mm or less. The coating may have a thickness of 1.5 mm or less. The coating may have a thickness of 1.2 mm or less. The coating may have a thickness of 1 mm or less. The coating may have a thickness of 800 pm or less. The coating may have a thickness of 500 pm or less. The coating may have a thickness of 250 pm or less. The coating may have a thickness of 200 pm or less. The coating may have a thickness of 100 pm or less. The coating may have a thickness of 10 pm to 2 mm, 50 pm to 1.5 mm, or 100 pm to 1.2 mm.

[0187] Embodiment 84 is the method of embodiment 82 or 83, wherein the coating is disposed on a porous substrate.

[0188] Embodiment 85 is the method of any one of embodiments 82 to 84, wherein the substrate includes a foam, a honeycomb structure, a spherical structure, or pellets.

[0189] Embodiment 86 is the method of any one of embodiments 56 to 81, wherein the material defines a bulk material of a molded article, a cast article, an extruded article, or an injection molded article.EXAMPLES

[0190] These Examples are merely for illustrative purposes and are not meant to be overly limiting on the scope of the appended claims. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the present disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0191] Unless otherwise noted, all parts, percentages, ratios, etc. in the examples and the rest of the specification are by weight. The following abbreviations may be used in the following examples: Mn = number average molecular weight; ppm = parts per million; ppb = parts per billion; mL = milliliter; L = liter; m = meter, mm = millimeter, min = minutes; s = seconds; cm = centimeter, pm = micrometer, kg = kilogram, g = gram, min = minute, s = second, h = hour, rpm = rounds or rotations per minute, C = degrees Celsius, °F = degrees Fahrenheit; wt-% = weight percent; M = molar; and DI water = deionized water.Example 1A

[0192] Materials prepared from an acid reactive salt and polymer binder with support particles were prepared and used to coat foams. The coated foam was used to sequester SCh from a gas flow. The breakthrough of acid was monitored.

[0193] A 2.5 inch (about 6.4 cm) deep by 3.5 inch (about 8.9 cm) diameter cylindrical bed of reticulated polyurethane foam was dip coated with a coating composition. The coatingcomposition included activated carbon particles (prepared from coconut shell; available from Calgon Carbon Corporation in Pittsburgh, PA) impregnated with K2CO3 (the acid reactive salt). The K2CO3 was first dissolved in 500 mL of water with sonication at ambient temperature. The carbon was then added to the solution by gentle mixing until completely dispersed. Thereafter, the suspension was shaken on a rotary mixer at 120 rpm for 24 h. Finally, the impregnated carbon was recovered by rotary evaporation at 12 rpm and 100 °C. The impregnation level was 30 wt-%. The coated foam was exposed to a flow of 100 ppm of SO2 at 20 L / min flowrate and 50 % relative humidity. The breakthrough of SO2 and the update of water were monitored. The results are shown in FIGS. 3A and 3B.

[0194] It was observed that the coated foam displayed unusual breakthrough behavior, as shown in FIG. 3A. In particular, the foams displayed temporal reductions in SO2 concentration following an initial breakthrough which lasted over 24 h. Moreover, as shown in FIG. 3B, the reductions in SO2 concentration corresponded directly with substantial uptakes in water being detected by mass spectrometer downstream. Specifically, the reduction in SO2 concentration from 45-75 h in FIG. 3A corresponds to an uptick in water content at precisely the same time frame. A similar correspondence was also observed from the 100-130 h mark, with small fluctuations in both water and SO2 concentrations being observed throughout the experimental measurement. Knowing that water is a byproduct of SO2 reaction with K2CO3, it was concluded that the basic sites were being consumed throughout the experiment rather than only in the initial 10 h zone at the forefront of breakthrough. Such a temporal accessibility of the active sites implied a chemical change occurred as the breakthrough progressed.Example IB

[0195] Foams were coated as described in Example 1 and exposed to 0.1 M H2SO4 to determine the degree of K2CO3 presented in the coating after application to the substrate. The stoichiometric amount of K2CO3 was approximated as the point of inflection in the resulting Boehm titration curves for 3.0 g samples of coated foam.

[0196] The coated foams displayed increasing basicity which was consistent with the increased amount of acid-reacting salt impregnated. The carbon impregnated with 30 wt.% basis of K2CO3 was used to coat the foam substrates. After coating, the sample weight was 51 g. With an effective final K2CO3 concentration of 13% for these samples - as measured by titration - the approximate K2CO3 content in 51g of foams was approximated as being 6.63g of base (e.g.,K2CO3). The K2CO3 content in the coated foams was measured via Boehm titration with IN H2SO4 and plotted against the initial K2CO3 content impregnated into the parent carbon powder. These measurements were collected to approximate the final basicity of the coated substrates and to assess the coating repeatability, as shown in FIG. 4A.

[0197] The calculated amount of SO2 adsorbed during breakthrough should, in theory, not exceed 3-5 g when converting on a per-weight basis between the K2CO3 level to a stoichiometric equivalency of SO2. The total amount of SO2 flown into the column during the experiment can be approximated as follows:

[0198] On this basis, with a cylinder feed rate of 1 L / min and a cylinder concentration of 1000 ppm, the approximate amount of SO2 fed into the reactor bed throughout the experiment was ~30 g. The SO2 was not adsorbed in its entirely as evidenced by the fact that some fraction was detected downstream after 10 h. However, during the first 10 h - during which time no SO2 was detected downstream - the sample adsorbed 1.7 g of SO2. Even assuming that only -50% of SO2 was adsorbed throughout the remaining experiment, the amount of SO2 captured by the sample (i.e., ~10+g) exceeded the stoichiometric maximum which should be chemically possible with the amount of impregnated K2CO3.

[0199] It should be noted that the activated carbon has a certain level of basicity, as well as an inherent microporosity, both of which could contribute to SO2 adsorption. To this end, breakthrough experiments were also performed with 250 ppm of SO2 at 20 L / min and 50 % relative humidity (RH) on 2.5 inch deep cylindrical stacks of 20 pore per inch (PPI) polyurethane foams by coating the substrates with unimpregnated carbon to assess the SO2 capacity without K2CO3. The results are shown in FIG. 4B. It was observed that total saturation of the media occurred, consistently, at about 3 h of testing. The total amount of SO2 fed into the column during the experiment can be estimated using the equation above, albeit with 250 ppm feedstock concentration instead of 100 ppm. Even assuming that 100 % of SO2 was adsorbed by the samples, the maximum amount of gas captured by the foams coated with activated carbon without K2CO3 cannot exceed 1.3 g of SO2. It was concluded that another mechanism was causing the heightened capacity shown in FIG. 4B.

[0200] In view of the results of Examples 1 A and IB, and because the polyurethane foam was covered by the coating, the Nylon binder could reasonably be assumed to be the source of the added acid gas capacity of the material. SEM images of the coated foams were obtained to visually observe changes in the coating. Coated samples before exposure are shown in FIGS. 5A and 5B, and after exposure in FIGS. 5C and 5D. Indeed, examining the coated 45 PPI foam sample after exposure to the SO2 breakthrough experiment in Example 1 A revealed a thinning of the coating, as seen in FIGS. 5C and 5D.Example 2

[0201] The capacity of electrospun polymer fibers made of nylon 66 (without acid reactive salt) to react with SO2 gas was evaluated.

[0202] A thin layer of electrospun nylon fine fibers -nylon 66 from BASF - was exposed to 4 L / min of 100 ppm SO2 at 50 % RH and 25 °C. The breakthrough of the sample is shown in FIG. 6. Micrographs of the fibers before and after SO2 exposure are displayed in FIGS. 7A-7D. The sample did not show immediate SO2 breakthrough, as would have been expected if no affinity towards the acid gas were present. Rather, a broad breakthrough front, consistent with chemical interactions, was observed. This experiment signified that some chemical reaction between nylon and hydrolyzed SO2 had occurred. It is generally known that exposing nylon 66 to concentrated sulfuric acid degrades the polymer into adipic acid and hexane-l,6-diamine. Without wishing to be bound by theory, it is postulated that the amine groups in the latter case further reacted with the HxSOy to form sulfonated salts of NH-SOx, thus abating the gaseous contaminant. This mechanism is only observed with concentrated acids but has not been previously observed at the ppm level. On the basis of such chemistry, it is hypothesized that any N-Hxcontaining polymer could be used in this manner including but not limited to polyurethanes, polyamides, polyacrylamide, and the like.

[0203] It was further observed that the sample microstructure under SEM was clearly modified by the acid gas as contrasted between the differences in FIG. 7A and FIG. 7C. Acidifying the fibers clearly compromised their structure and led to filming of the surface. Moreover, small salt particles were observed in FIG. 7D which were not present on the surface in FIG. 7B, indicating that a sublimation reaction had taken place. On this basis, it was concluded that the nylon had reacted with SO2.Example 3

[0204] Another experiment of coated foam was conducted, using commercially available polyurethane foam and K2CO3 impregnated active carbon particles.

[0205] Active carbon particles were impregnated on a per weight basis with 10, 15, 20, 25, and 30 wt.% of K2CO3. For example, a 1g sample of 10 wt.% K2CO3 would contain 0.1 g of K2CO3 and 0.9 g of carbon. The carbon particles were impregnated in 120 g batches. The K2CO3 was first dissolved in 500 mL of water with sonication at ambient temperature. The carbon was then added to the solution by gentle mixing until completely dispersed. Thereafter, the suspension was shaken on a rotary mixer at 120 rpm for 24 h. Finally, the impregnated carbon was recovered by rotary evaporation at 12 rpm and 100 °C.

[0206] The impregnated carbon was applied to commercially available polyurethane foams with 30 pores per inch (“PPI”) via dip coating. The dip coating mixture was 280 g of impregnated carbon (30 wt.% K2CO3), 26.1 g nylon 66 from BASF, 200 g ethanol, and 35 g of water. The foams were immersed in the dip coating slurry for 30 seconds, followed by drying at 100 °C in a high flow convection oven for 24 h.

[0207] The availability of the K2CO3 in the coating was determined by titration with H2SO4. The results are shown in FIG. 8. The amount of K2CO3 by titration was observed to increase almost linearly with the increased amount of K2CO3 added to the coating. It was concluded that the K2CO3 within the coating, as opposed to only on the surface of the coating, became available to react with the acid during the titration.

[0208] All references and publications cited herein are expressly incorporated herein by reference in their entirety into this disclosure, except to the extent they may directly contradict this disclosure. Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and / or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. It should be understood that this disclosure is not intended to be unduly limited by the illustrative embodiments and examples set forth herein and that such examples and embodiments are presented by way of example only with the scope of the disclosure intended to be limited only by the claims set forth here.

Claims

CLAIMSWhat is claimed is:

1. A material comprising: a binder polymer comprising amide groups; and acid reactive salt dispersed throughout the binder polymer.

2. The material of claim 1, wherein the binder polymer comprises one or more of aromatic polyamide, linear polyamide, polyacrylamide, polyimide, or polyurethane.

3. The material of claim 1 or 2, wherein the binder polymer comprises polyamide and has an amide group density in a range of 5 wt-% to 60 wt-% nitrogen moieties.

4. The material of any one of claims 1 to 3, wherein the binder polymer is soluble in one or more of organic alcohols, alkanes, alkenes, alkynes aldehydes, ketones, or cyclic hydrocarbons (benzene, toluene, xylene), chloroform, dichloromethane, dimethylformamide (DMF), or N- Methyl-2-pyrrolidone (NMP).

5. The material of any one of claims 1 to 4, wherein the binder polymer is degradable by an acid.

6. The material of claim 5, wherein the acid is an acid or an acid precursor and comprises SO2, H2S, NO, NO2, HC1, H2SO4, H3PO4, HNO3, acetic acid, or a combination of two or more thereof.

7. The material of any one of claims 1 to 6, wherein the acid reactive salt comprises LiCOs, LiHCO.3, RbCCh, RbHCO3, CsCO3, CsHCO3, K2CO3, KHCO3, Na2CO3, NaOH, Ca(OH)2, NaHCOs, CaO, MgO, BeO, SrO, BaO, or a combination of two or more thereof, optionally wherein the acid reactive salt comprises K2CO3.

8. The material of any one of claims 1 to 7, wherein the acid reactive salt is present as salt aggregates, optionally wherein the salt aggregates have a particle size of 2 nm or smaller.

9. The material of any one of claims 1 to 8, wherein the material comprises 1 wt-% to 95 wt-% reactive salt relative to combined weight of the binder polymer and the acid reactive salt.

10. The material of any one of claims 1 to 9, wherein the material comprises support particles dispersed throughout the binder polymer that are non-reactive to acids or wherein acids do not break down the support particles.

11. The material of any one of claims 1 to 10, wherein the material forms a coating on a substrate or wherein the material defines a bulk material of a molded article, a cast article, an extruded article, or an injection molded article.

12. The material of any one of claims 1 to 11, wherein a breakthrough curve of a reactive acid through the material exhibits a decrease in breakthrough of the reactive acid over time.

13. An article comprising the material of any one of claims 1 to 12.

14. A method of making the material of any one of claims 1 to 12, the method comprising: dissolving the binder polymer in a first solvent to form a first solution; dispersing the acid reactive salt in the first solution to form a mixture, wherein the acid reactive salt is not soluble in the first solvent, and removing at least some of the first solvent from the mixture to form the material.

15. The method of claim 14, comprising dissolving the acid reactive salt in a second solvent to form a second solution, and dispersing a plurality of support particles in the second solvent, to form impregnated support particles comprising the plurality of support particles impregnated with the acid reactive salt, wherein the dispersing the acid reactive salt in the first solution comprises dispersing the impregnated support particles in the first solution.

16. The method of claim 15, further comprising removing at least some of the second solvent from the second solution prior to dispersing the impregnated support particles in the first solution.

17. The method of claim 15 or 16, wherein the acid reactive salt forms salt aggregates in pores of the support particles, optionally wherein the salt aggregates have a particle size of 2 nm or smaller.

18. A method of sequestering an acid with the material of any of claims 1 to 12, the method comprising exposing at least a portion of the material to the acid, thereby causing at least a portion of the acid to react with the binder polymer, the acid reactive salt, or both.

19. The method of claim 18, wherein a breakthrough curve of the acid through the material exhibits a decrease in contaminant breakthrough concentration of the acid over time.

20. The method of claim 18 or 19, wherein the acid is gaseous or liquid.

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