Adsorbent Body Manufacturing via Binder Extraction

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for forming adsorbent bodies, such as metal-organic frameworks (MOFs) and covalent-organic frameworks (COFs), often collapse internal pores due to high pressures, leading to reduced sorbent capacity, and the use of binders either reduces performance or mechanical robustness, making it difficult to achieve high density, high surface area, and attrition resistance simultaneously.

Innovation Solution

A process involving a solvated adsorbent mixture with a polymeric organic binder, followed by solvent exchange to remove a significant portion of the binder, and solvent-drying to form an adsorbent body with controlled porosity, maintaining mechanical robustness and sorption capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of stationary object

If high pressure is applied to form adsorbent bodies, then density is improved, but internal pores collapse and sorbent capacity is reduced

Engineering Contradiction:

ImprovedensityVSAvoidsorbent capacity

Core Design Contradiction:

Volume of stationary objectVSReliability

Solution Approach 1:

A binder material is introduced as an intermediary substance that enables the formation of green compacts at lower pressures. The binder acts as a mechanical bridge between adsorbent particles, allowing body formation without excessive pressure that would collapse internal pores, thus preserving sorbent capacity while achieving adequate density

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The processing parameters are changed by introducing a binder system that allows formation at reduced pressures. This parameter change enables the trade-off between density and pore integrity to be resolved, as the binder provides structural support without requiring the high pressures that would collapse pores

Inventive Principle:

Principle #35Parameter changes

2Strength

If binder material is used to improve mechanical robustness, then attrition resistance is improved, but pore blockage occurs and performance is reduced

Engineering Contradiction:

Improvemechanical robustnessVSAvoidsorbent performance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The binder is applied locally to specific regions where mechanical strength is needed, rather than uniformly throughout the entire adsorbent body. This localized application provides attrition resistance at particle contacts while minimizing binder presence in the internal pore structure, thereby preserving sorbent performance

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

A controlled partial amount of binder is used - enough to provide mechanical robustness and attrition resistance, but not so much as to block pores. This partial action approach optimizes the balance between structural integrity and functional performance

Inventive Principle:

Principle #16Partial or excessive action

3Volume of stationary object

If high density is achieved through processing, then volume efficiency is improved, but internal pore collapse occurs

Engineering Contradiction:

Improvevolume efficiencyVSAvoidinternal pore structure

Core Design Contradiction:

Volume of stationary objectVSStability of the object's composition

Solution Approach 1:

The binder serves as an intermediary that enables compacting at lower pressures, achieving high density without collapsing internal pores. The binder particles fill interstices and provide a scaffold that maintains pore structure integrity during compression

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The process results in adsorbent bodies with enhanced micro and meso-porosity, high density, and improved mechanical robustness, suitable for gas storage systems, particularly in vehicular fuel tanks, while minimizing macroporosity and binder blockage.

Implementation Method 1

the polymeric organic binder is adsorbed onto the surface of the adsorbent material

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

the first solvent is distributed throughout the solvated adsorbent mixture

Methodology Applied

Scientific EffectSolvation: Solvation

Implementation Method 3

from 20wt% to 80wt% of the polymeric organic binder (initially present in the initial adsorbent body) is removed from the initial adsorbent body and is dissolved into the second solvent

Methodology Applied

Scientific EffectDissolution: Solvation

Implementation Method 4

solvent-drying the reduced-binder adsorbent body to form the adsorbent body

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentEP4433205B1A process of making an adsorbent body

Publication Date: 2026.04.15 CAMBRIDGE ENTERPRISE LTD

AI summary

The present invention relates to a process of making an adsorbent body, wherein the process comprises the steps of: (a) contacting adsorbent material with an initial mixture to form a solvated adsorbent mixture in a first solvent; (b) removing the first solvent and removing at least some of the first solvent from the solvated adsorbent mixture in the first solvent to form an initial adsorbent body; (c) contacting the initial adsorbent body with a second solvent to form a reduced-binder adsorbent body in a second solvent; and (d) solvent-drying the reduced-binder adsorbent body to form the adsorbent body. The invention further provides an adsorbent body, and the use of said adsorbent body in gas storage.