Encapsulated Activated Carbon for Odor Absorption

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Solution Overview

Problem

Existing methods for incorporating activated carbon into polymer products during melt processing reduce the porosity and odor-absorbing capability of activated carbon, making it unsuitable for applications requiring quick odor absorption.

Innovation Solution

Encapsulating activated carbon particles with a non-water soluble amorphous polymer, such as polystyrene, during melt processing to preserve their structure and odor-absorbing properties, while forming a polymer substrate that can be used in various applications like bags and films.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If activated carbon is blended with molten polymer during melt processing, then the polymer substrate can be formed, but the porosity of activated carbon is reduced due to polymer molecule penetration, worsening the odor absorbing capability

Engineering Contradiction:

Improvemelt processing capabilityVSAvoidodor absorbing capability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The activated carbon particles are encapsulated within a polymer shell, creating a nested structure where the carbon is protected inside the polymer coating. This prevents direct contact between the polymer matrix and carbon surface, maintaining porosity while enabling melt processing.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

A polymer coating acts as an intermediary layer between the activated carbon particles and the bulk polymer matrix. This intermediate layer prevents direct penetration of polymer molecules into the carbon pores while still allowing the composite to be processed as a melt.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If conventional wet processing methods are used to coat activated carbon, then the carbon can be protected, but additional washing steps are required, increasing labor and hygiene concerns

Engineering Contradiction:

Improvestructure protectionVSAvoidprocessing steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The wet processing method (chemical/coating approach) is replaced with a mechanical melt processing approach. The polymer coating is applied through mixing and extrusion in the melt state, eliminating the need for subsequent washing steps required by wet methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The processing utilizes phase transitions of the polymer material - heating to melt phase for mixing and coating application, then cooling to solid phase for product formation. This phase-based approach eliminates the need for solvent-based wet processing and washing steps.

Inventive Principle:

Principle #36Phase transitions

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 encapsulation method effectively maintains and enhances the odor-absorbing capability of activated carbon, allowing for efficient odor reduction in applications like trash bags and storage solutions without the need for additional washing steps or increased hygiene concerns.

Implementation Method 1

Encapsulating activated carbon particles with a non-water soluble amorphous polymer, such as polystyrene, during melt processing to preserve their structure and odor-absorbing properties

Methodology Applied

Scientific EffectEncapsulation:

Implementation Method 2

Activated carbon is known for odor absorption due to its highly porous nature and has been used in a variety of other industries for years for various odor control applications

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS8927078B2Encapsulated activated carbon and the preparation thereof

Publication Date: 2015.01.06 JPMORGAN CHASE BANK N A AS SUCCESSOR ADMINISTRATIVE AGENT & COLLATERAL AGENT

AI summary

The present invention relates to encapsulated activated carbon and a method of preparing the same to protect the structure of the activated carbon and preserve the odor absorbing capability of the activated carbon particles. Particularly, the present invention is directed to a polymer article having odor absorption capabilities comprising a film comprising a matrix polymer and activated carbon particles at least partially encapsulated with a non-water soluble amorphous polymer, wherein the non-water soluble amorphous polymer is incompatible with the matrix polymer. The polymer article can be a bag.