Zeolitic Adsorbent Article With Resin Immobilization
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Solution Overview
Problem
Existing adsorbent articles have low zeolite content, slow adsorption and desorption kinetics, and are prone to particle attrition, which limits their effectiveness in applications requiring high volumetric efficiency and rapid gas or liquid separation, such as Pressure Swing Adsorption (PSA) and Temperature Swing Adsorption (TSA).
Innovation Solution
An adsorbent article with high zeolite content (>60 wt%) is created by agglomerating zeolitic particles with an inorganic binder like natural clays and immobilizing them with a thermoplastic resin, ensuring mechanical integrity and reduced attrition, while maintaining high diffusion kinetics and volumetric efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If zeolite powder is dispersed within resin before injection or molding, then the adsorbent article can be manufactured with immobilized particles, but the zeolite content is relatively low (25-55 wt%) and adsorption kinetics are very slow
Solution Approach 1:
The patent changes the particle size parameter by using pre-formed zeolitic particles (0.1-2mm) instead of powder, and optimizes the resin content parameter (5-20 wt%) to balance particle immobilization with adsorption kinetics. This resolves the contradiction by maintaining particle stability while improving adsorption speed.
Solution Approach 2:
The patent creates a composite material system combining zeolitic particles with specific resin matrices, where the composite structure allows high zeolite content (60-95 wt%) while maintaining mechanical integrity and fast kinetics, overcoming the limitations of simple powder-resin mixtures.
2Productivity
If holes are created inside the composite material to distribute fluid, then contact surface between fluid and material is increased, but the material has low density and low volumetric capacity
Solution Approach 1:
The patent applies local quality by creating a heterogeneous structure where fluid distribution channels coexist with high-density zeolite regions. The article has localized porosity for fluid access while maintaining overall high volumetric capacity through optimized particle packing and resin distribution.
3Stress or pressure
If sorbent particles are bound onto a substrate with adhesive, then pressure drop is reduced, but the article is difficult to produce and there are risks of peeling off or detachment
Solution Approach 1:
The patent extracts the substrate component from the traditional sorbent-substrate structure, using only the adhesive-resin binder to form self-supporting articles. This eliminates the peeling risk associated with substrate-bound sorbents while maintaining low pressure drop through optimized particle arrangement and resin selection.
4Ease of manufacture
If adsorbent particles are not immobilized in the article, then fluid distribution is simple, but attrition between particles readily occurs
Solution Approach 1:
The patent applies partial immobilization by using sufficient resin content (5-20 wt%) to bind particles together without completely encasing them. This partial action maintains structural simplicity and fluid access while providing adequate attrition resistance for practical applications.
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 solution provides excellent adsorption and desorption kinetics, high volumetric efficiency, and reduced particle attrition, making it suitable for applications like gas and liquid separation, drying, and purification processes.
Implementation Method 1
said particles being bonded together with an organic resin(s), such as polymers, particularly thermoplastic polymers
Implementation Method 2
The said adsorbent has a high zeolite content, is able to ensure a rapid diffusion of fluids
Data Source
Figure 1~1bis
Figure 2~3
Figure 4~5
AI summary
The present invention relates to an adsorbent article with reduced attrition due to immobility of its components, said article comprising zeolitic particles of at least one zeolitic adsorbent, said particles being immobilized with at least one resin, wherein the average particle size of the at least one zeolitic adsorbent ranges from 0.03 mm to 3 mm, and wherein the zeolite content is equal to or greater than 60 wt%. The invention also relates to a method for separating a fluid from one or more other fluid(s) and/or separating a fluid from impurities contained in said fluid, comprising the step of contacting said fluid with at least one of said adsorbent article. Lastly, the invention relates to a blend of zeolitic particles and at least one resin, wherein the resin is preferably in the form of particles.