U.S. patent application number 11/175986 was filed with the patent office on 2006-12-28 for composite materials for fluid treatment.
Invention is credited to Kenneth D. Hughes.
Application Number | 20060289349 11/175986 |
Document ID | / |
Family ID | 32771325 |
Filed Date | 2006-12-28 |
United States Patent
Application |
20060289349 |
Kind Code |
A1 |
Hughes; Kenneth D. |
December 28, 2006 |
Composite materials for fluid treatment
Abstract
This invention relates generally to composite materials and to
devices which may alter fluid parameters. Devices incorporating the
composite materials of the invention are used to deliver, remove,
and generate, fluid treatment agents, and combinations thereof.
These materials and devices are applicable to many different fluid
processing situations including drinking water treatment,
wastewater treatment, emission treatment, pollution cleanup, and
sensing fluid composition. In its more particular aspects, the
invention relates to the field of composites that may be widely
tailored for many different treatment applications.
Inventors: |
Hughes; Kenneth D.;
(Alpharetta, GA) |
Correspondence
Address: |
SUTHERLAND ASBILL & BRENNAN LLP
999 PEACHTREE STREET, N.E.
ATLANTA
GA
30309
US
|
Family ID: |
32771325 |
Appl. No.: |
11/175986 |
Filed: |
July 6, 2005 |
Related U.S. Patent Documents
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Application
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Filing Date |
Patent Number |
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10359032 |
Feb 5, 2003 |
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11175986 |
Jul 6, 2005 |
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Current U.S.
Class: |
210/500.1 ;
55/486; 73/23.2; 73/53.01; 96/417 |
Current CPC
Class: |
B01D 53/02 20130101;
B01J 20/0292 20130101; C02F 2303/02 20130101; B01J 20/18 20130101;
B01J 20/06 20130101; B01J 20/12 20130101; B01J 20/261 20130101;
B01D 53/84 20130101; B01J 2220/46 20130101; C02F 1/76 20130101;
B01J 20/16 20130101; C02F 1/003 20130101; C02F 2305/04 20130101;
B01J 20/043 20130101; B01J 20/0233 20130101; B01J 20/0281 20130101;
A61L 2/0082 20130101; B01J 20/0248 20130101; C02F 1/28 20130101;
Y02A 50/2358 20180101; B01D 61/147 20130101; B01D 69/02 20130101;
B01D 2311/04 20130101; B01J 20/0237 20130101; C02F 1/52 20130101;
B01J 20/045 20130101; B01J 20/048 20130101; B01J 20/0211 20130101;
C02F 2305/14 20130101; B01D 53/94 20130101; B01J 20/0229 20130101;
A23L 27/74 20160801; A61L 12/08 20130101; B01J 20/02 20130101; B01J
20/0218 20130101; B01J 20/262 20130101; B01J 20/0277 20130101; B01J
20/28042 20130101; B01J 20/20 20130101; B01J 2220/44 20130101; C02F
1/50 20130101; C02F 1/70 20130101; B01D 35/02 20130101; B01J 20/103
20130101; C02F 1/66 20130101; B01D 53/1493 20130101; B01D 53/86
20130101; A61L 2/16 20130101; C02F 1/78 20130101; C02F 1/766
20130101; Y02A 50/20 20180101; B01J 20/24 20130101; C02F 1/288
20130101; C02F 1/72 20130101; A23L 2/39 20130101; B01J 20/0222
20130101; B01D 61/145 20130101; B01D 69/141 20130101; B01J 20/0244
20130101; B01D 61/16 20130101; B01D 2311/04 20130101; B01D 2311/12
20130101; B01D 2311/04 20130101; B01D 2311/2688 20130101 |
Class at
Publication: |
210/500.1 ;
096/417; 055/486; 073/023.2; 073/053.01 |
International
Class: |
B01D 24/00 20060101
B01D024/00 |
Claims
1-61. (canceled)
62. The composite material of claim 57, wherein the material
removes a gas containing elements selected from the following
group, oxygen, nitrogen, sulfur, and carbon.
63. The composite material of claim 62, wherein the material
removes an acid gas.
64. The composite material of claim 62, wherein the material
removes an organism incapacitating gas.
65-68. (canceled)
69. The composite material of claim 26 wherein the material
generates a gas when exposed to situations selected from the
following group, exposure to chemical agents, exposure to
biological agents, exposure to radiation, exposure to temperature
changes, or a combination thereof.
70. The composite material of 69 wherein the material generates a
gas selected from the following group, oxidizers, components of
breathing air, anesthetics, incapacitants, fuel sources, or
combinations thereof.
71. The composite material of 70 wherein the material generates a
gas selected from the following group, halogens, oxygen, chlorine
dioxide, carbon dioxide, nitrogen, hydrogen, and combinations
thereof.
72. The composite material of claim 26 comprising a plurality of
composite materials that, when placed in contact with a common
fluid, generate a gas, liquid, solid, or combination thereof.
73-84. (canceled)
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to composite materials and
to devices that may alter fluid parameters. Devices incorporating
the composite materials of the invention are used to deliver,
remove, and generate fluid treatment agents (naturally occurring
and synthetic chemical and biological agents), and combinations
thereof. These materials and devices are applicable to many
different fluid treatment situations including those targeting
drinking water, process fluids, fuels and emission, beverage
production, cleaning operations, and sensing fluid composition. In
its more particular aspects, the invention relates to the field of
multifunctional composite materials that may be tailored for many
different fluid treatment applications.
[0003] 2. Description of Related Art
Common Fluid Treatment Art
[0004] The treatment of fluids involves the removal of dissolved or
suspended contaminants, the modification of fundamental parameters
such as pH, dissolved gases, dissolved solids content, and
temperature, and the incorporation of chemical and biological
agents. Standard fluid treatment practice directed at these goals
involves the use of many different treatment agents, devices, and
techniques. Treatment agents are commonly applied in all three
states, gas, liquid, and solid. The nature of the contaminant that
must be removed or agent that must be added and the allowable cost
of the operation controls the choice of treatment, agent, device,
and methods used. Fluids are treated for a wide range of
applications including breathing, cleaning, ingestion, cooling, and
direct participation in industrial chemical and biological
processes.
Delivery of Fluid Treatment Chemicals
[0005] Fluid treatment agents are added to fluids to remove
contaminants, chemically convert contaminants, and to modify fluid
parameters including pH and the composition of dissolved
components. For example, chlorine containing compounds are useful
for disinfecting fluids and the containers and conduits used to
manage the fluids.
[0006] Depending upon the scale of the application, the technical
experience of personnel conducting the treatment process, and the
allowable costs, either solid, liquid, or gaseous forms of chlorine
are used. Additional fluid treatment examples include the dosing of
flocculating agents to remove small particulate matter suspended in
a fluid and the injection of carbon dioxide for beverages
production.
[0007] Delivery of solid, liquid or gaseous fluid treatment agents
to fluids is complicated and requires significant technical
experience to complete safely and efficiently. Injection and dosing
systems require the combination and optimization of well
characterized solutions of treatment agents, pumps, piping or
tubing, flow control devices including valves, and often a power
source. Typically, the equipment costs and technical skill required
to install, operate, and maintain injection and dosing equipment
limits the number of suitable application sites. Additionally,
incorrect setting of equipment often damages or substantially
decreases the lifetime of equipment positioned downstream of the
dosing operation.
[0008] Furthermore, many dosing and injection operations utilize
reservoirs containing concentrated forms of the treatment agents.
These reservoirs may pose safety hazards to both personnel who
operate the equipment or those in the vicinity and to equipment
that contacts these agents. Spills, splashing, and leaks often
require specialized cleanup agents, procedures, and often a
distinct team of specially trained personnel. As a result, all
fluid dosing and injection systems require constant supervision in
order to effectively maintain operations.
Chemical Generation and Delivery
[0009] Several important fluid treatment agents may not be stored
effectively and must be generated at the location of treatment.
Examples include, the on-site generation of chlorine dioxide and
ozone. Both are valuable oxidizing agents that may disinfect,
breakdown organic compounds, and react with dissolved inorganic
compounds. Flocculating agents based on hydroxide precipitates
including those containing aluminum and iron are also commonly
generated on site to maximize their particulate removal
efficiencies. Safety is also a consideration. Transport of reaction
precursors in pressurized and concentrated forms is typically
hazardous and a significant drawback to the technology.
Chemical and Biological Agent Collection, Sampling, and
Detection
[0010] There are certain fluid contaminants that pose a hazard at
extremely low concentrations. Examples include biological agents,
nerve agents, and heavy metals. Since many of these contaminants
accumulate in the body and fluid treatment components over time it
is important to employ detection methods that are sensitive to very
low concentrations of these agents. Commonly some type of
contaminant concentrating technique is used to retain and
accumulate the agent to facilitate qualitative as well as
quantitative analysis. Both solid phase adsorption and liquid based
extraction techniques are used for removing contaminants from the
fluid and concentrating. Analysis of the concentrated
contaminant(s) may involve stripping the contaminant from the
concentrating medium, analyzing the collection media directly, or
combinations thereof.
Application Space
[0011] A wide range of industrial processes and consumer activities
involve the use of fluids. In all cases fluids must be tailored for
the specific application. These fluids are either prepared and
packaged for direct use or equipment and products are fabricated
that modify the fluid for its desired purpose at the point of use.
Beverage products prepared for ingestion require fluids to be
initially purified and then formulated with agents to impart
flavor, color, or nutritional benefit. Examples include
commercially available ready-to-drink beverages as well as tap
water that is treated before entering a complex distribution
system. Similar situations exist for pharmaceutical and medical
solution preparation.
[0012] Many companies produce products that treat gases and liquids
at the point of use or the point of entry into an industrial
facility, a residence, or the environment. Common examples include
breathing air and drinking water. Treatment products for these
fluids vary tremendously in function, scale, and cost. In recent
years, the desire for air filtration in the home has become more
popular as a need has been demonstrated. Products with increasing
sophistication are now available, addressing the concerns of both
energy efficiency and indoor air quality. Many breathing air and
drinking water applications share contaminant types and removal
requirements.
[0013] Consumers use many types of household chemicals to modify
fluids for cleaning in and around the household. Consumers also use
many types of solutions for maintaining health and appearance
including solutions specialized for eye care, lens care, dental
care, and oral care. Additionally, leisure water activities
including the use of pools and spas require fluid treatment on a
continual basis.
[0014] Many industries must treat influent and effluent fluids in
bulk. In general, both air and water emissions from industry must
be of a higher quality than the original source. These include
those that treat drinking water, prepare food and beverages,
generate power, control equipment temperature, process chemical and
biological agents including fermentation processing and petroleum
component separation. Pharmaceutical and medicinal solutions of
gases and liquids require both purification and active agent
incorporation. Similarly, the removal of contaminants from
breathable air in hospitals and clean rooms, where ultrapurified
air is required, and in environments where air is recirculated,
such as aircraft, spacecraft, individual protective suits, small
group protective structures, and automobiles, is also an important
application for fluid treatment.
[0015] New materials and devices that may improve the function and
capacity of standard treatment operations as well as increase the
safety and cost effectiveness are highly desired.
SUMMARY OF THE INVENTION
[0016] To this end, novel composite materials and methods for
fabricating these composite materials have been discovered. These
materials and devices containing these materials incorporate the
beneficial aspects of both solid and liquid fluid treatment agents.
The method and process of the invention facilitates the generation
of a wide range of composite materials and devices including those
which may be used for, removing dissolved and suspended
contaminants, chemically reacting with dissolved or suspended
contaminants, delivering chemical and biological agents, generating
dissolved agents for further application, generating solids,
liquids, and gases for a broad range of applications. Likewise, the
materials and devices of the invention facilitate concentrating,
storing, detecting, and degrading contaminants that are present in
gases, liquids, and aerosols, at very low concentrations.
[0017] The composite materials and devices of the invention may be
used in a manner that directs or controls fluid flow and composite
material contact. Specifically, by controlling the composition of
the material, fluid may be directed through the material, across
the surface of the material, or a combination thereof. Manipulating
flow rates allows contact time between fluid and composite to be
controlled, and the selectivity of treatment application.
[0018] Composite materials and devices of the invention may be
generated in widely varying shapes and sizes, and with functions
that may be infinitely tailored and tuned for specific
applications. The invention is scale independent as it may be
utilized in very large as well as very small applications. The
materials and devices of the invention may contain a broad range of
fluid treatment agents for treating gases, liquids, and aerosols.
Likewise, these materials and devices may contain a broad range of
fluid additives commonly delivered into fluids for industrial and
consumer application.
[0019] The composite materials and methods of producing materials
and devices of the invention, incorporate solid materials that have
both fluid absorbing and fluid expanding characteristics. These
materials may be used independently or combined with materials that
do not expand when exposed to fluids. Composite materials may be
generated by combining fluid expanding solids and single
composition liquids, by combining fluid expanding solids and liquid
mixtures, by combining fluid expanding solids and liquids with
dissolved or suspended agents, by combining fluid expanding solids
and liquid mixtures which, when exposed to solids, liquids, or
gases, generate insoluble agents, by combining fluid expanding
solids and liquid mixtures which are then exposed to solids,
liquids, or gases generate liquids or gases, by combining fluid
expanding solids and liquid mixtures that generate soluble agents,
insoluble agents, and combinations thereof, when exposed to
radiation or thermal energy. The composite materials may carry
chemical and biological agents in the fluid used to expand the
solid, on the materials surface, or a combination thereof.
Composite materials may be further tailored by incorporating
material that does not expand substantially in the presence of
fluid. These non-expanding materials may serve multiple functions
in the composite including spacing, pore generation, fluid storage
and fluid treatment.
[0020] The materials and processes of the invention may be used to
prepare a wide range of devices with significant consumer,
industrial, space, humanitarian, and defense application. In
preferred applications the composite materials are fabricated in
the form of blocks, tubes, sheets, fibers, films, or as isolated
particles and are used to, modify the properties of fluids through
agent removal, conversion, addition, or a combination thereof, and
sensing of fluid composition. The materials and methods of the
invention provide a means of combining many standard fluid
treatment operations, processes, and materials into a single
composite material. In many cases, the efficiency, safety, and
economics of the treatment process are improved. The materials and
methods of the invention allow greater device design flexibility
that ultimately allows devices of new shapes and sizes to be
applied in new locations as well as to better fit into current
application space. Equally important is the manufacturing
flexibility that the materials and methods of the invention enable.
Materials and devices may be fabricated and assembled by hand or
adapted to high throughput equipment. The cost associated with
materials and manufacturing may be adapted to many manufacturing
environments and situations. Additionally, devices may be prepared
on the go, in the field, and in many cases serviced in a similar
manner.
[0021] As indicated above, many types of solid-liquid combinations
may be generated with the materials and method of the invention.
These materials and devices incorporating these materials are
immediately useful in a broad range of fluid treatment
applications. The materials and methods of the invention greatly
simplify the removal and delivery of chemical and biological agents
associated with fluids. Further the materials and methods of the
invention provide the capacity to simultaneously employ both solids
and liquids in the treatment of fluids. Furthermore, the devices
and methods of the invention improve the safety, and reduce the
complexity of many fluid treatment agent dosing and injection
operations. The solids incorporated into the composite materials of
the invention may be used for absorption, adsorption, chemical
reaction, dissolution, and a combination thereof. The liquids
incorporated into the composite materials of the invention may be
used for absorption, adsorption, chemical reaction, dissolution and
a combination thereof. The combination of solids and liquids
provides a platform for tailoring treatment materials where the
solids and liquids function synergistically.
[0022] A wide range of contaminants may be treated with the
materials and methods of the invention. These include naturally
occurring and synthetic organic and inorganic agents, in both
dissolved and particulate states, microorganisms in active and
dormant states, and combinations thereof.
[0023] Agents that may be delivered to fluids include naturally
occurring and synthetic organic and inorganic agents in dissolved
and particulate states, microorganisms in active and dormant
states, and combinations thereof.
[0024] The applications for the materials and devices of the
invention may be roughly separated into two groups for description
purposes but in no manner limits the applications and fields where
the materials and devices of the invention are useful. In many
cases, similar materials and devices of the invention may be
applied directly in both gas phase and liquid phase
applications.
[0025] The first group is the treatment of liquids including those
associated with drinking water, waste water, beverage production,
pharmaceutical and semiconductor processing, chemical processing,
biotechnology product processing, process streams that use
catalysts, cleaning solution preparation, eye and lens care, dental
and oral care, and toxin concentration, detection, and
degradation.
[0026] The second group is the treatment of gases including those
associated with breathing air, residential air, industrial
emissions, energy production, enclosed recirculated air systems,
process streams that use catalysts, and toxin concentration and
detection.
[0027] In typical embodiments, the invention relates to a composite
material for fluid treatment that consists of a fluid expandable
material such as a natural or synthetic polymer or clay that
carries a fluid with a composition that is typically different than
the fluid undergoing treatment. The fluid contained by the
expandable material and therefore the composite material may or may
not be removed from the composite material in the fluid treatment
operation.
[0028] Typical embodiments may also include composite materials
that are generated from a mixture of fluid expanding and fluid
nonexpanding materials. The nonexpanding materials provide a
dilution function, may affect porosity, and may also provide an
extension of the composite material's fluid treatment function.
Additionally, synergistic combinations and complex multistage
treatment functions are possible. Non-expanding solid materials
include carbon, activated carbons, natural and synthetic minerals,
textiles, ion-exchange materials, resins, metals, catalysts,
synthetic and natural molecules and polymers, and a wide range of
materials typically used in fluid treatment.
[0029] Typical embodiments may also include composite materials
that contain fluid soluble chemical and biological agents that
provide a fluid treatment function. Specifically, these agents are
used to remove contaminants or modify the composition of the fluid
contacting the material. The soluble agent may be included in the
composite in a dissolved or solid form.
[0030] Typical embodiments may also include composite materials
that contain fluid insoluble or slightly soluble chemical and
biological agents that provide a fluid treatment function.
Specifically, these agents are used to remove contaminants or
modify the composition of the fluid contacting the material.
[0031] Typical embodiments may also include a support structure for
the composite materials. The supports are porous in defined
locations and designs and prepared from rigid, semi-rigid, or
flexible materials and combinations thereof. These supports may be
prepared from synthetic as well as natural materials.
[0032] Typical embodiments may also include a housing for the
composite materials and associated support structures, if any, as
well as a passive or active system or mechanism for directing fluid
into contact with the composite materials. Examples would include
deflectors, foils, pumps, blowers, and cyclones. These may also be
combined with electric charging devices and precipitating
devices.
[0033] Typical embodiments may also include situations where the
agents contained by the composite material of the invention react
through exposure and contact with other agents in solid, liquid, or
gaseous form and generate additional solid, liquid, or gaseous
fluid treatment agents. The combination of these agents and
materials and the devices that control their contact are
representative of devices of the invention.
[0034] Typical embodiments may also include situations where the
chemical or biological agents removed from a contaminated fluid are
accumulated (concentrated) over time for the purpose of fluid
purification and contaminant identification and quantitation. The
materials and devices of the invention are ideally suited for
direct or indirect chemical and genetic analysis, non-destructive
and destructive spectroscopic analysis, as well as other types of
chemical analysis. Materials and devices of the invention
facilitate analysis in the laboratory as well as in the field with
a range of electronic and radiation based sensing methods.
[0035] Typical embodiments may also include situations where the
composite material serves as a tunable conduit between the fluid to
be treated and a reservoir. The reservoir may contain fluid
treatment agents for delivery to the fluid requiring treatment, or
it may serve as a collector for transfer of agents from the fluid
requiring treatment, or combinations thereof.
[0036] Typical embodiments for composite form may also include,
blocks, sheets, webs, membrane, fibers, and individual particles or
fibers that may be moved through a fluid in continuous or
semi-continuous fashion. Translation methods may include
mechanical, magnetic, and electric field manipulation, the use of
gravity, or combinations thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1A is a cross-sectional view illustrating a particular
embodiment of the invention, namely a porous support (two-sides)
containing composite material comprising fluid expandable material,
expanded with a fluid treatment agent and combined with an optional
fluid non-expanding material. An appropriate housing is positioned
in a cross-flow filtration geometry that connects a conduit
containing the fluid to be treated and a conduit or container that
collects and transfers treated fluid.
[0038] FIG. 1B is a cross-sectional view illustrating a particular
embodiment of the invention, namely a porous support (two-sides)
containing composite material comprising fluid expandable material,
expanded with a fluid treatment agent and combined with an optional
nonexpanding material. An appropriate housing is positioned in a
flow through geometry.
[0039] FIG. 1C is a cross-sectional view illustrating a particular
embodiment of the invention, namely a porous support (two-sides)
containing composite material comprising fluid expandable material,
expanded with a fluid treatment agent and combined with an optional
fluid nonexpanding material. An appropriate housing is positioned
in a cross-flow filtration geometry or a flow-through geometry and
connected to a reservoir that contains a fluid treatment agent.
[0040] FIG. 1D is a cross-sectional view illustrating a particular
embodiment of the invention, namely a porous support (two sides)
containing composite material comprising fluid expandable material,
expanded with a fluid treatment agent and combined with an optional
nonexpanding material. An appropriate housing is positioned in a
geometry that may control fluid flow based on porosity and changing
porosity of the composite material.
[0041] FIGS. 2A and 2B are cross-sectional views illustrating
particular embodiments of the invention, namely a porous support
(cartridge) containing composite material comprising fluid
expandable material, expanded with a fluid treatment agent and
combined with an optional nonexpanding material. The cartridge
containing the composite material contains a central bore that
allows radial flow through the material of the invention and out of
the cartridge housing. FIG. 2B includes an extension of the central
bore outside of the composite material. By adjusting the length of
this extended central bore fluid composite material contact may be
controlled. Choice of cartridge housing porosity may also be used
in conjunction with central bore location to fine tune fluid
treatment parameters. The cartridge housing is contained in a
larger vessel that connects to tanks and conduits that direct fluid
flow in and out of the vessel.
[0042] FIGS. 3A and 3B are cross-sectional views illustrating
particular embodiments of the invention, namely a porous support
(two-sides) containing composite material comprising fluid
expandable material, expanded with a fluid treatment agent and
combined with an optional nonexpanding material and presented in a
planar format that is typical of air filters. The planar format is
a flow through design that allows many different thicknesses to be
used. FIG. 3b extends the embodiment to include the wrapping of
planar sheets containing the materials of the invention around a
central bore. This geometry allows cross-flow as well as flow
through in a radial geometry.
[0043] FIGS. 4A and 4B are cross-sectional views illustrating
particular embodiments of the invention, namely a porous drop zone
(four sides), a reservoir containing composite material comprising
fluid expandable material, expanded with a fluid treatment agent,
and including a collection basin. In this embodiment expanded
composite particles move through the drop zone by the force of
gravity. While moving through the zone the particles collect
contaminants that are analyzed in the collection basin or are
removed and analyzed. FIG. 4A presents the embodiment in a
rectangular format while 4B presents the embodiment in a
cylindrical format. In both orientations the dropped particles may
also be guided using fibers, meshes, or screens. This embodiment is
easily extended to fibers and sheets that are pulled manipulated
the fluid contact zone.
[0044] FIGS. 5A is a cross-sectional view illustrating a particular
embodiment of the invention, namely a porous housing (bag)
containing composite material comprising fluid expandable material,
expanded with a fluid treatment agent and combined with an optional
nonexpanding material and presented in "tea-bag" format that is
commonly available for consumer-use in preparing beverages and
introducing fragrances into the air. In this format beverages may
be prepared based on the contents of the composite material. In
some cases this embodiment includes the treatment of fluid
contaminants present in the fluid used to prepare the beverage.
[0045] FIGS. 5B is a cross-sectional view illustrating a particular
embodiment of the invention, namely loose composite materials
(fibers, particles) comprising fluid expandable material, expanded
with a fluid treatment agent and combined with an optional
nonexpanding material and presented in "loose-coffee-maker" format
that is commonly available for consumer-use in preparing beverages.
In this format beverages may be prepared based on the contents of
the composite material. In some cases this embodiment includes the
treatment of fluid contaminants present in the fluid used to
prepare the beverage.
DETAILED DESCRIPTION OF THE INVENTION
[0046] As indicated above in the Summary, in its general
embodiments the invention relates to composite materials and
devices incorporating the composite materials that combine fluids
and fluid expandable materials. General embodiments also include
the mixture of fluid expandable and non-fluid expandable materials
into composites. Devices based on these general embodiments may be
fabricated by adding the fluid expanding and optionally
non-expanding materials to porous containers or supports and
subsequently to housings that provide fluid contact. These porous
containers may take the form of canisters, coatings, membranes, and
sheets and may be combined, wrapped, or prepared in a wide range of
geometric structures. Devices may be produced in any shape or size
and may be rigid or flexible. The materials of the invention may be
utilized in direct contact with membrane materials including those
incorporating hollow fibers.
[0047] Fluid flow through or across the composite material may be
tuned by the selection of components, size of the granular or
fibrous fluid expanding and optional nonexpanding components and
the porous structural support, if necessary for the application. As
used herein, the term "composite material" does not denote any
particular geometrical shape. Nonlimiting examples of "composite
materials" as this term is intended to be used include tubes and
annular rings, as well as more conventional geometrical solids.
Material formed into flexible composite materials is particularly
suitable for use in pipes or tubes that serve as the fluid filter
medium and in combination with membrane systems including hollow
fiber systems.
[0048] One of the desirable features of composite materials
generated with the invention is that devices may be formed into any
desired shape. This provides ease of handling and extremely high
scalability. For example, a composite material may be formed into a
monolith or wrapped sheet that fits into conventional fluid
treatment housings. It may be shaped to provide fluid treatment as
part of a portable or personal system or shaped to provide emission
treatment for large industrial sites. The material may be formed
into several different pieces, through which fluid flows in series
or in parallel. Sheets or membranes of the composite purification
material may also be formed. The rigidity of the purification
material and subsequent devices, whether in block form or in
sheet/membrane form, may be altered through inclusion of flexible
support structures that contain the expanding and optional
non-expanding material.
[0049] The expanding material may be in the form of particles
ranging in size from 0.05 microns through 100 millimeters, fibers
with diameters of 0.05 microns through 100 millimeters, or
combinations thereof. The optional non-expanding material may have
similar sizes.
[0050] Preferred and applicable expanding fluid treatment matter
includes material that expands as a result of absorption of fluids
(either gases or liquids) and may be generated from a range of
synthetic and natural materials. These materials include synthetic
and natural polymers, as well as certain natural and synthetic
clays.
[0051] The class of materials known as "superabsorbents" is
particularly suitable in this regard. Superabsorbents are natural,
synthetic, or mixed polymers that are not fully cross-linked. They
may be classified as polyelectrolyte or nonpolyelectrolyte types as
well covalent, ionic, or physical gelling materials. These
materials have the capacity to absorb many times their own volume
in fluid. Examples of synthetic materials include polyacrylic
acids, polyacrylamides, poly-alcohols, polyamines, and polyethylene
oxides. The composite superabsorbent material may also be selected
from derivatives of polyacrylic acids, polyacrylamides,
poly-alcohols, polyamines, polyethylene oxides, cellulose, chitins,
gelatins, starch, polyvinyl alcohols and polyacrylic acid,
polyacrylonitrile, carboxymethyl cellulose, alginic acids,
carrageenans isolated from seaweeds, polysaccharides, pectins,
xanthans, poly-(diallyldimethylammonium chloride),
poly-vinylpyridine, poly-vinylbenzyltrimethylammonium salts,
polyvinylacetates, polylactic acids, or combinations thereof. The
composite material may also comprises a material selected from
resins obtained by polymerizing derivatives of acrylic acid or
resins obtained by polymerizing derivatives of acrylamide.
[0052] Biodegradable materials that are suitable include cellulose
derivatives, chitins, and gelatins. Additionally mixtures of
synthetic polymer and natural polymers either as distinct chains or
in copolymers may be used to generate these absorbent materials.
Examples include starch polyacrylic acid, polyvinyl alcohols and
polyacrylic acid, starch and polyacrylonitrile, carboxymethyl
cellulose, alginic acids carrageenans isolated from seaweeds,
polysaccharides, pectins, xanthans, poly(diallyldimethylammonium
chloride), polyvinylpyridine, polyvinylbenzyltrimethylammonium
salts, cellulose, alginic acids, carrageenans isolated from
seaweeds, polysaccharides, pectins, xanthans, starch, or
combinations thereof, polyethyleneglycol, a polylactic acid, a
polyvinylalcohol, a co-polylactideglycolide, cellulose, alginic
acids, carrageenans isolated from seaweeds, polysaccharides,
pectins, xanthans, and starch.
[0053] As those experienced in the art will understand the process
of crosslinking polymer chains derived from either any source or
combinations of sources, are variable and will affect the magnitude
of fluid absorption, and the types of fluids that may be
absorbed.
[0054] Additionally those experienced in the art will understand
that molecular characteristics such as polymer chain composition,
functional group position and distribution as well as polymer
molecular weight and distribution will effect performance, and will
know how to modify these parameters to vary the properties of the
resulting composite consistent with the basic tenets of the
invention. Further those experienced in the art will understand the
expansion or final volume capacity of a material is also subject to
the type and composition of the fluid in which the material is
exposed.
[0055] Inorganic sources of expanding particles include
aluminosilicates, smectic or montmorillinite clays, and a preferred
clay, bentonite.
[0056] Preferred and applicable optional non-expanding materials
include naturally occurring, synthetic, and recycled materials.
Suitable optional non-expanding materials include insoluble
phosphate containing minerals selected from calcium phosphates,
iron phosphates, manganese phosphates, aluminum phosphates,
magnesium phosphates, magnesium phosphates, silver phosphates,
copper phosphates, zinc phosphates, zirconium phosphates, calcium
monophosphates, diphosphates, tricalicum phosphates, octaphosphate,
metaphosphates, metal oxides selected such as aluminum oxides, iron
oxides, magnesium oxides, calcium oxides, manganese oxides, zinc
oxides, copper oxides, titanium oxides, silicon oxides, aluminum
containing minerals such as, alumina bauxite, kaoline, iron
containing minerals such as iron oxide amorphous hydrous ferric
oxide, maghemite, hematite, goethite, lepidocrocite, manganese
containing minerals such as, manganese oxide, pyrolusite, silica
containing minerals including, silica, quartz, metals such as iron,
copper, manganese, silver, gold, platinum, rhodium, zinc, alloys
prepared from iron, copper, zinc, carbon, chromium, manganese,
nickel, carbonates such as calcium carbonate, magnesium carbonate,
iron carbonate, aluminum carbonate, sulfates including magnesium
sulfate, and calcium sulfate, hydroxides such as aluminum
hydroxide, iron hydroxide, magnesium hydroxide, calcium hydroxide,
and copper hydroxide. Synthetic and natural fibers, including
strings, yarns and textiles including, cotton, wool, polypropylene,
rayon, polyester, nylon, acrylic are also applicable. Ion exchange
material is a preferred material and includes resins selected from
functionalized styrenes, vinylchlorides, divinyl benzenes,
methacrylates, acrylates, or mixtures, copolymers, and blends
thereof. Natural and synthetic zeolites such as clinoptilolite and
glauconate are preferred.
[0057] Catalytic materials generated from these components are
quite common and these are applicable in all known forms. Those
experienced in the art will recognize that the deposition of
molecules containing active sites that include metals and atoms and
nanocomposites of metals and semimetals on the surface of support
materials are immediately applicable.
[0058] Fast and slowly dissolving as well as time release materials
are also available in particulate and fiber form and these are
applicable as non-expanding materials. Preferred materials include
those that impart flavor, sweetness, medicinal benefits and dietary
benefits. Furthermore nutrients such as nitrogen, potassium, and
phosphorus containing materials are preferred. Many of these
materials have been designed into slow dissolving and time released
formats. Those experienced in the art will recognize the ease of
applying these materials in the current invention.
[0059] Those experienced in the art will also understand that both
the expanding materials and the optional non-expanding materials
may be surface modified with a range of compounds and different
binding methods. Examples of preferred surface modification
chemicals include chemical agents selected from
3-acryloxypropylotrichlorosilane,
3-acrlyoxypropylotrimethocysilane, Allyltrichlorosilane,
allyltrimethoxysilane, allyltriethoxysilane,
3-bromopropylotrichlorosilane, 3-bromopropyltrimethoxysilane,
(p-chloromethyl)phenyltrichlorosilane),
(p-chloromethyl)phenyltrimethoxysilane,1-trimethoxysilyl-2-2(p,m-chlorome-
thyl)-phenylethane, chloromethyltrichlorosilane,
chloromethyltriethoxysilane, 2-chloroethyltriethoxysilane,
3-chloropropyltrichlorosilane, 3-chloropropyl-trimethoxysilane,
3-glycidoxypropyltrimethoxysilane, 3-iodopropyl trimethoxysilane,
3-isocyanatopropyltriethoxysilane, 2-(diphenylphosphino)
ethyltriethoxysilane, vinyltriacetoxysilane,vinyltrichlorosilane,
vinyltriethoxysilane, vinyltrimethoxysilane,
3-mercaptopropyltrimethoxysilane, 3-mercaptopropyltriethoxysilane,
N-(triethoxysilylpropyl) urea, 3-aminopropyltriethoxysilane,
3-aminopropyltrimethoxy silane,
N-(2-aminoethyl)-3-aminopropyltrimethoxysilane, 2-(carbomethoxy)
ethyltrichlorosilane, N-[(3-trimethoxysilyl)propyl]ethylenediamine
triacetic acid, trisodium salt, 3-cyanopropyltrichlorosilane,
3-cyanopropyltriethoxysilane,
2-(4-chlorosulfonylphenyl)ethyltrichlorosilane,
2-(4-chlorosulfonylphenyl) ethyltrimethoxysilane,
2-(trimethoxysilyl) ethyl-2-pyridine,
N-(3-trimethoxysilylpropyl)pyrrole,
N-octadecyldimethyl-1(3-trimethoxysilyl) propyl]ammoniumchloride,
N-trimethoxysilylpropyl-n,n,n-trimethyl ammoniym chloride,
3-(trimethoxysilyl)propyldimethyloctadecylammonium chloride silane
quaternary amine, chloropropyl trihydroxy silane, polyamines,
polyamides, polyalcohols, polysaacharides, polyacrylamides,
polyacrylates, humic acids, peptides, proteins,
polorganozirconates, p-olyorganoaluminates, polysiloxanes,
polysilanes, polysilazanes, polycarbosilanes, polyborosilanes,
zirconium dimethacrulate, zirconium tetramethacrylate, zirconium
2-ethylhexanoate, aluminum butoxides, aluminum diisopropoxide
ethylacetoacetate, tetramethyldisiloxanes and derivatives thereof,
tristrimethylsilylphosphate and tristrimethylsiloxyboron,
polyamines such as poly(DADMAC), poly-DADM, polyamine-poly(DADMAC)
blends, polyquartenary amines, inorganic-polyamine blends, and
inorganic poly(DADMAC) blends, cationic starch, cationic
poly-methylmethacrylates, copolymers of vinylimidazolium
methochloride and vinylpyrrolidone, quarternized
vinylpyrrolidone/dimethyl-aminoethyl-methacrylate copolymer,
polyethyleneimine, or combinations thereof.
[0060] Additionally, surface binding methods that provide the
capacity of immobilizing genetic material, proteins, peptides,
antibodies, and pharmaceutical agents are preferred means of
modifying the surfaces of both the expanding and non-expanding
materials. Those experienced in the art will recognize that
numerous procedures exist for generating stable surface coatings of
these materials. Furthermore the ability to immobilize genetic
information as well as proteins and peptides facilitates the use of
the materials of the invention in sensing and sensor
development.
[0061] The materials and methods of the invention are unique in the
capacity to expand with a range of different fluids that are useful
for fluid treatment. Expandable materials may be expanded with
synthetic and natural fluids, inorganic, organic, and combinations
of both, such as acids, bases, oxidizing agents, reducing agents,
precipitating agents, polymerization agents, flocculating agents,
surfactants, salts, halogens, peroxides, persulfates, carbonates,
amines, polyamines, quaternary amines, medicinal agents, eye care
agents, lens care agents, dental care agents, oral care agents,
pharmaceutical agents, nutraceuticals, dietary supplements, alcohol
or mixture of alcohols, fragrances, odor neutralizing agents, odor
masking agents, disinfecting agents, preservatives, biocides,
bacteriostats, fungistats, osmostic regulators, sequestering
agents, chelating agents, and binders pesticides, insecticides,
herbicides, phermones, and animal attractants, cleaning solutions,
fatty acids, soaps, and sweetening agents.
[0062] Additionally, appropriate combinations of the listed agents
with solvent combinations, and sequestering agents facilitates the
expanding of the expandable material with an extremely wide range
of solution types and ratios. Fluids used to expand the materials
of the invention may be delivered to the fluid that is to be
treated or retained. Those experienced in the art will recognize
the compatibility issues between fluid types and dissolved species
carried by the fluids. Further, those experienced in the art will
recognize that the nature and identity of the expandable material
will vary in the presence of these fluid types and the dissolved
species carried by the fluids. Furthermore, those experienced in
the art will recognize that the properties of the expandable
materials will be modified as the concentrations of fluids and
dissolved species they contain vary throughout the course of fluid
treatment. Furthermore, those experienced in the art will recognize
that physical parameters including temperature and irradiation will
effect the materials of this invention.
[0063] The materials and methods of the invention are further
unique in the capacity to generate fluid treatment compounds from
soluble precursors associated with the fluid expanding material,
optional nonexpanding materials, or combinations of both. By
expanding the fluid expandable material with solutions containing
soluble chemical species and subsequently exposing the material to
appropriate agents and physical processes, insoluble or reduced
solubility materials may be formed. This method of material
fabrication allows many materials to be generated in a form that
maintains certain aspects of their function. Examples of preferred
materials that may be formed in this manner include insoluble
minerals such as phosphates, sulfates, sulfides, carbonates,
chlorides, bromides, iodides, fluorides, oxides, hydroxides,
silicates, cyanides, thiocyanates, arsenates, oxalates, chromates,
manganates, reduced metals, and combinations thereof. Further,
organic and biological reactions may be used to generate useful
fluid treatment agents in and associated with the expandable fluid
materials and optional nonexpanding materials. Furthermore,
electrochemical, photochemical, and thermally induced reactions may
be conducted in the materials of the invention which allows the
fabrication of unique materials. Examples include the synthesis of
polymers and the reduction of metals.
[0064] The materials and methods of the invention are further
unique in the capacity to generate agents such as gases and liquids
containing reactive agents by contacting the fluid expanded
materials with gas, liquid, and solid agents of combinations
thereof. This capacity allows safe and controlled reactions to
occur. Agents that may be generated with these materials include
gases, and liquids and fluids that contain the products of these
reactions. Preferred reactions include those that generate gases
for disinfection, cleaning, energy production, breathing, and
controlling atmospheric components. Likewise preferred applications
where liquids and dissolved agents are utilized include medicinal,
dental, cleaning, disinfection, and power generation.
[0065] The porosity of the composite materials of the invention may
be tuned through the choice of expandable and non-expandable
materials, fluids, and dissolved or suspended materials. The
porosity of the materials may be tailored to allow complete absence
of flow through the material through complete passage. Those
experienced in the art will understand the contact time, bypass,
and backpressure parameters that are associated with these flow
dynamics.
[0066] The composite materials of the invention are widely
applicable to many industries, fluid treatment situations, and for
the development of products that serve the needs of consumers,
healthcare, industry, and defense related operations. The material
of this invention requires no expensive instrumentation or
equipment, or significant expertise to fabricate. Expanding and
optional non-expanding materials may be mixed, homogenously or
heterogeneously in any ratio and composition and may simply be
added to a supporting structure of sufficient size and strength to
contain the composite. This facilitates the production of many
different sizes, shapes, and designs.
[0067] The composite materials of the invention allow contaminants
to be removed from a fluid, converted to less toxic forms as well
as collected and concentrated for further analysis. Materials and
devices of the invention are also well suited for the delivery of
agents to fluids. The latter capacity allows the materials to be
used in fluid treatment for the preparation of beverages, cleaning
solutions, eye care solutions, lens care solutions, dental
solutions, oral cavity treatment solutions, and agents for further
reaction.
[0068] The invention has numerous advantages compared to former
means of completing many of these fluid treatment tasks. These
include the elimination of electrical equipment such as pumps and
technical know-how required to correctly dose agents into fluids in
a stable and consistent fashion. When the fluid to be used in
dosing applications is hazardous incorporation into the expandable
materials increases the safety of handling the agent, eliminating
the possibility of spills and leaks, and facilitating
neutralization and cleanup if a need existed. When solutions are
prepared in correct ratios and used to expand the materials of the
invention they may be used as concentrates for the production of
beverages, or cleaning solutions for fluids, surfaces, chemical
toxins, teeth, dental structures, and contact lenses, as well as
treatment solutions for eyes, skin, hair and other body parts, with
reduced concentrations. Accurate composite material preparation
allows accurate solutions to be prepared in a safer and more
controlled manner. Additionally, the materials of the invention may
be used for sensing and detecting microorganisms in fluid streams.
The materials of the invention may also be used for connecting a
reservoir to a system for fluid treatment. The fluid expandable
material provides a barrier between the fluid requiring treatment
and a reservoir that contains a fluid treatment agent. The
properties of the composite material control the rate of agent
transport between the reservoir and the fluid. The reservoir may
contain solid, liquid or gaseous agents. The materials of the
invention may also be used to increase the safety of chemical
reactions that produce fluid treatment agents such as disinfection
gases, by allowing two solid materials (one true solid and one
fluid expandable carrier) to be combined instead of a hazardous
liquid and a solid.
[0069] Those familiar with the art of fluid filtration will
understand that the pore size and physical dimensions of the
composite purification material may be manipulated for different
applications and that variations in these variables will alter flow
rates, back-pressure, and the magnitude of chemical and/or
microbiological contaminant removal or delivery. Likewise those
knowledgeable in the art will recognize that variations in the
percentages of each component of the composite purification
material will provide variable utility. For example, increasing the
percentage of expanding matter in the composite purification
material will result in a material having an increased pressure
drop and lower flow, while decreasing the percentage of expanding
matter will result in a composite purification material having flow
rate and pressure drop properties closer to that of granular
materials.
[0070] In one particular embodiment of the invention, the composite
material is formulated to remove contaminants from a gas. Gas phase
contaminants may include acid gases formed during combustion
processes, dry particulate matter, and aerosols. Many excellent
materials and devices may be generated by the materials and methods
of the invention. As example, a suitable treatment material may be
generated by expanding polyacrylic acid particles with an agent
such as an aqueous solution of sodium hydroxide or another
hydroxide containing agent, and placing the material in a porous
polyethylene container. A suitable example is provided in FIG. 4A.
When acid gases such as hydrogen chloride, carbon dioxide, nitrogen
oxides, sulfur oxides, and hydrogen cyanide contact the composite
media the gases are neutralized and the neutralization products
dissolved in the liquid matrix of the composite material. Likewise
aerosols of aqueous solutions when contacting the composite media
are absorbed into the matrix of the composite material as long as
the capacity of the individual particles has not been reached.
Particulate matter depending upon size is adsorbed on the surface
of the composite material, incorporated into the liquid matrix of
the composite material, or combinations thereof. Particulate
material is also mechanically removed by interaction with the
support structure for the composite material which can be
constructed from membrane materials. Sensing an monitoring of
hydroxide concentration in the composite can be completed by a
number of different methods including colorimetric indicators, and
electrochemical sensors.
[0071] In another particular embodiment of the invention, the
composite material detailed in the previous embodiment is used is
used to remove dissolved and particulate contaminants and modify
the pH of water to be used for drinking. Drinking water
contaminants include dissolved metals and suspended particulate
matter. Acidic pH water is corrosive to plumbing systems. When the
contaminated low pH water is exposed to the composite media
dissolved metal ions such as iron form insoluble hydroxides that
may be mechanically removed from the fluid. Additionally these
materials adsorb other dissolved contaminants including dissolved
metals and organics. Suspended particulate matter is adsorbed on
the surface of the composite materials and mechanically removed
from the fluid by both the support (container) and the pore size of
the composite material. Finally, as the acid water contacts the
composite material the water is neutralized, raising the pH to
acceptable levels. Sensing an monitoring of hydroxide concentration
in the composite can be completed by a number of different methods
including colorimetric indicators, and electrochemical sensors.
[0072] In another particular embodiment of the invention, the
composite material detailed in the previous embodiment is used is
used to remove dissolved and particulate contaminants and modify
the pH of water to be used for drinking, but is also connected to a
reservoir. This reservoir contains a concentrated form of sodium
hydroxide. An example of the device is provided in FIG. 1C.
Drinking water contaminants include dissolved metals and suspended
particulate matter. Acidic pH water is also corrosive to plumbing
systems. When the contaminated water is exposed to the composite
media dissolved metal ions such as iron form insoluble hydroxides
that may be mechanically removed from the fluid. Additionally these
materials adsorb other dissolved contaminants including dissolved
metals and organics. Suspended particulate matter is not removed
from the fluid stream, by the composite media, in this embodiment.
Finally, as the acid water contact the composite material the water
is neutralized, raising the pH to acceptable levels. The reservoir
in this embodiment may be prepared using solid or liquid sodium
hydroxide, or other hydroxide generating mechanism, including those
based on electrochemical and electrode incorporation. The
properties of the fluid being treated, the total area of the
composite material as well as other physical and chemical
parameters control the movement of treatment agent to the fluid. In
this embodiment, there may also be removal of contaminants from the
fluid undergoing treatment to the reservoir. This depends upon the
nature of the fluid, contaminant, and method of the invention.
[0073] In another particular embodiment of the invention, the
composite material is prepared with a beverage concentrate for the
production of a beverage. An aqueous solution containing a high
concentration of sweetening agents, natural and artificial
flavorings, phosphoric acid, and coloring agents is used to expand
polyacrylic acid particles. When these composite materials are
exposed to water, in devices as depicted in FIGS. 5A and 5B, the
concentrated beverage agents contained in the composite are
released, generating a beverage. In this embodiment, containment of
the composite material is provided by a porous sheet (FIG. 5A) and
by a porous mesh screen (FIG. 5B). In this embodiment, dissolved
and suspended contaminants may also be removed by interacting with
the composite material as well as the support system provided for
containing and/or isolating the composite material. As example,
water hardness ions and dissolved metal species may adsorb to the
surface of the polyacrylic acid and to the support system for the
device used to contain the composite material. This embodiment may
also be extended by incorporating a reservoir with the beverage
concentrate. Likewise, this embodiment demonstrates the ability to
deliver other agents including, bacteriostatic and disinfection
agents, medicinal agents, cleaning agents, eye care solutions, lens
cleaning solutions, dental care and oral care solutions, solutions
for neutralizing chemical toxins, and health and dietary
agents.
[0074] In another particular embodiment of the invention, a
composite material is formed by generating insoluble fluid
treatment compounds using soluble precursors contained by the
expandable matter. Many different insoluble fluid treatment
compounds may be generated through the method of this invention. As
a specific example, a water soluble sodium phosphate compound may
be used to expand polyacrylic-polyacrylamide particles. When these
particles are exposed to an aqueous solution of calcium chloride,
calcium phosphate is generated. The composite material may be used
directly for fluid treatment. An additional example includes the
expanding of the same polymer particles with an aqueous solution of
aluminum sulfate. When these particles are exposed to solutions
with elevated pH, aluminum hydroxides are formed and the material
may be directly used in fluid treatment.
[0075] In another particular embodiment of the invention, the
composite material may be used to generate agents for fluid
treatment such as gases. Many different gases are commonly injected
into fluids for different reasons. Carbon dioxide is injected for
beverage production, chlorine dioxide and chlorine are injected for
disinfection purposes, oxides of nitrogen are injected for
medicinal purposes, and oxygen and nitrogen ratios are varied for
respiratory purposes. Gases may also be generated for power
production and fuel cell operation. Gases are often generated by
the reaction of soluble chemicals, electrochemical reactions, or
through direct injection of the stored gas. In this embodiment
gases are generated either through chemical reaction between an
agent contained by the composite material and a second reagent in
solid, liquid, gaseous form or by contacting an electrode with the
composite media for the same purpose. Those experienced in the art
will understand that electrode function may affect the expansion
characteristics of the composite material. As example, a
polyacrylic acid may be expanded with an aqueous solution of
hydrogen chloride. Exposure of this materials to sodium bicarbonate
generates carbon dioxide. Those experienced in the art will
recognize that many different acids may be used for similar
purpose. In an additional example that illustrates this embodiment
an aqueous solution of ammonium chloride is used to expand
polyacrylic acid particles. Exposure of this material to solid
sodium hydroxide pellets, generates ammonia gas. This gas may be
used for cleaning operations as well as fuel cell operation. In
these examples the water and soluble reaction products generated
may also be contained by the composite material, avoiding the
leaking of liquids from the device used to conduct the fluid
treatment operation.
[0076] In another particular embodiment of the invention, a
composite material is fabricated which is used to prepare cleaning
solutions. Cleaning solutions often contain surfactants and acidic
or caustic agents that are irritating to the user. For many
applications these solutions are usually sold in concentrated form.
The mixing and subsequent use of the cleaning fluids may pose a
hazard even when prepared correctly. In this embodiment
concentrated cleaning solutions are used to expand
polyacrylic-polyacrylamide particles. When this composite material
is exposed to water in a device as depicted, in FIGS. 1A, 1B, 1C,
and 1D, a cleaning solution ready for direct use is generated.
These materials and devices may safely store and allow application
of the hazardous solutions. These devices allow incorporation into
mechanical systems such as sprayers.
[0077] In another embodiment of the invention, the composite
material is constructed to treat hydrocarbon fuels that are
contaminated with water and dissolved and suspended chemical and
biological agents. Composites may be prepared to remove the water
and associated contaminants and if needed simultaneously deliver
biocidial agents.
[0078] In another embodiment of the invention, the composite
material is constructed to withstand sterilization. Sterilization
processes include thermal processes, such as steam sterilization or
other processes wherein the composite purification material is
exposed to elevated temperatures or pressures or both, resistive
heating, radiation sterilization wherein the composite purification
material is exposed to elevated radiation levels, including
processes using ultraviolet, infrared, microwave, and ionizing
radiation, and chemical sterilization, wherein the composite
purification material is exposed to elevated levels of oxidants or
reductants or other chemical species, and which is performed with
chemicals such as halogens, reactive oxygen species, formaldehyde,
surfactants, metals and gases such as ethylene oxide, methyl
bromide, beta-propiolactone, and propylene oxide. Additionally,
sterilization may be accomplished with electrochemical methods by
direct oxidation or reduction with microbiological components or
indirectly through the electrochemical generation of oxidative or
reductive chemical species. Combinations of these processes are
also used on a routine basis. It should also be understood that
sterilization processes may be used on a continuous or sporadic
basis while the composite material is in use.
[0079] In another particular embodiment of the invention, a
composite material is fabricated for the sensing of microorganisms.
Here, polyacrylic acid polyacrylamide particles are expanded with a
nutrient media that supports growth of bacteria. When the composite
material is exposed to an aerosol containing bacteria the bacteria
are adsorbed to the particle surface. The nutrient solution
contained by the particle allows propagation of the organisms, as
well as sensing, identification, and quantitation of the biological
agents. Those experienced the art will recognize that indicator
agents may be used in the nutrient media or that the nutrient media
may be replaced with a detection media that allows many different
types of genetic screening to be completed. Those experienced in
the art will also recognize that the surface properties of the
composite material may be modified for specific selection of
different organisms as well as the stability of the interaction of
the organisms on the surface. Those experienced in the art will
also recognize that other particle types can simultaneously be
collected and that the use of electrical charging of particles
through a variety of mechanisms can enhance the collection
efficiency of devices incorporating the materials of the
invention.
[0080] In another particular embodiment of the invention, a
composite material is fabricated for the treatment of chemical
weapons such as nerve agents. Here, polyacrylic acid polyacrylamide
particles are expanded with a solution that collects, neutralizes,
and degrades chemical agents and toxins. When the composite
material is exposed to the chemical agent chemical reactions which
reduce the toxicity of the chemical agents occur. Many of these
reactions are exothermic and thus provide a basis for sensing and
monitoring the presence of the agents and their degradation.
Monitoring these interactions can yield devices which provide
information on chemical agent presence as well as providing an
indicator for device "end of life" or remaining functional
capacity.
[0081] In another particular embodiment of the invention, a
composite material is fabricated for the treatment of ground water
in subsurface locations. Here polyacrylic acid-polyacrylamide
particles are expanded with agents that react with contaminants in
a fluid plume. These particles may be mixed with minerals such as
apatites and with metals such as zero-valent-iron. The composite
material may also be linked to a reservoir that contains additional
agents for replenishing the composite material. The advantages to
the material and devices of this embodiment include the ability to
deliver chemical agents in a spatially controlled and timed
manner.
[0082] In general, the invention comprises a method and a means for
fabricating materials and devices for the treatment of fluid, and
more specifically for the removal and conversion of contaminants,
for the delivery of agents, and for sensing and detection purposes.
Fluids of particular interest and importance include drinking
water, beverage production, cleaning solution preparation, and
breathing air. Agent generation of particular interest includes
gases such as oxygen, chlorine dioxide, ammonia, and carbon
dioxide. Contaminants that need to be removed from drinking water
include, metals, microorganisms, pesticides, and the byproducts of
the disinfection process. Agents that need to be delivered to
beverages include flavorings, sweeteners, colorants, gases, and
nutritional and medicinal agents.
[0083] A typical specific embodiment of an apparatus containing the
composite material of the invention that incorporates a porous
composite material is now described. A removable housing is mated
with a cap, the cap having an inflow orifice and an outflow
orifice. A water or air supply conduit is joined to the inflow
orifice to deliver non-treated water or air into the device, and a
water or air discharge conduit is joined to the outflow orifice to
conduct treated water or air from the device. Water or air passes
into the housing and the pressure of the water or air flow forces
it through the porous composite material, that is formed in the
shape of hollow cylinder with an axial bore, the treated water or
air passing into the axial bore that connects to the outflow
orifice. It is to be understood that other configurations where
water or air is caused to pass through a porous composite material
(which may have different geometrical shapes and/or different flow
properties) are contemplated to be within the scope of the
invention. The composite material is formed by placing both
expanding and optional non-expanding media between two capped
porous supports of which the outer support limits the outer
diameter and the inner support is the central bore. Both supports
are chosen to have a pore size smaller than the particles used. In
this specific embodiment the pore size of the supports is less than
300 microns and the support composition is polyethylene.
[0084] Multiple embodiments where the composite purification
material of the invention is used in the form of a sheet, fiber,
film, web, or with independent particles moving through a fluid,
are envisioned. A composite material used in connection with normal
flow-through geometries has the fluid being treated by passage
through the sheet, fiber, film, web, particle or combinations
thereof. Alternatively a composite purification material may be
used in connection with crossflow filtration. Embodiments where the
particles are loosely held or introduced into a stream by
injection, dropping, or other physical mechanisms as well as
magnetic and electrical field control mechanisms are possible.
Collection of the injected particles allows identification of
contaminant level changes over periods of time. Likewise, movement
of long fibers allows temporal information to be obtained.
[0085] With reference to the drawings, the invention and a mode of
practicing it will now be described with regard to several
particular embodiments, which depict use of the composite materials
of the invention and devices incorporating materials of the
invention.
[0086] FIG. 1A illustrates a typical specific embodiment of a cross
flow fluid treatment apparatus containing the composite material of
the invention, which incorporates a porous block material that
allows limited passage of fluid through the composite material. A
removable housing 4 houses the composite material 3 and is situated
between fluid conduit 1 (inflow) and treated fluid conduit 6. Fluid
conduit 2 indicates outflow for fluid conduit 1.
[0087] FIG. 1B illustrates a typical specific embodiment of a fluid
treatment apparatus containing the composite material of the
invention, that incorporates a porous block material that allows
passage of fluid through the composite material. A removable
housing 4 houses the composite material 3 and is situated between
fluid conduit 1 (inflow) and treated fluid conduit 2.
[0088] FIG. 1C illustrates a typical specific embodiment of a
cross-flow or flow-through fluid treatment apparatus containing the
composite material of the invention, that incorporates a porous
block material that allows limited passage of fluid through the
composite material, and a reservoir. A removable housing 4 houses
the composite material 3 and is situated between fluid conduit 1
(inflow) and treated fluid conduit 6. Fluid conduit 2 indicates
outflow for fluid conduit 1. Removable housing 4 and composite
material 3 are connected to a reservoir 5.
[0089] FIG. 1D illustrates a typical specific embodiment of a fluid
treatment apparatus containing the composite material of the
invention, that incorporates a porous block material that allows
controlled passage of fluid through the composite material as well
as directing fluid flow. A removable housing 4 houses the composite
material 3 and is situated between fluid conduit 1 (inflow) and
treated fluid conduit 2. Two different fluid conduit 2s are
depicted, one where fluid is translated through the composite
material and one where fluid only has a limited surface interaction
with the composite material. Removable housing 4 and composite
material 3 could be connected to a reservoir as indicated in FIG.
1C, if desired.
[0090] FIG. 2A illustrates a typical specific embodiment of a fluid
treatment apparatus containing the composite material of the
invention, that incorporates a porous block material that allows
passage of fluid through the composite material. A removable
housing 4 houses the composite material 3 that has a central bore 7
for fluid 2 to exit (outflow). Fuid inflow 1 is through a cap on
container 9 that houses removal housing 4. This figure illustrates
a standard radial flow device.
[0091] FIG. 2B illustrates a typical specific embodiment of a fluid
treatment apparatus containing the composite material of the
invention, that incorporates a porous block material that allows
passage of fluid through the composite material. A removable
housing 4 houses the composite material 3 that has a central bore 7
for fluid 2 to exit (outflow). Fuid inflow 1 is through a cap on
container 9 that houses removal housing 4. This figure illustrates
a standard radial flow device. In this device the central bore 7
extends past the composite material housing 4 and reduces
interaction with fluid inflow 1, and is one method of increasing
flow and reducing contact with composite material 3.
[0092] FIG. 3A illustrates an embodiment where the composite
material of the invention is used in the form of a sheet or film.
Composite material 3 housing 4 is used to treat influent fluid 1.
Two effluent fluids 2 exist one that demonstrates a cross flow
design and one that demonstrates a flow through design.
[0093] FIG. 3B illustrates an embodiment where the composite
material of the invention is used in the form of a sheet or film
and wrapped around a central bore 7. Composite material 3 and
housing 4 is used to treat influent fluid 1. Two effluent fluids 2
exist one that demonstrates a cross flow design and one that
demonstrates a flow through design.
[0094] FIG. 4A illustrates a typical specific embodiment of a fluid
contaminant sensing apparatus (planar) containing the composite
material of the invention, which individual particles of the
material that pass through the fluid to be sensed. A housing 4
contains both a reservoir and a receptacle for composite material
particles 3. Fuid flow 1 interacts with particles falling in
housing 4. Particles 3 may be guided by a porous mesh (no shown for
clarity).
[0095] FIG. 4B illustrates a typical specific embodiment of a fluid
contaminant sensing apparatus (cylindrical) containing the
composite material of the invention, which individual particles of
the material that pass through the fluid to be sensed. A housing 4
contains both a reservoir and a-receptacle for composite material
particles 3. Fluid flow 1 interacts with particles falling in
housing 4. Particles 3 may be guided by a porous mesh (not shown
for clarity).
[0096] FIG. 5A illustrates a typical specific embodiment of a fluid
treatment apparatus containing the composite material of the
invention, which individual particles contained in a disposable
single use package. A housing 4 contains composite material
particles 3. When housing 4 and material 3 is placed in contact
with fluid 1 the contents of particles 3 are released into fluid 1.
This "tea-bag" example is illustrated with a string 10 for
positioning.
[0097] FIG. 5B illustrates a typical specific embodiment of a fluid
treatment apparatus containing the composite material of the
invention, which individual particles are placed loose into a
housing 4. Fluid 1 is placed in with particles 3 and plunger 11
that holds a porous material is used to confine particles 3 when
liquid is poured from housing 4. A housing 4 contains composite
material particles 3. When particulate material 3 is placed in
contact with fluid 1 the contents of particles 3 are released into
fluid 1. This "loose-coffee-maker" example is illustrated in a
common configuration.
[0098] The following examples exemplify the type of composite
materials that may be generated under the methods of the
invention.
EXAMPLES
Example 1
[0099] A beverage syrup containing phosphoric acid, coloring
agents, sweeteners, and flavoring agents, was absorbed in an
expandable polyacrylic acid particle. The syrup was then released
when exposed to water.
Example 2
[0100] An iodide solution was absorbed in an expandable polyacrylic
acid particle. A purple colored composite was generated. The color
was removed when a solution containing ascorbic acid was exposed to
the composite.
Example 3
[0101] The following acids were absorbed into an expandable
polyacrylic acid particle: hydrochloric, phosphoric, sulfuric,
hydrofluoric, citric, and boric. The composites were stable for
many days.
Example 4
[0102] The following bases were absorbed into an expandable
polyacrylic acid and polyacrylamide-polyacrylic acid particles:
sodium hydroxide, ammonium hydroxide, and potassium hydroxide. The
composites were stable for many days.
Example 5
[0103] The following salt solutions were absorbed into an
expandable polyacrylic acid and polyacrylamide-polyacrylic acid
particles: sodium chloride, sodium bicarbonate, silver nitrate, and
calcium chloride. The composites were stable for many days.
Example 6
[0104] Nanometer size particles of reduced silver were generated
with expandable polyacrylic acid and polyacrylamide-polyacrylic
acid particles using silver nitrate and irradiation. Composite
color was tunable based upon parameters used and included blues and
reds. When the composite material was exposed to tap water silver
chloride was formed. After a period of time silver ion was
generated.
Example 7
[0105] The following metal ion solutions were absorbed into an
expandable polyacrylic acid-polyacrylamide particle, copper, iron,
lanthanum, and aluminum. The composites could be dried and
re-expanded upon exposure to fluid.
Example 8
[0106] A mixed ionic flocculating solution was absorbed into an
expandable polyacrylic acid-polyacrylamide particle. The
flocculating agent was released upon exposure to fluid.
Example 9
[0107] A potassium permanganate solution was absorbed into an
expandable polyacrylic acid-polyacrylamide particle. Manganese
oxide(s) was formed in the process. Dried composite particles
expanded when exposed to fluid. When composite particles were
exposed to hydrogen peroxide, oxygen gas was generated.
Example 10
[0108] A hydrochloric acid solution was absorbed into an expandable
polyacrylic acid-polyacrylamide particle and when exposed to solid
sodium bicarbonate, carbon dioxide evolved.
Example 11
[0109] A hydrochloric acid solution was absorbed into an expandable
polyacrylic acid-polyacrylamide particle and when exposed to solid
sodium chlorite, chlorine dioxide evolved.
Example 12
[0110] A sodium thiosulfate solution was absorbed into an
expandable polyacrylic acid particle. When the composite was
exposed to a solution containing hypochlorous acid the acid was
neutralized.
Example 13
[0111] An alcoholic solution containing a mixture of vitamins was
absorbed into an expandable polyacrylic acid particle. The
composite was stable for many days.
Example 14
[0112] A concentrated solution of monoethanolamine was absorbed
into an expandable polyacrylic acid particle. The composite was
stable for many days.
Example 15
[0113] A concentrated solution of octenol, an insect attractant was
absorbed into an expandable polyacrylic acid particle. The
composite was stable for many days.
Example 16
[0114] A solution containing cyclodextrins and odor neutralizing
compounds was absorbed into an expandable polyacrylic acid
particle. The composite was stable for many days.
Example 17
[0115] A solution containing sodium bicarbonate absorbed into an
expandable polyacrylic acid particle, and when exposed to calcium
ion calcium carbonate formed.
Example 18
[0116] Tap water was absorbed into an expandable polyacrylic
acid-polyacrylamide particle and frozen. Upon warming, the
composite returned to a hydrated form.
Example 19
[0117] The following oxidizers were absorbed into an expandable
polyacrylic acid and polyacrylamide-polyacrylic acid particles:
hypochlorous acid, sodium monopersulfate, stabilized chlorine, and
hydrogen peroxide. The stability of the composite was determined by
oxidizer concentration and environmental parameters.
Example 20
[0118] A solution containing a dissolved aspirin tablet was
absorbed into an expandable polyacrylic acid particle. The
composite was stable for many days.
Example 21
[0119] A solution containing ethylenediaminetetraacetic acid (EDTA)
was absorbed into an expandable polyacrylic acid particle. The
composite was stable for many days.
Example 22
[0120] An eye care solution containing saline, boric acid, and
borate, as well as a disinfectant was absorbed into an expandable
polyacrylic acid particle. The composite was stable for many
days.
Example 23
[0121] A dental/oral care solution containing alcohol, flavoring,
coloring, and plaque treatment agent, was absorbed into an
expandable polyacrylic acid particle. The composite was stable for
many days.
Example 24
[0122] A biodegradable cleaning solution containing polyethylene
glycol,ethers, modified sulfonates, and coloring agents, was
absorbed in concentrated form into polyacrylic acid particles. The
composite was stable for many days.
[0123] As described above, the composite material and mixtures of
different composite materials of the invention are extremely useful
in the area of containing or storing chemical species for reaction
of or delivery into fluids. Composites when exposed to fluids may
release their contents under controlled situations, may generate
gases, may interact with radiation, may react with species in the
fluid stream and in many cases may be used in a reversible manner
or recharged for further use. The composites are useful in both gas
filtration and liquid purification, particularly in the area of
purifying breathable air and drinking water. Because of the high
efficiency and simplicity with which the composite materials of the
present invention may function the materials of the invention are
useful in many industries and consumer products, and appliances.
Specifically, the products may be used in drinking water
applications, passive air treatment application, forced air
applications, humidification and dehumidification systems, water
used for recreational purposes, such as water used in swimming
pools, hot tubs, and spas. The materials may be used in appliances
such as refrigerators, fluid coolers/chillers, water fountains, and
beverage dispensing systems. They may be used in cleaning systems
that use automatic washers, manual washers, high pressure sprayers,
and the like.
[0124] As the result of the ability of the material of the
invention to efficiently collect, immobilize, and provide a
platform for microorganism and other biological agents sensing, it
has numerous applications in both civilian and military defense
applications. Further, the material of the invention can house
reactive solutions which can collect, isolate, detect, neutralize,
and degrade chemical toxins.
[0125] The pharmaceutical and medical fields may use materials of
the invention to treat blood, surgical fluids, wounds, and provide
protective devices for both patient and attendant. The eye care,
lens care, dental care, and oral care fields may utilize the
materials of the invention The material may also be used in
hospital, industrial areas, or enclosed areas requiring highly
purified air having extremely low content of microorganisms, e.g.,
in intensive care wards, operating theaters, and clean rooms used
for the therapy of immunosuppressed patients, or in industrial
clean rooms used for manufacturing electronic and semiconductor
equipment.
[0126] The material of the invention has multiple uses in
fermentation applications and cell culture, where it may be used to
remove microorganisms from aqueous fluids, such as fermentation
broths or process fluids, allowing these fluids to be used more
efficiently and recycled, e.g., without cross-contamination of
microbial strains. In addition, because the material is so
efficient at removing microorganisms and at retaining them once
removed, it may be used as an immobilization medium for enzymatic
and other processing requiring the use of microorganisms. A seeding
solution containing the desired microorganisms is first forced
through the material of the invention, and then substrate
solutions, e.g., containing proteins or other materials serving as
enzymatic substrates, are passed through the seeded material. As
these substrate solutions pass through the material, the substrates
dissolved or suspended therein come into contact with the
immobilized microorganisms, and more importantly, with the enzymes
produced by those microorganisms, that may then catalyze reaction
of the substrate molecules. The reaction products may then be
eluted from the material by washing with another aqueous
solution.
[0127] The material of the invention has numerous other industrial
uses, e.g., treating water used in cooling systems. Cooling water
often passes through towers, ponds, or other process equipment
where contaminants may come into contact with the fluid.
[0128] Similarly, breathable air is often recycled in
transportation systems, either to reduce costs (as with commercial
airliners) or because a limited supply is available (as with
submarines and spacecraft). Efficient removal of contaminants
permits this air to be recycled more safely. In addition, the
material of the invention may be used to increase indoor air
quality in homes, buildings, enclosed areas, and protective
shelters, in conjunction with the air circulation and conditioning
systems already in use therein. The composite material of the
invention may also be used to purify other types of gases, such as
anesthetic gases used in surgery or dentistry (e.g., nitrous
oxide), gases used in the carbonated beverage industry (e.g.,
carbon dioxide), gases used to purge process equipment (e.g.,
nitrogen, carbon dioxide, argon), and/or to remove particles from
surfaces, etc.
[0129] The composite materials of the invention may be used to
generate catalytic devices based upon chemicals such as metals,
metal oxides, and biochemical agents such as enzymes. These devices
may be used to treat or remediate emission gases such as those
generated by the chemical, mining, power, and manufacturing
industries as well as those generated from consumer products such
as those powered with combustion engines. They may be used to
generate gases for specific applications such as oxygen for
respiration.
[0130] In each of these applications, the method of using the
material of the invention is relatively simple and should be
apparent to those of skill in the filtration art. The fluid to be
treated is simply conducted to one side of the composite material
of the invention, typically disposed in some form of housing, and
forced through the material as the result of a pressure drop across
the composite purification material, or conducted across the
surface. Treated fluid is then conducted away from the "exit" side
of the material and further processed or used.
[0131] The invention having been thus described by reference to
certain of its specific embodiments, it will be apparent to those
of skill in the art that many variations and modifications of these
embodiments may be made within the spirit of the invention, that
are intended to come within the scope of the appended claims and
equivalents thereto.
* * * * *