U.S. patent application number 16/619347 was filed with the patent office on 2020-05-07 for polymeric sorbents for aldehydes.
The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to Michael W. Kobe, Michael S. Wendland.
Application Number | 20200139345 16/619347 |
Document ID | / |
Family ID | 62904532 |
Filed Date | 2020-05-07 |
![](/patent/app/20200139345/US20200139345A1-20200507-C00001.png)
![](/patent/app/20200139345/US20200139345A1-20200507-C00002.png)
![](/patent/app/20200139345/US20200139345A1-20200507-C00003.png)
![](/patent/app/20200139345/US20200139345A1-20200507-C00004.png)
![](/patent/app/20200139345/US20200139345A1-20200507-C00005.png)
![](/patent/app/20200139345/US20200139345A1-20200507-C00006.png)
![](/patent/app/20200139345/US20200139345A1-20200507-C00007.png)
United States Patent
Application |
20200139345 |
Kind Code |
A1 |
Wendland; Michael S. ; et
al. |
May 7, 2020 |
POLYMERIC SORBENTS FOR ALDEHYDES
Abstract
Polymeric sorbents for aldehydes including formaldehyde are
provided. More particularly, the polymeric sorbents are a reaction
product of a hydrolyzed divinylbenzene/maleic anhydride polymeric
material having carboxylic acid groups with a nitrogen-containing
compound having at least two primary amino groups and/or secondary
amino groups. The nitrogen-containing compound is ionically
attached to the hydrolyzed divinylbenzene/maleic anhydride within
the polymeric sorbent and has at least one primary amino and/or
secondary amino group available for reacting with an aldehyde.
Additionally, methods of making the polymeric sorbents, methods of
sorbing aldehydes (i.e., aldehydes that are volatile under use
conditions) on the polymeric sorbents, compositions resulting from
the sorption of aldehydes on the polymeric sorbents, composite
granules containing the polymeric sorbents, methods of making the
composite granules, and methods of sorbing aldehydes on the
composite granules are provided.
Inventors: |
Wendland; Michael S.; (North
St. Paul, MN) ; Kobe; Michael W.; (Lake Elmo,
MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
St. Paul |
MN |
US |
|
|
Family ID: |
62904532 |
Appl. No.: |
16/619347 |
Filed: |
June 13, 2018 |
PCT Filed: |
June 13, 2018 |
PCT NO: |
PCT/IB2018/054312 |
371 Date: |
December 4, 2019 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62520792 |
Jun 16, 2017 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01D 53/02 20130101;
B01D 2253/202 20130101; B01J 20/3042 20130101; B01J 20/264
20130101; B01D 2257/70 20130101; B01J 20/28069 20130101; B01J
20/265 20130101 |
International
Class: |
B01J 20/26 20060101
B01J020/26; B01J 20/30 20060101 B01J020/30; B01D 53/02 20060101
B01D053/02 |
Claims
1-15. (canceled)
16. A composition comprising: (a) a polymeric sorbent comprising a
reaction product of a hydrolyzed divinylbenzene/maleic anhydride
polymeric material having carboxylic acid groups; and a
nitrogen-containing compound having at least two amino groups of
formula --NHR wherein R is hydrogen or alkyl and wherein the
nitrogen-containing compound is attached to the hydrolyzed
divinylbenzene/maleic anhydride polymeric material with an ionic
bond; and (b) an aldehyde sorbed on the polymeric sorbent, the
aldehyde being of Formula (I) R.sub.2-(CO)--H (I) wherein R.sub.2
is hydrogen, alkyl, vinyl, or aryl and wherein the molecular weight
of the aldehyde of Formula (I) is no greater than 200
grams/mole.
17. The composition of claim 16, wherein the hydrolyzed
divinylbenzene/maleic anhydride polymeric material is a hydrolyzed
product of a divinylbenzene/maleic anhydride precursor material,
the divinylbenzene/maleic anhydride precursor material being formed
from a polymerizable composition comprising 1) 8 to 65 weight
percent maleic anhydride based on the total weight of monomers in
the polymerizable composition; 2) 30 to 85 weight percent
divinylbenzene based on the total weight of monomers in the
polymerizable composition; and 3) 0 to 40 weight percent of a
styrene-type monomer based on the total weight of monomers in the
polymerizable composition, wherein the styrene-type monomer is
styrene, an alkyl-substituted styrene, or a combination
thereof.
18. The composition of claim 16, wherein the polymerizable
composition comprises 15 to 65 weight percent maleic anhydride, 30
to 85 weight percent divinylbenzene, and 0 to 40 weight percent of
a styrene-type monomer.
19. The composition of claim 16, wherein the polymerizable
composition comprises 25 to 65 weight percent maleic anhydride, 30
to 75 weight percent divinylbenzene, and 1 to 20 weight percent
styrene-type monomer.
20. The composition of claim 16, wherein the nitrogen-containing
compound is of Formula (V) R.sub.4NHR.sub.1 (V) wherein R.sub.1 is
hydrogen or an alkyl; R.sub.4 is a group of formula
--R.sub.5-NHR.sub.6, or --(C=NH)--NH.sub.2; R.sub.5 is an alkylene,
(hetero)arylene, (hetero)aralkylene, heteroalkylene having one or
more oxy (--O--) groups, or heteroalkylene having one or more
--NH-groups, wherein the (hetero)arylene and (hetero)aralkylene are
optionally substituted with a primary amino group and/or a
secondary amino group; and R.sub.6 is hydrogen, alkyl, or
--(C=NH)--NH.sub.2.
21. The composition of claim 16, wherein the nitrogen-containing
compound is of Formula (VI) R.sub.7-(NHR.sub.1).sub.z (VI) wherein
R.sub.1 is hydrogen or alkyl; R.sub.7 is a z-valent radical of an
alkane or a z-valent radical of a heteroalkane; and z is an integer
in a range of 3 to 10.
22. The composition of claim 16, wherein the nitrogen-containing
compound has a molecular weight no greater than 2000 Daltons.
23. The composition of claim 16, wherein the polymeric sorbent
further comprises an acid-base dye.
24. The composition of claim 16, wherein the polymeric sorbent is
in a composite granule that comprises the polymeric sorbent and a
binder.
25. A method of sorbing an aldehyde on a polymeric sorbent, the
method comprising: providing a polymeric sorbent comprising a
reaction product of a) a hydrolyzed divinylbenzene/maleic anhydride
polymeric material having carboxylic acid groups; and b) a
nitrogen-containing compound having at least two amino groups of
formula --NHR wherein R is hydrogen or alkyl and wherein the
nitrogen-containing compound is attached to the hydrolyzed
divinylbenzene/maleic anhydride polymeric material with an ionic
bond; sorbing the aldehyde on the polymeric sorbent, the aldehyde
being of Formula (I) R.sub.2-(CO)--H (I) wherein R.sub.2 is
hydrogen, alkyl, vinyl, or aryl and wherein the molecular weight of
the aldehyde of Formula (I) is no greater than 200 grams/mole.
26. The method of claim 25, wherein R.sub.2 is hydrogen or
methyl.
27. The method of claim 25, wherein the polymeric sorbent sorbs an
amount of aldehyde in a range of 0.5 to 15 millimoles per gram
based on a weight of the polymeric sorbent.
28. The method of claim 25, wherein the polymeric sorbent comprises
an acid-base dye and wherein the acid-base dye changes color when
the aldehyde sorption capacity of the polymeric sorbent is reached
or is close to being reached.
29. The method of claim 25, wherein the polymeric sorbent is in a
composite granule that comprises the polymeric sorbent and a
binder.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 62/520792, filed Jun. 16, 2017, the
disclosure of which is incorporated by reference herein in its
entirety.
TECHNICAL FIELD
[0002] Polymeric sorbents for aldehydes, methods of sorbing
aldehydes on the polymeric sorbents, composite granules that
include the polymeric sorbent, and compositions resulting from the
sorption of aldehydes on the polymeric sorbents are provided.
BACKGROUND
[0003] Formaldehyde is a known carcinogen and allergen. For this
reason, the Occupational Safety and Health Administration (OSHA) in
the United States has set an eight-hour exposure limit of 0.75
parts per million and a 15-minute exposure limit of 2 parts per
million for formaldehyde vapor. Despite its toxicity, formaldehyde
is a high volume industrial compound. It is used, for example, to
prepare polymeric materials that find widespread use in various
building materials including foam insulation, particle board,
carpet, paint, and varnish. Out-gassing of residual formaldehyde
from these building materials makes formaldehyde one of the most
prevalent indoor air pollutants. Formaldehyde is also a by-product
of the combustion of organic materials. Thus, formaldehyde is a
common outdoor pollutant as well arising from automobile exhaust,
methane combustion, forest fires, and cigarette smoke.
[0004] While in North America strict formaldehyde out-gassing
limitations are placed on building materials, this is not the case
in all parts of the world. In some Asian countries, for example,
few restrictions are placed on building materials. Combined with an
increased use of biofuels to heat homes and to run automobiles,
dangerous levels of formaldehyde vapor may occur in both indoor and
outdoor air. For this reason, there is an immediate need for
solutions to mitigate human exposure to formaldehyde vapor both as
an indoor and an outdoor air pollutant.
[0005] The high volatility of formaldehyde (it is a gas at room
temperature) makes it extremely difficult to capture by the
mechanism of physisorption alone. However, because formaldehyde is
reactive, it can be more readily captured through chemisorption.
With chemisorption, the formaldehyde vapors are captured by
chemically reacting with the sorbent itself or with chemicals
impregnated in the sorbent. Thus, the key to making high capacity
sorbents for formaldehyde is to provide a sorbent with many
reactive sites for formaldehyde.
[0006] One typical sorbent material that has been used for
capturing formaldehyde is based on activated carbon scaffolds. The
scaffold of activated carbon, however, is relatively inactive and
this inactivity makes it difficult to incorporate a high density of
reactive groups into the activated carbon scaffold itself For this
reason, most of the efforts in making sorbents for formaldehyde
have been focused on finding impregnation chemistries that can
react with formaldehyde. Thus, the activated carbon scaffolds are
typically impregnated with various chemistries that react with
formaldehyde. The two most common impregnation chemistries used for
formaldehyde capture are the sodium salt of sulfamic acid and
ethylene urea co-impregnated with phosphoric acid. Various other
metal salts have also been used.
[0007] Impregnation in general has some drawbacks for making
sorbents. First, impregnation chemistries can migrate and this is
problematic especially if other sorbents are used in the same
product. Another disadvantage to impregnation is that it removes
activated carbon's capacity for adsorbing volatile organic
compounds (VOCs). The impregnation chemistry occupies the pores of
the activated carbon thus reducing the surface area available to
capture non-reactive vapors that are captured by physisorption
only.
SUMMARY
[0008] Polymeric sorbents for aldehydes including formaldehyde are
provided. More particularly, the polymeric sorbents are ionic
polymeric materials having ionically bonded nitrogen-containing
groups. The polymeric sorbents have primary and/or secondary amino
groups that can react with an aldehyde. Additionally, granule
composites containing the polymeric sorbents, methods of sorbing
aldehydes (i.e., aldehydes that are volatile under use conditions)
on the polymeric sorbents, and compositions resulting from the
sorption of aldehydes on the polymeric sorbents are provided.
[0009] In a first aspect, a polymeric sorbent is provided. The
polymeric sorbent is a reaction product of a) a hydrolyzed
divinylbenzene/maleic anhydride polymeric material having
carboxylic acid groups and b) a nitrogen-containing compound having
at least two amino groups of formula --NHR, wherein R is hydrogen
or alkyl and wherein the nitrogen-containing compound is attached
to the hydrolyzed divinylbenzene/maleic anhydride polymeric
material with an ionic bond.
[0010] In a second aspect, a method of sorbing an aldehyde on a
polymeric sorbent is provided. The method includes providing a
polymeric sorbent as described above and then sorbing the aldehyde
on the polymeric sorbent. The aldehyde is of Formula (I)
R.sub.2--(CO)--H (I)
where R.sub.2 is hydrogen, alkyl, vinyl, or aryl. The molecular
weight of the aldehyde of Formula (I) is typically no greater than
200 grams/mole.
[0011] In a third aspect, a composition is provided that includes
(a) a polymeric sorbent as described above and (b) an aldehyde
sorbed on the polymeric sorbent. The aldehyde is of Formula (I)
R.sub.2-(CO)--H (I)
where R.sub.2 is hydrogen, alkyl, vinyl, or aryl. The molecular
weight of the aldehyde of Formula (I) is typically no greater than
200 grams/mole.
[0012] In a fourth aspect, a method of preparing a polymeric
sorbent is provided. The method includes providing a
divinylbenzene/maleic anhydride precursor polymeric material. The
method further includes hydrolyzing the divinylbenzene/maleic
anhydride precursor polymeric material to form a hydrolyzed
divinylbenzene/maleic anhydride polymeric material having
carboxylic acid groups (--COOH groups). The method still further
includes reacting the hydrolyzed divinylbenzene/maleic anhydride
polymeric material with a nitrogen-containing compound having at
least two amino groups of formula --NHR where R is hydrogen or
alkyl. The reaction results in the formation of the polymeric
sorbent having ionically attached nitrogen-containing groups.
[0013] In a fifth aspect, composite granules are provided that
includes (a) a polymeric sorbent as described above and (b) a
binder.
[0014] In a sixth aspect, a method of making composite granules is
provided that includes preparing a polymeric sorbent as described
above. The method further includes blending the polymeric sorbent
with a binder to form a blended material and preparing the
composite granules from the blended material.
[0015] In a seventh aspect, a method of sorbing (i.e., capturing)
an aldehyde on composite granules is provided. The method includes
providing composite granules, as described above, that contain a
polymeric sorbent and a binder. The method further includes
exposing the composite granules to an aldehyde and sorbing the
aldehyde on the polymeric sorbent. The aldehyde is of Formula
(I)
R.sub.2-(CO)--H (I)
wherein R.sub.2 is hydrogen, alkyl, vinyl, or aryl. The molecular
weight of the aldehyde of Formula (I) is no greater than 200
grams/mole.
DETAILED DESCRIPTION
[0016] Polymeric sorbents are provided. Additionally, methods of
making the polymeric sorbents, methods of sorbing aldehydes on the
polymeric sorbents, compositions resulting from sorption of
aldehydes on the polymeric sorbents, composite granules containing
the polymeric sorbents, methods of making the composite granules,
and methods of sorbing aldehydes on the composite granules are
provided. The polymeric sorbents typically are porous, with the
pores often being in the size range of mesopores and/or
micropores.
[0017] More particularly, the polymeric sorbents are a reaction
product of a hydrolyzed divinylbenzene/maleic anhydride polymeric
material having carboxylic acid groups (--COOH groups) with a
nitrogen-containing compound having two primary and/or secondary
amino groups. The nitrogen-containing compound has a first primary
and/or secondary amino group that is ionically attached to the
hydrolyzed divinylbenzene/maleic anhydride polymeric material in
the polymeric sorbent. Further, the nitrogen-containing compound
has at least one second primary amino group and/or secondary amino
group that can react with an aldehyde.
[0018] The polymeric sorbent can be used to sorb aldehydes that are
volatile at room temperature or under use conditions. Suitable
aldehydes are typically of Formula (I)
R.sub.2-(CO)--H (I)
where R.sub.2 is hydrogen, alkyl, vinyl, or aryl. The molecular
weight of the aldehyde of Formula (I) is typically no greater than
200 grams/mole. In some embodiments, the aldehyde is formaldehyde
(R.sub.2 is hydrogen) or acetaldehyde (R.sub.2 is methyl).
[0019] The terms "a", "an", and "the" are used interchangeably with
"at least one" to mean one or more of the elements being
described.
[0020] The term "and/or" means either or both. For example, "A
and/or B" means only A, only B, or both A and B.
[0021] The term "alkyl" refers to a monovalent radical of an
alkane, which is a saturated hydrocarbon. The alkyl can have at
least 1 carbon atom, at least 2 carbon atoms, or at least 3 carbon
atoms and can have up to 20 carbon atoms, up to 18 carbon atoms, up
to 16 carbon atoms, up to 12 carbon atoms, up to 10 carbon atoms,
up to 6 carbon atoms, or up to 4 carbon atoms.
[0022] The term "(hetero)alkylene" refers to a heteroalkylene
and/or alkylene. The term "alkylene" refers to a divalent radical
of an alkane. The alkylene can have at least 1 carbon atom, at
least 2 carbon atoms, or at least 3 carbon atoms and can have up to
20 carbon atoms, up to 18 carbon atoms, up to 16 carbon atoms, up
to 12 carbon atoms, up to 10 carbon atoms, up to 6 carbon atoms, or
up to 4 carbon atoms.
[0023] The term "heteroalkylene" refers to a divalent radical of a
heteroalkane. The heteroalkylene has one or more groups of formula
-R.sub.b-O--R.sub.b- or -R.sub.b-NH--R.sub.b--where R.sub.b is an
alkylene as defined above. Each R.sub.b often has 1 to 10 carbon
atoms, 1 to 6 carbon atoms, 1 to 4 carbon atoms, 1 to 3 carbon
atoms, or 1 to 2 carbon atoms.
[0024] The term "(hetero)aryl" refers to a heteroaryl and/or an
aryl.
[0025] The term "aryl" refers to a monovalent radical of a
carbocyclic aromatic ring compound. The aryl can have at least 5
carbon atoms or at least 6 carbon atoms and can have up to 20
carbon atoms, up to 18 carbon atoms, up to 16 carbon atoms, up to
12 carbon atoms, or up to 10 carbon atoms. The aryl can have more
than one or more carbocyclic aromatic rings. Multiple carbocyclic
aromatic rings can be bonded by a single bond or fused
together.
[0026] The term "heteroaryl" refers to a monovalent radical of a
heterocyclic aromatic ring compound. The heteroaryl contains one or
more heteroatoms selected from nitrogen, oxygen, and sulfur. The
heteroaryl can have at least 2 carbon atoms, at least 3 carbon
atoms, at least 4 carbon atoms, or at least 5 carbon atoms and can
have at least 1 heteroatoms, at least 2 heteroatoms, or at least 3
heteroatoms. The heteroaryl often has 2 to 10 carbon atoms and 1 to
5 heteroatoms, 2 to 6 carbon atoms and 1 to 3 heteroatoms, or 2 to
4 carbon atoms and 1 to 3 heteroatoms. The heteroaryl can have one
or more heteroaromatic rings. The one or more heteroaromatic rings
can be fused to or connected with a single bond to another aromatic
ring that is carbocyclic or heterocyclic.
[0027] The term "(hetero)arylene" refers to a heteroarylene and/or
an arylene.
[0028] The term "arylene" refers to a divalent radical of a
carbocyclic aromatic ring compound. The arylene can have at least 5
carbon atoms or at least 6 carbon atoms and can have up to 20
carbon atoms, up to 18 carbon atoms, up to 16 carbon atoms, up to
12 carbon atoms, or up to 10 carbon atoms. The carbocyclic arylene
can have more than one or more carbocyclic aromatic rings. Multiple
carbocyclic aromatic rings can be bonded by a single bond or fused
together.
[0029] The term "heteroarylene" refers to a divalent radical of a
heterocyclic aromatic ring compound. The heteroarylene contains one
or more heteroatoms selected from nitrogen, oxygen, and sulfur. The
heteroarylene can have at least 2 carbon atoms, at least 3 carbon
atoms, at least 4 carbon atoms, or at least 5 carbon atoms and can
have at least 1 heteroatoms, at least 2 heteroatoms, or at least 3
heteroatoms. The heteroarylene often has 2 to 10 carbon atoms and 1
to 5 heteroatoms, 2 to 6 carbon atoms and 1 to 3 heteroatoms, or 2
to 4 carbon atoms and 1 to 3 heteroatoms. The heteroarylene can
have one or more heteroaromatic rings. The one or more
heteroaromatic rings can be fused to or connected with a single
bond to another aromatic ring that is carbocyclic or
heterocyclic.
[0030] The term "(hetero)aralkylene" refers to a heteroaralkylene
and/or aralkylene. The term "aralkylene" refers to a divalent group
that is alkylene substituted by an aryl group, an arylene
substituted with an alkyl group, or an arylene bonded to an
alkylene group. The aryl, arylene, and alkyl groups are the same as
defined above.
[0031] The term "heteroaralkylene" refers to a divalent group that
is an alkylene substituted by a heteroaryl, a heteroarylene
substituted with an alkyl group, or a heteroarylene bonded to an
alkylene group. The heteroaryl, heteroarylene, and alkyl groups are
the same as defined above.
[0032] The term "vinyl" refers to a group of formula
CHR.sub.8=CR.sub.8-- where each R.sub.8 independently is hydrogen
or alkyl (e.g., methyl).
[0033] The term "primary amino group" refers to a group of formula
--NHR where R is equal to hydrogen and the term "secondary amino
group" refers to a group of formula --NHR where R is equal to
alkyl.
[0034] The terms "polymer" and "polymeric material" are used
interchangeably and refer to materials formed by reacting one or
more monomers. These terms include homopolymers, copolymers,
terpolymers, or the like. Likewise, the terms "polymerize" and
"polymerizing" refer to the process of making a polymeric material
that can be a homopolymer, copolymer, terpolymer, or the like.
[0035] The term "porous" when referring to a polymeric material
means that the polymeric material has pores and can sorb gaseous
substances such as, for example, aldehydes. In most embodiments,
the polymeric sorbent is porous. Porous materials such as the
polymeric sorbents can be characterized based on the size of their
pores. The term "micropores" refers to pores having a diameter less
than 2 nanometers. The term "mesopores" refers to pores having a
diameter in a range of 2 to 50 nanometers. The term "macropores"
refers to pores having a diameter greater than 50 nanometers. The
porosity of a polymeric material can be characterized from an
adsorption isotherm of an inert gas such as nitrogen or argon by
the polymeric material under cryogenic conditions (e.g., liquid
nitrogen at 77 K). The adsorption isotherm is typically obtained by
measuring adsorption of the inert gas such as nitrogen or argon by
the polymeric material at multiple relative pressures)(p/p.degree.
in a range of about 10.sup.-6 to about 0.98.+-.0.01. The isotherms
are then analyzed using various methods such as the BET
(Brunauer-Emmett-Teller) method to calculate specific surface area
and the Density Functional Theory (DFT) to characterize the
porosity and the pore size distribution.
[0036] The term "sorbing" and similar words such as "sorb",
"sorbed", and "sorption" refer to the addition of a first substance
(e.g., a gas such as an aldehyde) to a second substance (e.g., a
polymeric material such as the polymeric sorbent) by adsorbing,
absorbing, or both. Likewise, the term "sorbent" refers to a second
substance that sorbs a first substance by adsorbing, absorbing, or
both.
[0037] The term "surface area" refers to the total area of a
surface of a material including the internal surfaces of accessible
pores. The surface area is typically calculated from adsorption
isotherms obtained by measuring the amount of an inert gas such as
nitrogen or argon that adsorbs on the surface of a material under
cryogenic conditions (e.g., liquid nitrogen at 77 K) over a range
of relative pressures. The term "BET specific surface area" is the
surface area per gram of a material (typically, m.sup.2/gram) that
is usually calculated from adsorption isotherm data of the inert
gas over a relative pressure range of 0.05 to 0.30 using the BET
method.
[0038] The term "polymerizable composition" includes all materials
included in the reaction mixture used to form the polymeric
material. The polymerizable composition includes, for example, the
monomer mixture, the organic solvent, the initiator, and other
optional components. Some of the components in the polymerizable
composition such as the organic solvent may not undergo a chemical
reaction but can influence the chemical reaction and the resulting
polymeric material. The term "monomer mixture" refers to that
portion of a polymerizable composition that includes the monomers.
More specifically, as used herein, the monomer mixture includes at
least divinylbenzene and maleic anhydride.
[0039] The terms "divinylbenzene/maleic anhydride polymeric
material" and "divinylbenzene/maleic anhydride precursor polymeric
material" and "precursor polymeric material" and "precursor
polymer" are used interchangeably and refer to a polymeric material
prepared from divinylbenzene, maleic anhydride, and optionally a
styrene-type monomer. This polymeric material is the precursor to
the hydrolyzed divinylbenzene/maleic anhydride polymeric
material.
[0040] The term "hydrolyzed divinylbenzene/maleic anhydride
polymeric material" and "hydrolyzed polymeric material" and
"hydrolyzed polymer" are used interchangeably and refer to a
polymeric material formed by treating a divinylbenzene/maleic
anhydride precursor polymeric material with a hydrolyzing agent and
optionally an acid such that the hydrolyzed divinylbenzene/maleic
anhydride polymeric material has carboxylic acid groups (--COOH).
The carboxylic acid groups can form an ionic bond with a
nitrogen-containing compound having primary and/or secondary amino
groups.
[0041] The term "styrene-type monomer" refers to styrene, an
alkyl-substituted styrene (e.g., ethyl styrene), or mixtures
thereof These monomers are often present in divinylbenzene as
impurities. The term "room temperature" refers to a temperature in
a range of 20.degree. C. to 30.degree. C., in a range of 20.degree.
C. to 25.degree. C., in a range close to and including 25.degree.
C., or 25.degree. C.
[0042] In one aspect, a polymeric sorbent is provided. In another
aspect, a method of preparing a polymeric sorbent is provided. The
polymeric sorbent is formed by reacting a hydrolyzed
divinylbenzene/maleic anhydride polymeric material having
carboxylic acid groups and a nitrogen-containing compound having at
least two amino groups of formula --NHR where R is hydrogen or
alkyl.
[0043] One of the at least two amino groups forms an ionic bond
with carboxylic acid groups in the hydrolyzed divinylbenzene/maleic
anhydride polymeric material. That is, the nitrogen-containing
compound becomes part of the polymeric sorbent.
[0044] The hydrolyzed divinylbenzene/maleic anhydride polymeric
material is formed from a divinylbenzene/maleic anhydride precursor
polymeric material. The conditions used to synthesize the precursor
polymeric material are typically selected so that this material has
a BET specific surface area equal to at least 100 m.sup.2/gram.
[0045] The precursor polymeric material (i.e., the
divinylbenzene/maleic anhydride precursor polymeric material) is
typically synthesized from a polymerizable composition that
includes a monomer mixture containing maleic anhydride,
divinylbenzene, and an optional styrene-type monomer. The precursor
polymeric material is usually formed from a monomer mixture
containing 1) 8 to 65 weight percent maleic anhydride, 2) 30 to 85
weight percent divinylbenzene, and 3) 0 to 40 weight percent of a
styrene-type monomer, wherein the styrene-type monomer is styrene,
an alkyl-substituted styrene, or a combination thereof The amounts
are based on the total weight of monomers in the monomer mixture,
which is equal to the total weight of monomers in the polymerizable
composition. When the precursor polymeric material is used to form
a polymeric sorbent that is particularly effective for sorption of
aldehydes, the monomer mixture often contains 1) 15 to 65 weight
percent maleic anhydride, 2) 30 to 85 weight percent
divinylbenzene, and 3) 0 to 40 weight percent of a styrene-type
monomer, wherein the styrene-type monomer is styrene, an
alkyl-substituted styrene, or a combination thereof The maleic
anhydride that is included in the monomer mixture results in the
formation of maleic anhydride monomeric units of Formula (II)
within the precursor polymeric material.
##STR00001##
[0046] The asterisks in this formula and other formulas contained
herein denote the location of attachment of the monomeric unit to
another monomeric unit or to a terminal group.
[0047] The amount of maleic anhydride used to form the precursor
polymeric material influences the amount of nitrogen-containing
compound that can react with the precursor polymeric material to
form the polymeric sorbent. The nitrogen-containing compound reacts
with the anhydride group to become ionically attached to the
polymeric material that is the polymeric sorbent.
[0048] In some embodiments, the amount of maleic anhydride included
in the monomer mixture is at least 8 weight percent, at least 10
weight percent, at least 12 weight percent, at least 15 weight
percent, or at least 20 weight percent. The amount of maleic
anhydride can be up to 65 weight percent, up to 60 weight percent,
up to 55 weight percent, up to 50 weight percent, up to 45 weight
percent, up to 40 weight percent, up to 35 weight percent, up to 30
weight percent, or up to 25 weight percent. For example, the maleic
anhydride may be present in a range of 8 to 65 weight percent, 15
to 65 weight percent, 15 to 60 weight percent, 15 to 50 weight
percent, 15 to 40 weight percent, 20 to 65 weight percent, 20 to 60
weight percent, 20 to 50 weight percent, 20 to 40 weight percent,
30 to 65 weight percent, 30 to 60 weight percent, 30 to 50 weight
percent, 40 to 65 weight percent, or 40 to 60 weight percent. The
amounts are based on the total weight of monomers in the monomer
mixture contained in the polymerizable composition used to form the
precursor polymeric material.
[0049] Stated differently, the precursor polymeric material
contains monomeric units of Formula (II) in a range of 8 to 65
weight percent, 15 to 65 weight percent, 15 to 60 weight percent,
15 to 50 weight percent, 15 to 40 weight percent, 20 to 65 weight
percent, 20 to 60 weight percent, 20 to 50 weight percent, 20 to 40
weight percent, 30 to 65 weight percent, 30 to 60 weight percent,
30 to 50 weight percent, 40 to 65 weight percent, or 40 to 60
weight percent. These amounts are based on the total weight of the
monomeric units in the precursor polymeric material.
[0050] The divinylbenzene included in the monomer mixture results
in the formation of divinylbenzene monomeric units of Formula (III)
within the precursor polymeric material.
##STR00002##
[0051] The two groups attached to the benzene ring can be in an
ortho, meta, or para arrangement to each other. The monomeric units
of Formula (III) contribute to the high crosslink density and to
the formation of a rigid polymeric material having micropores
and/or mesopores.
[0052] The amount of divinylbenzene used to form the precursor
polymeric material can have a strong influence on the BET specific
surface area of both the precursor polymeric material and the
polymeric sorbent. The BET specific surface area tends to increase
with an increase in the amount of divinylbenzene in the monomer
mixture used to form the precursor polymeric material and with the
resulting amount of monomeric units of Formula (III) in the
polymeric sorbent. If the amount of divinylbenzene is less than 30
weight percent, the polymeric sorbent may not have a sufficiently
high BET specific surface area. On the other hand, if the amount of
divinylbenzene is greater than 85 weight percent, the amount of
aldehyde sorbed may be compromised because there are fewer
nitrogen-containing groups in the polymeric sorbent. In some
embodiments, the amount of divinylbenzene included in the monomer
mixture is at least 30 weight percent, at least 35 weight percent,
at least 40 weight percent, or at least 45 weight percent. The
amount of divinylbenzene can be up to 85 weight percent, up to 80
weight percent, up to 75 weight percent, up to 70 weight percent,
up to 65 weight percent, up to 60 weight percent, or up to 50
weight percent. For example, the amount can be in a range of 30 to
85 weight percent, 30 to 80 weight percent, 30 to 75 weight
percent, 30 to 70 weight percent, 30 to 65 weight percent, 30 to 60
weight percent, 30 to 55 weight percent, 30 to 50 weight percent,
35 to 80 weight percent, 35 to 70 weight percent, 35 to 60 weight
percent, 40 to 85 weight percent, 40 to 80 weight percent, 40 to 70
weight percent, or 40 to 60 weight percent. The amounts are based
on the total weight of monomers in the monomer mixture contained in
the polymerizable composition used to form the precursor polymeric
material.
[0053] Stated differently, the precursor polymeric material
contains monomeric units of Formula (III) in a range of 30 to 85
weight percent, 30 to 80 weight percent, 30 to 75 weight percent,
30 to 70 weight percent, 30 to 65 weight percent, 30 to 60 weight
percent, 30 to 55 weight percent, 30 to 50 weight percent, 35 to 80
weight percent, 35 to 70 weight percent, 35 to 60 weight percent,
40 to 85 weight percent, 40 to 80 weight percent, 40 to 70 weight
percent, or 40 to 60 weight percent. These amounts are based on the
total weight of the monomeric units in the precursor polymeric
material.
[0054] Divinylbenzene can be difficult to obtain in a pure form.
For example, divinylbenzene is often commercially available with
purity as low as 55 weight percent. Obtaining divinylbenzene with
purity greater than about 80 weight percent can be difficult and/or
expensive. The impurities accompanying divinylbenzene are typically
styrene-type monomers such as styrene, alkyl-substituted styrene
(e.g., ethyl styrene), or mixtures thereof. Thus, styrene-type
monomers are often present along with divinylbenzene and maleic
anhydride in the monomer mixture contained in the polymerizable
composition used to form the precursor polymeric material. The
monomer mixture typically contains 0 to 40 weight percent
styrene-type monomers based on the total weight of monomers in the
monomer mixture. If the content of the styrene-type monomer is
greater than 40 weight percent, the crosslink density may be too
low and/or the distance between crosslinks may be too large to
provide a divinylbenzene/maleic anhydride precursor polymeric
material having a BET specific surface area equal to at least 100
m.sup.2/gram. As the crosslink density decreases, the polymeric
sorbent tends to be less rigid and less porous. Typically,
divinylbenzene having a purity of 55 weight percent is not suitable
for use in the monomer mixtures used to form the precursor
polymeric material because the content of styrene-type monomer
impurities is too high. If the monomer mixture contains too much
styrene-type monomer, the amount of divinylbenzene may be
undesirably low. Using divinylbenzene having a lower purity than
about 80 weight percent can result in the formation of a precursor
polymeric material and/or a polymeric sorbent with an undesirably
low BET specific surface area.
[0055] The styrene-type monomers included in the monomer mixture
result in the presence of styrene-type monomeric units of Formula
(IV) within the precursor polymeric material.
##STR00003##
[0056] Group R.sub.3 is hydrogen or alkyl (e.g., an alkyl having 1
to 10 carbon atoms, 1 to 6 carbon atoms or 1 to 4 carbon
atoms).
[0057] In some embodiments, the amount of styrene-type monomers
used to form the precursor polymeric material, is at least 1 weight
percent, at least 2 weight percent, or at least 5 weight
percent.
[0058] The amount of styrene-type monomers can be up to 40 weight
percent, up to 30 weight percent, up to 20 weight percent, or up to
10 weight percent. For example, the amount can be in a range of 0
to 40 weight percent, 1 to 40 weight percent, 5 to 40 weight
percent, 10 to 40 weight percent, 0 to 30 weight percent, 1 to 30
weight percent, 5 to 30 weight percent, 10 to 30 weight percent, 0
to 20 weight percent, 1 to 20 weight percent, 5 to 20 weight
percent, or 10 to 20 weight percent. The amounts are based on the
total weight of monomers in the monomer mixture contained in the
polymerizable composition used to form the precursor polymeric
material.
[0059] Stated differently, the precursor polymeric material
contains monomeric units of Formula (IV) in a range of 0 to 40
weight percent, 1 to 40 weight percent, 5 to 40 weight percent, 10
to 40 weight percent, 0 to 30 weight percent, 1 to 30 weight
percent, 5 to 30 weight percent, 10 to 30 weight percent, 0 to 20
weight percent, 1 to 20 weight percent, 5 to 20 weight percent, or
10 to 20 weight percent. These amounts are based on the total
weight of the monomeric units in the precursor polymeric
material.
[0060] Overall, the precursor polymeric material is formed from a
polymerizable composition containing a monomer mixture that
includes 8 to 65 weight percent maleic anhydride, 30 to 85 weight
percent divinylbenzene, and 0 to 40 weight percent of a
styrene-type monomer. In some embodiments, the monomer mixture
contains 15 to 65 weight percent maleic anhydride, 30 to 85 weight
percent divinylbenzene, and 0 to 40 weight percent (or 5 to 40
weight percent) of a styrene-type monomer. Some embodiments contain
25 to 65 weight percent maleic anhydride, 30 to 75 weight percent
divinylbenzene, and 1 to 20 weight percent (or 5 to 20 weight
percent) styrene-type monomer. Some embodiments contain 25 to 60
weight percent maleic anhydride, 30 to 75 weight percent
divinylbenzene, and 1 to 30 weight percent (or 5 to 30 weight
percent or 10 to 30 weight percent) styrene-type monomer. In still
other embodiments, the monomer mixture contains 30 to 65 weight
percent maleic anhydride, 30 to 70 weight percent divinylbenzene,
and 1 to 20 weight percent (or 5 to 20 weight percent or 10 to 20
weight percent) styrene-type monomer. In still other embodiments,
the monomer mixture contains 30 to 60 weight percent maleic
anhydride, 30 to 65 weight percent divinylbenzene, and 1 to 20
weight percent (or 5 to 20 weight percent or 10 to 20 weight
percent) styrene-type monomer. In further embodiments, the monomer
mixture contains 40 to 60 weight percent maleic anhydride, 30 to 55
weight percent divinylbenzene, and 1 to 20 weight percent (or 5 to
20 weight percent, or 10 to 20 weight percent) styrene-type
monomers. In still further embodiments, the monomer mixture
contains 20 to 40 weight percent maleic anhydride, 50 to 70 weight
percent divinylbenzene, and 1 to 20 weight percent (or 5 to 20
weight percent or 10 to 20 weight percent) styrene-type monomer.
The weight percent values are based on the total weight of monomers
in the monomer mixture used to form the precursor polymeric
material.
[0061] The monomer mixture included in the polymerizable
composition used to form the precursor polymeric material typically
contains at least 95 weight percent monomers selected from maleic
anhydride, divinylbenzene, and styrene-type monomer. For example,
at least 97 weight percent, at least 98 weight percent, at least 99
weight percent, at least 99.5 weight percent, at least 99.9 weight
percent, or 100 weight percent of the monomers in the monomer
mixture are selected from maleic anhydride, divinylbenzene, and
styrene-type monomer. In some embodiments, where high purity
divinylbenzene is used, the monomer mixture contains only
divinylbenzene and maleic anhydride. That is, the sum of the amount
of divinylbenzene and maleic anhydride is 100 weight percent.
[0062] In addition to the monomer mixture, the polymerizable
composition used to form the precursor polymeric material includes
an organic solvent. The polymerizable composition is a single phase
prior to polymerization. Stated differently, prior to
polymerization, the polymerizable composition is not a suspension.
The organic solvent is selected to dissolve the monomers included
in the monomer mixture and to solubilize the precursor polymeric
material as it begins to form. The organic solvent typically
includes a ketone, ester, acetonitrile, or mixture thereof.
[0063] The organic solvent can function as a porogen during the
formation of the precursor polymeric material. The organic solvent
choice can strongly influence the BET specific surface area and the
size of the pores formed in the precursor polymeric material. Using
organic solvents that are miscible with both the monomers and the
forming polymer tends to result in the formation of micropores and
mesopores within the precursor polymeric material. Good solvents
for the monomers and the forming polymer tend to result in a larger
fraction of the porosity of the precursor polymeric material being
in the form of micropores and mesopores. Organic solvents that are
particularly suitable for producing precursor polymeric materials
with micropores and mesopores include ketones, esters,
acetonitrile, and mixtures thereof. The organic solvent can affect
the BET specific surface area of the precursor polymeric material.
Typically, it is desirable that the precursor polymeric material
has a BET surface area equal to at least 100 m.sup.2/gram. Provided
that the resulting precursor polymeric material has a BET specific
surface area equal to at least 100 m.sup.2/gram, other organic
solvents can be added along with one or more of the organic
solvents listed above. Examples of suitable ketones include, but
are not limited to, alkyl ketones such as methyl ethyl ketone and
methyl isobutyl ketone. Examples of suitable esters include, but
are not limited to, acetate esters such as ethyl acetate, propyl
acetate, butyl acetate, amyl acetate, and tent-butyl acetate.
[0064] The organic solvent can be used in any desired amount. The
polymerizable compositions often have percent solids in a range of
1 to 75 weight percent (i.e., the polymerizable composition
contains 25 to 99 weight percent organic solvent). If the percent
solids is too low, the polymerization time may become undesirably
long. The percent solids is often at least 1 weight percent, at
least 2 weight percent, at least 5 weight percent, at least 10
weight percent, or at least 15 weight percent. If the weight
percent solids is too great, however, the monomers do not form a
single phase with the organic solvent. Further, increasing the
percent solids tends to result in the formation of precursor
polymeric material with a lower BET specific surface area. The
percent solids usually can be up to 75 weight percent, up to 70
weight percent, up to 60 weight percent, up to 50 weight percent,
up to 40 weight percent, up to 30 weight percent, or up to 25
weight percent. For example, the percent solids can be in a range
of 5 to 75 weight percent, 5 to 70 weight percent, 5 to 60 weight
percent, 5 to 50 weight percent, 5 to 40 weight percent, 5 to 30
weight percent, or 5 to 25 weight percent. In addition to the
monomer mixture and organic solvent, the polymerizable compositions
used to form the precursor polymeric material typically include an
initiator for free radical polymerization reactions. Any suitable
free radical initiator can be used. Suitable free radical
initiators are typically selected to be miscible with the monomers
included in the polymerizable composition. In some embodiments, the
free radical initiator is a thermal initiator that can be activated
at a temperature above room temperature. In other embodiments, the
free radical initiator is a redox initiator. Because the
polymerization reaction is a free radical reaction, it is desirable
to minimize the amount of oxygen in the polymerizable
composition.
[0065] Both the type and amount of initiator can affect the
polymerization rate. In general, increasing the amount of the
initiator tends to lower the BET specific surface area; however, if
the amount of initiator is too low, it may be difficult to obtain
high conversions of the monomers to polymeric material.
[0066] The free radical initiator is typically present in an amount
in a range of 0.05 to 10 weight percent, 0.05 to 8 weight percent,
0.05 to 5 weight percent, 0.1 to 10 weight percent, 0.1 to 8 weight
percent, 0.1 to 5 weight percent, 0.5 to 10 weight percent, 0.5 to
8 weight percent, 0.5 to 5 weight percent, 1 to 10 weight percent,
1 to 8 weight percent, or 1 to 5 weight percent. The weight percent
is based on the total weight of monomers in the polymerizable
composition.
[0067] Suitable thermal initiators include organic peroxides and
azo compounds. Example azo compounds include, but are not limited
to, those commercially available under the trade designation VAZO
from E.I. du Pont de Nemours Co. (Wilmington, DE) such as VAZO 64
(2,2'-azobis(isobutyronitrile)), which is often referred to as
AIBN, and VAZO 52 (2,2'-azobis(2,4-dimethylpentanenitrile)). Other
azo compounds are commercially available from Wako Chemicals USA,
Inc. (Richmond, VA) such as V-601 (dimethyl
2,2'-azobis(2-methylproprionate)), V-65 (2,2'-azobis(2,4-dimethyl
valeronitrile)), and V-59 (2,2'-azobis(2-methylbutyronitrile)).
Organic peroxides include, but are not limited to,
bis(1-oxoaryl)peroxides such as benzoyl peroxide (BPO),
bis(1-oxoalkyl)peroxides such as lauroyl peroxide, and dialkyl
peroxides such as dicumyl peroxide or di-tent-butyl peroxide and
mixtures thereof The temperature needed to activate the thermal
initiator is often in a range of 25.degree. C. to 160.degree. C.,
in a range of 30.degree. C. to 150.degree. C., in a range of
40.degree. C. to 150.degree. C., in a range of 50.degree. C. to
150.degree. C., in a range of 50.degree. C. to 120.degree. C., or
in a range of 50.degree. C. to 110.degree. C.
[0068] Suitable redox initiators include arylsulfinate salts,
triarylsulfonium salts, or N,N-dialkylaniline (e.g.,
N,N-dimethylaniline) in combination with a metal in an oxidized
state, a peroxide, or a persulfate. Specific arylsulfinate salts
include tetraalkylammonium arylsulfinates such as
tetrabutylammonium 4-ethoxycarbonylbenzenesulfinate,
tetrabutylammonium 4-trifluoromethylbenzenesulfinate, and
tetrabutylammonium 3-trifluoromethylbenzenesulfinate. Specific
triarylsulfonium salts include those with a triphenylsulfonium
cation and with an anion selected from PF.sub.6.sup.-,
AsF.sub.6.sup.-, and SbF.sub.6.sup.-. Suitable metal ions include,
for example, ions of group III metals, transition metals, and
lanthanide metals. Specific metal ions include, but are not limited
to, Fe(III), Co(III), Ag(I), Ag(II), Cu(II), Ce(III), Al (III),
Mo(VI), and Zn(II). Suitable peroxides include benzoyl peroxide,
lauroyl peroxide, and the like. Suitable persulfates include, for
example, ammonium persulfate, tetraalkylammonium persulfate (e.g.,
tetrabutylammonium persulfate), and the like.
[0069] The polymerizable composition is typically free or
substantially free of surfactants. As used herein, the term
"substantially free" in reference to the surfactant means that no
surfactant is purposefully added to the polymerizable composition
and any surfactant that may be present is the result of being an
impurity in one of the components of the polymerizable composition
(e.g., an impurity in the organic solvent or in one of the
monomers). The polymerizable composition typically contains less
than 0.5 weight percent, less than 0.3 weight percent, less than
0.2 weight percent, less than 0.1 weight percent, less than 0.05
weight percent, or less than 0.01 weight percent surfactant based
on the total weight of the polymerizable composition. The absence
of a surfactant is advantageous because these materials tend to
restrict access to and, in some cases, fill micropores and
mesopores in a precursor polymeric material.
[0070] When the polymerizable composition is heated in the presence
of a free radical initiator, polymerization of the monomers in the
monomer mixture occurs. By balancing the amounts of each monomer in
the monomer mixture and by selection of an organic solvent that can
solubilize all the monomers and the growing polymeric material
during its early formation stage, a precursor polymeric material
can be prepared that has a BET specific surface area equal to at
least 100 m.sup.2/gram. The BET specific surface area of the
precursor polymeric material can be at least 150 m.sup.2/gram, at
least 200 m.sup.2/gram, or at least 300 m.sup.2/gram. The BET
specific surface area can be, for example, up to 1000 m.sup.2/gram
or higher, up to 900 m.sup.2/gram, up to 800 m.sup.2/gram, up to
750 m.sup.2/gram, or up to 700 m.sup.2/gram. The structure of the
divinylbenzene/maleic anhydride polymeric material is particularly
well suited for use as a precursor polymeric material for the
porous polymeric sorbent. Providing that the content of monomeric
units of Formula (IV) from styrene-type monomers is low, the
divinylbenzene/maleic anhydride precursor polymeric material has
alternating monomeric units from divinylbenzene and maleic
anhydride. This structure results in high crosslinking and
contributes to the formation of a porous polymeric material,
particularly a porous polymeric material having a high content of
micropores and/or mesopores.
[0071] The precursor polymeric material is the reaction product of
the polymerizable composition. The precursor polymeric material is
usually formed from the polymerizable composition that contains (a)
8 to 65 weight percent of a first monomeric unit of Formula
(II),
##STR00004##
[0072] (b) 30 to 85 weight percent of a second monomeric unit of
Formula (III), and
##STR00005##
[0073] (c) 0 to 40 weight percent of a third monomeric unit of
Formula (IV) wherein R.sub.3 is hydrogen or alkyl (e.g., an alkyl
having 1 to 10 carbon atoms, 1 to 6 carbon atoms, or 1 to 4 carbon
atoms).
##STR00006##
[0074] In many embodiments, to be particularly effective as a
polymeric sorbent for aldehydes, the precursor polymeric material
contains (a) 15 to 65 weight percent of a first monomeric unit of
Formula (II), (b) 30 to 85 weight percent of a second monomeric
unit of Formula (III), and (c) 0 to 40 weight percent (or 5 to 40
weight percent) of a third monomeric unit of Formula (IV). Each
weight percent value is based on the total weight of monomeric
units in the precursor polymeric material.
[0075] Some embodiments of the precursor polymeric material contain
25 to 65 weight percent of the first monomeric unit of Formula
(II), 30 to 75 weight percent of the second monomeric unit of
Formula (III), and 1 to 20 weight percent (or 5 to 20 weight
percent) of the third monomeric unit of Formula (IV).
[0076] Some embodiments contain 25 to 60 weight percent of the
first monomeric unit of Formula (II), 30 to 75 weight percent of
the second monomeric unit of Formula (III), and 1 to 30 weight
percent (or 5 to 30 weight percent or 10 to 30 weight percent) of
the third monomeric unit of Formula (IV). In still other
embodiments, the monomer mixture contains 30 to 65 weight percent
of the first monomeric unit of Formula (II), 30 to 70 weight
percent of the second monomeric unit of Formula (III), and 1 to 20
weight percent (or 5 to 20 weight percent or 10 to 20 weight
percent) of the third monomeric unit of Formula (IV). In still
other embodiments, the monomer mixture contains 30 to 60 weight
percent of the first monomeric unit of Formula (II), 30 to 65
weight percent of the second monomeric unit of Formula (III), and 1
to 20 weight percent (or 5 to 20 weight percent or 10 to 20 weight
percent) of the third monomeric unit of Formula (IV). In further
embodiments, the monomer mixture contains 40 to 60 weight percent
of the first monomeric unit of Formula (II), 30 to 55 weight
percent of the second monomeric unit of Formula (III), and 1 to 20
weight percent (or 5 to 20 weight percent, or 10 to 20 weight
percent) of the third monomeric unit of Formula (IV). In still
further embodiments, the monomer mixture contains 20 to 40 weight
percent of the first monomeric unit of Formula (II), 50 to 70
weight percent of the second monomeric unit of Formula (III), and 1
to 20 weight percent (or 5 to 20 weight percent or 10 to 20 weight
percent) of the third monomeric unit of Formula (IV). The weight
percent values are based on the total weight of monomeric units
used in the precursor polymeric material.
[0077] The precursor polymeric material is hydrolyzed to form a
hydrolyzed divinylbenzene/maleic anhydride polymeric material.
Hydrolysis results in the ring opening of the groups of Formula
(II) in the precursor polymeric material. That is, the hydrolyzed
divinylbenzene/maleic anhydride polymeric material includes one or
more of the following types of groups (VII-A, VII-B, and VII-C)
depending on the pH conditions and the particular hydrolyzing agent
selected.
##STR00007##
[0078] Groups of Formula (VII-A) have two carboxylic acid groups.
Groups of Formula (VII-B) have both a carboxylic acid group and a
carboxylate anion. Groups of Formula (VII-C) have two carboxylate
anions. In groups of Formulas (VII-B) and (VII-C), M.sup.+ can be
any suitable cation but is often an alkaline metal cation such as
sodium or potassium. The hydrolysis reaction typically converts at
least 70 mole percent, at least 75 mole percent, at least 80 mole
percent, at least 85 mole percent, at least 90 mole percent, at
least 95 mole percent, at least 97 mole percent, at least 98 mole
percent, at least 99 mole percent, or 100 mole percent of the
anhydride groups to carboxylic acid and/or carboxylate groups.
[0079] The hydrolysis reaction is often performed at room
temperature or close to room temperature by mixing the precursor
polymeric material with a solution of an alkaline metal hydroxide,
alkaline metal carbonate, alkaline metal bicarbonate, or
combination thereof. Specific examples include, but are not limited
to sodium hydroxide, potassium hydroxide, sodium carbonate,
potassium carbonate, sodium carbonate, sodium bicarbonate, or
mixtures thereof. The solutions are typically water-based,
alcohol-based, or both.
[0080] Alternatively, the hydrolysis reaction may occur by simply
heating the precursor polymer at an elevated temperature (e.g., 25
to 120.degree. C.) in water.
[0081] After hydrolysis, the hydrolyzed product is usually treated
with a dilute acid to convert any carboxylate groups to carboxylic
acid groups. That is, groups of Formula (VII-B) and/or (VII-C) are
usually converted to groups of Formula (VII-A) prior to treatment
with the nitrogen-containing compound. That is, the hydrolyzed
divinylbenzene/maleic anhydride polymeric material that is reacted
with the nitrogen-containing compound has carboxylic acid
groups.
[0082] The hydrolyzed (e.g., fully hydrolyzed)
divinylbenzene/maleic anhydride polymeric material typically has a
BET specific surface area equal to at least 50 m.sup.2/gram or at
least 100 m.sup.2/gram. In some embodiments, the BET specific
surface area is at least 150 m.sup.2/gram, at least 175
m.sup.2/gram, at least 200 m.sup.2/gram, at least 225 m.sup.2/gram,
at least 250 m.sup.2/gram, or at least 300 m.sup.2/gram. The BET
specific surface area can be up to 600 m.sup.2/gram or higher, up
to 500 m.sup.2/gram, or up to 400 m.sup.2/gram. In some
embodiments, the BET specific surface area is in a range of 50 to
600 m.sup.2/gram, in a range of 75 to 600 m.sup.2/gram, in a range
of 100 to 600 m.sup.2/gram, or in a range of 200 to 600
m.sup.2/gram.
[0083] The polymeric sorbent is formed by reacting the hydrolyzed
polymeric material having carboxylic acid groups with a
nitrogen-containing compound to form an ionic bond. The
nitrogen-containing compound, which is usually basic, contains a
first primary and/or secondary amino group that reacts with a
carboxylic acid group in the hydrolyzed divinylbenzene/maleic
anhydride polymeric material. That is, the first amino primary
and/or secondary amino group within the nitrogen-containing
compound reacts with a carboxylic acid group in the monomeric units
of Formula (VII-A) within the hydrolyzed divinylbenzene/maleic
anhydride polymeric material. This reaction results in the
formation of an ionic bond linking the nitrogen-containing compound
to the polymeric material in the polymeric sorbent. The ionically
bonded nitrogen-containing compound has at least one second primary
and/or secondary amino group that can react with an aldehyde.
[0084] The nitrogen-containing compound has two or more groups of
formula --NHR where R is hydrogen or alkyl. This compound can have
two or more primary amino groups (where R is equal to hydrogen),
can have two or more secondary amino groups (where R is equal to an
alkyl), or can have at least one primary amino group plus at least
one secondary amino group. Suitable alkyl R groups often have 1 to
20 carbon atoms. For example, the alkyl can have at least 1 carbon
atom, at least 2 carbon atoms, or at least 4 carbon atoms and can
have up to 20 carbon atoms, up to 18 carbon atoms, up to 16 carbon
atoms, up to 10 carbon atoms, up to 6 carbon atoms, or up to 4
carbon atoms. In some embodiments, the alkyl has 1 to 10 carbon
atoms, 1 to 6 carbon atoms, or 1 to 4 carbon atoms.
[0085] Many suitable nitrogen-containing compounds are of Formula
(V).
R.sub.4NHR.sub.1 (V)
[0086] In Formula (V), the group R.sub.1 is hydrogen or an alkyl.
The group R.sub.4 is a group of formula --R.sub.5--NHR.sub.6 or
--(C=NH)--NH.sub.2. The group R5 is an alkylene, (hetero)arylene,
(hetero)aralkylene, heteroalkylene having one or more oxy (--O--)
groups, or heteroalkylene having one or more --NH-groups.
(Hetero)arylene and (hetero)aralkylene R.sub.5 groups can
optionally be substituted with a primary amino group and/or a
secondary amino group. The group R.sub.6 is hydrogen, alkyl, or
--(C=NH)--NH.sub.2.
[0087] Suitable alkyl groups for R.sub.1 in Formula (V) can have at
least 1 carbon atom, at least 2 carbon atoms, or at least 4 carbon
atoms and can have up to 20 carbon atoms, up to 18 carbon atoms, up
to 12 carbon atoms, up to 10 carbon atoms, or up to 6 carbon atoms.
In some embodiments, the alkyl has 1 to 10 carbon atoms, 1 to 6
carbon atoms, or 1 to 4 carbon atoms. In some embodiments, R.sub.4
in Formula (V) is a group of formula --R.sub.5-NHR.sub.6 and the
nitrogen-containing compound is of Formula (V-1).
R.sub.6HN--R.sub.5-NHR.sub.1 (V-1)
Such compounds have at least two amino groups of formula --HR.
Suitable alkyl groups for R.sub.6 in Formula (V-1) can have at
least 1 carbon atom, at least 2 carbon atoms, or at least 4 carbon
atoms and can have up to 20 carbon atoms, up to 18 carbon atoms, up
to 12 carbon atoms, up to 10 carbon atoms, or up to 6 carbon atoms.
In some embodiments, the alkyl has 1 to 10 carbon atoms, 1 to 6
carbon atoms, or 1 to 4 carbon atoms. The group R.sub.5 can be an
alkylene, (hetero)arylene, (hetero)aralkylene, heteroalkylene
having one or more oxy (--O--) groups, or heteroalkylene having one
or more --NH-groups. (Hetero)arylene and (hetero)aralkylene R.sub.5
groups can optionally be substituted with a primary amino group
and/or a secondary amino group.
[0088] Suitable alkylene R.sub.5 groups in Formula (V-1) usually
have at least 1 carbon atom, at least 2 carbon atoms, at least 3
carbon atoms, or at least 4 carbon atoms and can have up to 20
carbon atoms, up to 16 carbon atoms, up to 12 carbon atoms, up to
10 carbon atoms, or up to 6 carbon atoms. Some nitrogen-containing
compounds are of Formula (V-1) with RI being hydrogen, R.sub.5
being an alkylene, and R.sub.6 being hydrogen. Examples of such
nitrogen-containing compounds are alkylene diamines such as, for
example, methylene diamine, ethylene diamine, propylene diamine,
and butylene diamine. Nitrogen-containing compounds of Formula
(V-1) having both R.sub.1 and R.sub.6 equal to alkyl include
N,N'-dimethylethylene diamine.
[0089] In other embodiments of the compounds of Formula (V-1), the
group R.sub.5 is a heteroalkylene (i.e., a heteroalkylene is a
divalent radical of a heteroalkane, which is an alkane having
catenary heteroatoms) having at least one catenary --O-- or
--NH-group. Stated differently, heteroalkylene R.sub.3 groups have
one or more groups of formula --R.sub.a-[O--R.sub.b].sub.n- or
--R.sub.a-[NH-R.sub.b].sub.n- where each R.sub.a and each R.sub.b
are independently an alkylene and n is an integer in a range 1 to
50, 1 to 40, 1 to 30, 1 to 20, 1 to 10, 1 to 6, or 1 to 4. Suitable
R.sub.a and R.sub.b alkylene groups often have 1 to 10 carbon
atoms, 1 to 6 carbon atoms, 1 to 4 carbon atoms, or 1 to 3 carbon
atoms. The heteroalkylene often has up to 30 carbon atoms and up to
16 heteroatoms, up to 20 carbon atoms and up to 11 heteroatoms, or
up to 10 carbon atoms and up to 6 heteroatoms. Such
nitrogen-containing compounds can be represented by Formulas (V-2)
and (V-3).
R.sub.6HN--R.sub.a-[O--R.sub.b].sub.n-NHR.sub.1 (V-2)
R.sub.6HN-R.sub.a-[NH--R.sub.b].sub.n-NHR.sub.1 (V-3)
Some nitrogen-containing compounds are of Formula (V-2) with
R.sub.1 being hydrogen, R.sub.5 being a heteroalkylene with
--O-groups, and R.sub.6 being hydrogen. Examples of such
nitrogen-containing compounds are poly(alkylene oxide) diamines
such as polyethylene glycol diamine and polypropylene glycol
diamine. Further nitrogen-containing compounds are of Formula (V-3)
with R.sub.1 being hydrogen, R.sub.5 being a heteroalkylene with
--NH-groups, and R.sub.6 being hydrogen. Such nitrogen-containing
compounds can be, for example, compounds of formula
H.sub.2N-[(CH.sub.2).sub.xNH].sub.y-(CH.sub.2).sub.xNH.sub.2 where
x is an integer in a range of 1 to 4 and y is in a range of 1 to
10. Examples include diethylene triamine, triethylene tetramine,
and tetraethylene pentamine.
[0090] The R.sub.5 group in Formula (V-1) can also be a
(hetero)arylene or (hetero)aralkylene group. The (hetero)arylene or
(hetero)aralkylene can optionally be substituted with a primary
amino group and/or a secondary amino group. Suitable arylene
R.sub.5 groups often have 6 to 12 carbon atoms and are often
phenylene or diphenylene. Suitable heteroarylene R.sub.5 groups
often have 2 to 10 carbon atoms and 1 to 5 heteroatoms selected
from nitrogen, oxygen and sulfur. Suitable (hetero)aralkylene
R.sub.5 groups often have an alkylene or alkyl portion having 1 to
10 carbon atoms, 1 to 6 carbon atoms, or 1 to 4 carbon atoms. The
aryl or arylene portion of the aralkylene often has 6 to 12 carbon
atoms and is often either phenyl or phenylene. The heteroaryl or
heteroarylene portion of the heteroaralkylene often has 2 to 10
carbon atoms and 1 to 5 heteroatoms selected from nitrogen, oxygen,
and sulfur. In many embodiments, the heteroatoms are nitrogen.
[0091] Example nitrogen-containing compounds of Formula (V-1) with
both R.sub.1 and R.sub.6 being hydrogen and R.sub.5 being arylene
include, but are not limited to, phenylene diamine. An example
nitrogen-containing compound of Formula (V-1) with both R.sup.I and
R.sup.6 being hydrogen and R.sub.5 being a heteroarylene is
melamine (i.e., melamine is an heteroarylene with three nitrogen
heteroatoms, wherein the heteroarylene is substituted with a
primary amino group).
[0092] Yet other nitrogen-containing compounds are of Formula (V-1)
with R.sub.6 being --(C=NH)--NH.sub.2 as shown in Formula
(V-4).
NH.sub.2--(C=NH)--HN-R.sub.5-NHR.sub.1 (V-4)
[0093] Such compounds have at least two amino groups of formula
-NHR. In some compounds of Formula (V-4), R.sub.1 is hydrogen and
R.sub.5 is alkylene. One such compound is agmatine. Agmatine can be
represented by other resonance structures as well but is considered
to be within the scope of both Formula (V-1) and (V-4).
[0094] In other embodiments of Formula (V), R.sub.4 is a group
--(C=NH)-NH.sub.2. The resulting compounds are of Formula
(V-5).
H.sub.2N--(C=NH)--NHR.sub.1 (V-5)
[0095] Such compounds have at least two amino groups of formula
-NHR. The compound of Formula (V-5) is guanidine when R.sub.1 is
hydrogen.
[0096] Other suitable nitrogen-containing compounds are polyamines
having at least three groups of formula -NHR.sub.1 where R.sub.1 is
hydrogen or alkyl. Such compounds can be of Formula (VI).
R.sub.7-(NHR.sub.1).sub.z (VI)
In Formula (VI), R.sub.1 is defined as above and the variable z is
equal to at least 3 and can be up to 10, up to 8, up to 6, or up to
4. The R.sub.7 group is often a z-valent radical of an alkane or a
z-valent radical of a heteroalkane. Suitable z-valent radicals of
alkanes often have a branching carbon atom with at least three of
the four adjacent groups being --CH.sub.2--. Suitable z-valent
radicals of heteroalkanes often have a branching nitrogen atom with
three adjacent carbon atoms (e.g., three adjacent groups that are
alkylene or alkyl groups) or a branching carbon atom with at least
three of the four adjacent atoms being carbon (e.g., three adjacent
groups that are alkylene or alkyl groups). These z-valent radicals
of heteroalkanes often include one or more groups of formula
-R.sub.c-[NH-R.sub.d].sub.p-where each R.sub.c and each R.sub.d are
independently an alkylene and p is an integer in a range 1 to 50, 1
to 40, 1 to 30, 1 to 20, 1 to 10, 1 to 6, or 1 to 4. Suitable
R.sub.cand R.sub.d alkylene groups often have 1 to 10 carbon atoms,
1 to 6 carbon atoms, 1 to 4 carbon atoms, or 1 to 3 carbon atoms.
The z-valent radicals of alkanes often have at least 2 carbon
atoms, at least 3 carbon atoms, at least 4 carbon atoms, or at
least 5 carbon atoms and up to 20 carbon atoms, up to 16 carbon
atoms, up to 12 carbon atoms, or up to 8 carbon atoms. The z-valent
radicals of heteroalkanes often have up to 30 carbon atoms and up
to 16 heteroatoms, up to 20 carbon atoms and up to 11 heteroatoms,
or up to 10 carbon atoms and up to 6 heteroatoms.
[0097] Specific polyamines of formula R.sub.7-(NHR.sub.1).sub.z
include various polyimines. Some polyimines include one or more
branching nitrogen atoms with each nitrogen-branching atom
connected to three groups of formula
-R.sub.c-[NH--R.sub.d].sub.p--. The end group of each branched
segment is often a group of formula --NHR.sub.1 such as --NH.sub.2.
Examples include various branched polyethyleneimines. Another
specific polyamine is 2-(aminomethyl)-2-methyl-1,3-propanediamine
where R.sub.7 is a trivalent radical of an alkane (i.e., the carbon
branching atom is connected to four carbon atoms with three
adjacent alkylene groups and one adjacent methyl group), each
R.sub.1 is hydrogen, and z is equal to 3.
[0098] In many embodiments, the nitrogen-containing compounds such
as those of Formula (V) (including Formula V-1 to V-5) and Formula
(VI) have a molecular weight (or weight average molecular weight)
that is no greater than 2000 Daltons (Da). For example, the
molecular weight (or weight average molecular weight) is no greater
than 1500 Da, no greater than 1000 Da, no greater than 750 Da, no
greater than 500 Da, or no greater than 250 Da.
[0099] Up to one mole of the nitrogen-containing compound can be
added per mole of carboxylic acid present in the hydrolyzed
divinylbenzene/maleic anhydride polymeric material. That is, up to
100 mole percent nitrogen-containing compound can react with the
hydrolyzed polymeric material based on the total moles of
carboxylic acid. In some embodiments, the amount of
nitrogen-containing compound added is up to 95 mole percent or
higher, up to 90 mole percent, up to 85 mole percent, up to 80 mole
percent, up to 70 mole percent, up to 60 mole percent, or up to 50
mole percent based on the total moles of carboxylic acid. The
amount of the nitrogen-containing compound can be at least 1 mole
percent, at least 2 mole percent, at least 5 mole percent, at least
10 mole percent, at least 20 mole percent, at least 30 mole
percent, at least 40 mole percent, at least 50 mole percent, at
least 60 mole percent, or at least 80 mole percent based on the
total moles of monomeric units of Formula (II) in the precursor
polymeric material. In some embodiments, the amount of
nitrogen-containing compound is in a range of 1 to 100 mole
percent, in a range of 10 to 100 mole percent, in a range of 20 to
100 mole percent, in a range of 30 to 100 mole percent, a range of
40 to 100 mole percent, in a range of 50 to 100 mole percent, in a
range of 60 to 100 mole percent, or in a range of 80 to 100 mole
percent based on the total moles of carboxylic acid.
[0100] To react the nitrogen-containing compound with the
hydrolyzed polymeric material resulting in the formation of an
ionic bond, the nitrogen-containing compound is often dissolved in
water and/or a suitable organic solvent. Suitable organic solvents
are those that dissolve but do not react with the
nitrogen-containing compound. Exemplary organic solvents include,
but are not limited to, alcohols, ethers such as tetrahydrofuran
and diethyl ether, and various chlorinated solvents such as
methylene chloride and chloroform. The concentration of the
nitrogen-containing compound in water and/or organic solvent can be
any suitable amount depending on the solubility of the
nitrogen-containing compound. In some embodiments, the
concentration of the nitrogen-containing compound in water and/or
organic solvent is in a range of 1 to 40 weight percent, in a range
of 1 to 30 weight percent, in a range of 1 to 20 weight percent, or
in a range of 1 to 10 weight percent.
[0101] The solution of the nitrogen-containing compound is mixed
with the hydrolyzed polymeric material. The reaction can occur at
room temperature or can occur by heating the mixture to a
temperature above room temperature. For example, the mixture can be
heated at temperatures in a range of 30.degree. C. to 120.degree.
C. for several hours to several days. In some embodiments, the
suspension is heated at 30.degree. C. to 100.degree. C., 40.degree.
C. to 90.degree. C., 50.degree. C. to 90.degree. C., or 60.degree.
C. to 80.degree. C. for 12 to 24 hours.
[0102] The polymeric sorbent typically has a BET specific surface
area that is less than that of the precursor polymeric material.
The opening of the anhydride group to form the hydrolyzed polymeric
material may sufficiently increase the conformational freedom in
the backbone resulting in decreased porosity. In addition, hydrogen
bonding between the nitrogen-containing groups in the polymeric
sorbent could possibly restrict or block access to pores. Because
of this decrease, it is often desirable to prepare a precursor
polymeric material having the highest possible BET specific surface
area, yet having sufficient anhydride groups to react with the
nitrogen-containing compound. The BET specific surface area of the
polymeric sorbent is typically at least 25 m.sup.2/gram.
[0103] In some embodiments, the polymeric sorbent further includes
an acid-base indicator. The acid-base colorimetric indicator (i.e.,
a dye (typically an organic dye) that changes color when it
undergoes a transition from being in an acidic form to being in a
basic form) can be added at the same time as the
nitrogen-containing compound or can be added after addition of the
nitrogen-containing compound. The acid-base colorimetric indicator
is typically selected to have a pK.sub.b that is less than a
pK.sub.b of the nitrogen-containing compound. That is, the
acid-base colorimetric indicator is selected to change from a first
color to a second color when all or a significant portion of the
available nitrogen-containing groups on the polymeric sorbent have
reacted with an aldehyde. The change in color signals that the
capacity of the polymeric sorbent for sorption of an aldehyde has
been reached or is close to being reached. As used herein, the term
"close to being reached" means that at least 60 percent or more of
the capacity has been reached (i.e., a least 60 percent or more of
the available sorption sites have been used for sorption of an
aldehyde). For example, at least 70 percent, at least 80 percent,
at least 90 percent, or at least 95 percent of the sorption sites
have been used for sorption of an aldehyde.
[0104] Knowing the pK.sub.b of the nitrogen-containing compound,
one of skill in the art can readily select an acid-base
colorimetric indicator that has a lower pK.sub.b value. In some
applications, the difference between the pK.sub.b value of the
nitrogen-containing compound and the pK.sub.b of the acid-base
colorimetric indicator is at least 1, at least 2, at least 3, or at
least 4. The pK.sub.b of the acid-base colorimetric indicator is
often in a range of 3 to 10.
[0105] Example acid-base colorimetric indicators include, but are
not limited to, methyl red, bromoxylenol blue, pararosaniline,
chrysoidine, thymol blue, methyl yellow, bromophenyl blue, Congo
red, methyl orange, bromocresol green, azolitmin, bromocresol
purple, bromothymol blue, phenol red, neutral red,
naphtholphthalein, cresol red, phenolphthalein, and
thymolphthalein.
[0106] The acid-base colorimetric indicators can be added to the
polymeric sorbent using any suitable method. In some embodiments,
the polymeric sorbent is soaked in a solution of the acid-base
colorimetric indicator for at least 10 minutes, at least 20
minutes, at least 30 minutes, at least 1 hour, at least 2 hours, at
least 4 hours, or at least 8 hours. The solution of the acid-base
colorimetric indicator is often in a concentration range of 5 to 10
milligrams per milliliter. Often, about 0.5 grams of the polymeric
sorbent is soaked in about 10 milliliters of the solution.
[0107] In another aspect, composite granules that contain a binder
and a polymeric sorbent material for capturing aldehydes such as
formaldehyde are provided. The polymeric sorbent material is the
same as described above.
[0108] The polymeric sorbent and/or the precursor of the polymeric
sorbent included in the composite granules is often prepared in a
pressurized reactor as a single block of polymeric material. This
block of polymeric material is then broken up and crushed into fine
particles using a rotary hammer mill. Typical mills include a
screen to help control the particle size by keeping all crushed
particles smaller than the size of the holes in the screen. During
the crushing and milling of the polymeric material, a significant
amount of fine particles are produced that can be too small for use
in some applications such as filtration applications. For example,
as much as one third of the polymeric material that is crushed and
milled can be too small for use in certain filtration applications.
What is considered to be too small can vary depending on the
particular application and on the allowable pressure drop.
[0109] The fine particles of the polymeric material can be formed
into larger particles (i.e., composite granules) by combination
with a binder. The composite granules typically have a size that is
suitable for use in filtration applications. Thus, formation of the
composite granules allows full use of all of the polymeric material
formed within the reactor and thereby reduces the overall
production costs of the polymeric sorbent.
[0110] Furthermore, some processes for making articles (e.g.,
filtration articles) containing the polymeric sorbents can result
in the formation of additional fine particles. For example, making
polymeric sorbent loaded webs, loading respirator cartridges, and
ultrasonic welding of respirators and respirator cartridges can
lead to pulverization of the polymeric sorbent materials resulting
in the formation of fine particles. Providing polymeric sorbents in
a form that reduces pulverization can be beneficial from a
processing perspective. It has been found that combining the
polymeric sorbent with a binder can result in the formation of
composite granules with improved toughness (e.g., less likely to
crumble apart) compared to polymeric sorbent in the absence of a
binder. In addition, the composite granules of the present
disclosure can be produced without negatively impacting the ability
of the polymeric sorbent to sorb aldehyde compounds to such an
extent that the composite granules are not useful as sorbents.
[0111] The binder included in the composite granules can be an
organic material (such as a polymeric material), an inorganic
material (such as, for example, a metal silicate salt), or a
combination thereof (a compound having an inorganic portion and an
organic portion such as, for example, a metal carboxylate salt). In
many embodiments, the binder is a salt or a polymeric material such
as, for example, a cellulose resin.
[0112] In certain embodiments, the binder includes a
polyelectrolyte material. Any suitable polyelectrolyte material can
be used including those with organic or inorganic counterions. Some
suitable polyelectrolyte material is derived from natural polymers
or modified natural polymers. Example polyelectrolyte include, but
are not limited to, polyamines, polyamides, polyalcohols,
polysacharides, polyacrylamides, polyacrylates, humic acids,
proteins, polydiallyldimethylammonium salts such as
polydiallyldimethylammonium chloride,
polyamine-polydiallyldimethylammonium chloride blends,
polyquartenary amines, inorganic-polyamine blends,
inorganic-polydiallyldimethylammonium chloride blends, cationic
starches, cationic polymethylmethacrylates, copolymers of
vinylimidazolium methochloride and vinylpyrrolidone, quarternized
vinylpyrrolidone/dimethylaminoethyl methacrylate copolymers,
polyethyleneimines, and mixtures thereof. In certain embodiments,
the polyelectrolyte material includes cationic starches.
[0113] In certain embodiments, the binder includes metal
hydroxides, metal oxides, metal salts, organometallic compounds, or
combinations thereof. Some suitable metal oxide, metal hydroxide,
and metal salt binders are derived from aluminum, calcium,
magnesium, or iron (including polyaluminum sulfates and
polyaluminum chlorides). Other example binders are
polyorganozirconates, polyorganoaluminates, polysiloxanes,
polysilanes, polysilazanes, polycarbosilanes, polyborosilanes,
zirconium dimethacrylate, zirconium tetramethacrylate, zirconium
2-ethylhexanoate, aluminum butoxides, aluminum diisopropoxide
ethylacetoacetate, tetramethyldisiloxanes,
tristrimethylsilylphosphate, tristrimethylsiloxyboron, and
combinations thereof. Some example metal salts are metal
carboxylate salts such as metal carboxylate salts having 10 to 20
carbon atoms (e.g., magnesium stearate). Other example inorganic
binders are silicate salts (e.g., metal silicates). Example metal
silicates include sodium silicate (e.g., sodium metasilicate),
potassium silicate, calcium silicate, magnesium silicate, and
combinations thereof. In certain embodiments, the silicate is
sodium metasilicate.
[0114] Other example binders include a thermoplastic polymer. The
thermoplastic polymer can be selected, for example, from polyamides
(such as nylons), polyolefins (such as polyethylenes, e.g., LDPE,
LLDPE, HDPE, polyethylene copolymers with other polyolefins, and
polypropylenes), polyvinylchlorides (both plasticized and
unplasticized), fluorocarbon resins (such as
polytetrafluoroethylene), polystyrenes, acrylic resins (such as
polyacrylates and polymethacrylates), styrene copolymers (such as
acrylonitrile-butadiene-styrenes and acrylonitrile-styrenes),
polycarbonates, polyvinylacetates, ethylene-vinyl acetate
copolymers, polyvinyl alcohols, polyoxymethylene, polyformaldehyde,
polyacetals, polyesters (such as polyethylene terephthalate),
polyether ether ketones, and phenol-formaldehyde resins (such as
resols and novolacs), and combinations thereof.
[0115] Yet other example binders include a thermoset polymer. For
example, the thermoset polymer is selected from polyurethanes,
silicones, fluorosilicones, phenolic resins, melamine resins,
melamine formaldehyde resins, and urea formaldehyde resins.
[0116] Still other example binders include an elastomer. In certain
embodiments, the elastomer is selected from natural rubbers,
synthetic rubbers (such as styrene-butadiene rubber,
polychloroprene (neoprene), nitrile rubber, and butyl rubber),
silicones, polyurethanes, alkylated chlorosulfonated polyethylenes,
polyolefins, chlorosulfonated polyethylenes, perfluoroelastomers,
ethylene-propylene-diene terpolymers, chlorinated polyethylene,
fluoroelastomers, and mixtures thereof.
[0117] In certain embodiments, the binder includes a naturally
occurring polymer. Example naturally occurring polymer can be
selected from celluloses, collagens, organic acids, and
combinations thereof. For example, the naturally occurring polymer
can be a biodegradable polymer. Suitable biodegradable polymers can
be selected from polyethyleneglycols, polylactic acids,
polyvinylalcohols, cellulosic resins (such as cellulose acetate
butyrates, carboxy methyl cellulose, and cellulose ethers such as
hydroxypropyl methylcellulose), alginic acid, carrageenans isolated
from seaweed, polysaccharides, pectins, xanthans, starches,
copolymers of polylactideglycolide, and combinations thereof. In
some embodiments, the biodegradable polymer is selected from
polyethyleneglycols, polylactic acids, polyvinylalcohols,
copolymers of polylactideglycolide, and mixtures thereof.
[0118] In certain embodiments, the binder includes an electrically
conductive polymer. Example electrically conductive polymers can be
selected from doped polyanilines and polythiophenes.
[0119] In certain embodiments, the binder includes a gelling
material, an absorbent material, or combinations thereof. Example
absorbent binder material can be a superabsorbent material such as
polyacrylic acids, polyacrylamides, polyalcohols, polyamines,
polyethylene oxides, cellulose such as carboxymethyl cellulose,
chitins, gelatins, starches, polyvinyl alcohols, polyacrylic acid,
polyacrylonitrile, alginic acid, carrageenans isolated from
seaweeds, polysaccharides, pectins, xanthans,
polydiallyldimethylammonium chloride, polyvinylpyridine,
polyvinylbenzyltrimethylammonium salts, polyvinylacetates,
polylactic acids, and combinations thereof.
[0120] The composite granules often contain binder in an amount of
at least 1 weight percent, at least 2 weight percent, at least 5
weight percent, or at least 10 weight percent based on the total
weight of the composite granules. In certain embodiments, the
binder is present in the composite granules in an amount of up to
30 weight percent, up to 25 weight percent, or up to 20 weight
percent, based on the total weight of the composite granules.
[0121] The composite granules often contain polymeric sorbent in an
amount of at least 70 weight percent, at least 75 weight percent,
or at least 80 weight percent, based on the total weight of the
composite granules. In certain embodiments, the polymeric sorbent
is present in the composite granules in an amount of up to 90
weight percent, up to 95 weight percent, up to 98 weight percent,
or up to 99 weight percent, based on the total weight of the
composite granules.
[0122] In some embodiments, the composite granules contain 1 to 30
weight percent binder and 70 to 99 weight percent polymeric sorbent
based on the total weight of the composite granules. For example,
the composite granules can contain 5 to 30 weight percent binder
and 70 to 95 weight percent polymeric sorbent, 10 to 30 weight
percent binder and 70 to 90 weight percent polymeric sorbent, 1 to
25 weight percent binder and 75 to 99 weight percent polymeric
sorbent, 5 to 25 weight percent binder and 75 to 95 weight percent
polymeric sorbent, 10 to 25 weight percent binder and 75 to 90
weight percent polymeric sorbent, 1 to 20 weight percent binder and
80 to 99 weight percent polymeric sorbent, 5 to 20 weight percent
binder and 80 to 95 weight percent polymeric sorbent, or 10 to 20
weight percent binder and 80 to 90 weight percent polymeric
sorbent.
[0123] The polymeric sorbent and the binder are often blended
together without the use of any liquid such as water or an organic
solvent. The blended material can then be pressed into a pellet or
disk that is subsequently ground or milled and then sieved to
obtain composite granules of the desired size (e.g., the composite
granules of the desired size are retained on the sieve). Any
material that goes through the sieve can be collected and recycled
by pressing into additional pellets or disks.
[0124] Any suitable pressure can be used to form the pellets or
disks. The blended material can optionally be heated during the
process of forming the pellets or disks. In some embodiments, the
blended material can be heated to a temperature near (but often
below) the melting point of the binder.
[0125] The pressure and temperature are selected to provide pellets
or disks that do not crumble (or that undergo minimal crumbling)
when broken. The pellets or disks can have any suitable size, such
as for example, from 0.5 to 3 centimeters, from 1 to 3 centimeters,
or from 2 to 3 centimeters.
[0126] The pressure selected for forming the pellets or disks is
typically in a range of 6,000 pounds per square inch (psi) to
60,000 psi or even higher. For example, the pressure is often at
least 6,000 psi, at least 6,400 psi, at least 6,500 psi, at least
10,000 psi, at least 20,000 psi, or at least 25,000 psi and can be
up to 60,000 psi, up to 50,000 psi, up to 40,000 psi, or up to
30,000 psi. The dwell time (the time the force is applied) can vary
from a few seconds to several minutes. For example, the dwell time
can be in range of 1 seconds to 10 minutes.
[0127] The polymeric sorbents offer a distinct advantage over
sorbents based on impregnation of a capture agent. The capture
agents are typically simply sorbed on the matrix material such as,
for example, activated carbon. That is, the capture agents are
usually not ionically attached to the matrix material and can
migrate. In contrast, the polymeric sorbents described herein have
ionically attached nitrogen-containing groups that interact with
the aldehyde and that do not migrate.
[0128] In another aspect, a method of sorbing an aldehyde on a
polymeric sorbent is provided. The method includes providing a
polymeric sorbent and then sorbing the aldehyde on the polymeric
sorbent. The polymeric sorbent is a reaction product of (a) a
hydrolyzed divinylbenzene/maleic anhydride polymeric material
having carboxylic acid groups and (b) a nitrogen-containing
compound having at least two amino groups of formula --NHR where R
is hydrogen or alkyl. Any of the polymeric sorbents described above
can be used. If desired, the polymeric sorbent can be part of a
composite granule.
[0129] The polymeric sorbent sorbs aldehydes. Suitable aldehydes
are of Formula (I)
R.sub.2-(CO)--H (I)
where R.sub.2 is hydrogen, alkyl, vinyl, aryl, or aryl substituted
with an alkyl. Suitable alkyl groups typically have 1 to 10 carbon
atoms, 1 to 6 carbon atoms, 1 to 4 carbon atoms, 1 to 3 carbon
atoms, or 1 carbon atom. The aryl group can have up to 12 carbon
atoms or up to 6 carbon atoms. The aryl group is often phenyl. The
aryl group can be substituted with an alkyl group such as an alkyl
group having 1 to 4 carbon atoms or 1 to 3 carbon atoms.
[0130] The aldehyde is sorbed by the polymeric sorbent when it is
in the form of a vapor. Thus, the molecular weight of the aldehyde
is typically no greater than 200 grams/mole, no greater than 150
grams/mole, no greater than 100 grams/mole, no greater than 75
grams/mole, or no greater than 50 grams/mole. Suitable aldehydes
include, but are not limited to formaldehyde, acetaldehyde,
propionaldehyde, butyraldehyde, pentanal (valeraldehyde),
isovaleraldehyde, hexanal, benzaldehyde, 2,5-dimethylbenzaldehyde,
2,4-dimethylbenzaldehyde, 2,3-dimethylbenzaldehyde, tolualdehydes
(ortho-tolualdehyde, meta-tolualdehyde, para-tolualdehyde, and
mixtures thereof), acrolein and crotonaldehyde.
[0131] The aldehyde can be sorbed at room temperature or at any
desired temperature such as in a range of -30.degree. C. to
150.degree. C., -30.degree. C. to 100.degree. C., or in a range of
-20.degree. C. to 50.degree. C.
[0132] In another aspect, a composition is provided that includes
the polymeric sorbent and an aldehyde sorbed on the polymeric
sorbent. The polymeric sorbent and the aldehyde are the same as
described above. The aldehyde can react with any primary amino
group or secondary amino group present on the polymeric
sorbent.
[0133] In some embodiments, the polymeric sorbent is formed using a
compound of Formula (V) as the nitrogen-containing compound.
R.sub.4NHR.sub.1 (V)
The resulting polymeric sorbent has ionic groups of formula
--COO.sup.-(NH.sub.2R.sub.1R.sub.4).sup.+. The anion (--COO--) is
from the hydrolyzed divinylbenzene/maleic anhydride polymeric
material and the cation ((NH.sub.2R.sub.1R.sub.4).sup.+) is from
the nitrogen-containing compound. Groups R.sub.1 and R.sub.4 are
the same as defined above.
[0134] In some embodiments, the polymeric sorbent is formed using a
compound of Formula (V-1) as the nitrogen-containing compound.
R.sub.6HN-R.sub.5-NHR.sub.1 (V-1)
The resulting polymeric sorbent can have ionic groups of formula
--COO.sup.-(NH.sub.2R.sub.6-R.sub.5-NHR.sub.1).sup.+,
--COO.sup.-(NH.sub.2R.sub.1-R.sub.5-NHR.sub.6).sup.+, or both. If
the terminal R.sub.1 of the group of formula
--COO.sup.-(NH.sub.2R.sub.6-R.sub.5-NHR.sub.1).sup.+ is hydrogen,
the polymeric sorbent after exposure to the aldehyde
R.sub.2--(CO)--H can have groups of formula
--COO.sup.-(NH.sub.2R.sub.6-R.sub.5-NH-CHR.sub.2--OH.sub.2).sup.+,
--COO.sup.-(NH.sub.2R.sub.6-R.sub.5-N(CHR.sub.2--OH).sub.2).sup.+,
--COO.sup.-(NH.sub.2R.sub.6-R.sub.5-N=CR.sub.2H).sup.+, or a
mixture thereof. Likewise, if the terminal R.sub.6 of the group of
formula --COO.sup.-(NH.sub.2R.sub.1-R.sub.5-NHR.sub.6).sup.+is
hydrogen, the polymeric sorbent after exposure to the aldehyde
R.sub.2--(CO)--H can have groups of formula
--COO.sup.-(NH.sub.2R.sub.1-R.sub.5-NH-CHR.sub.2--OH).sup.+,
--COO.sup.-(NH.sub.2R.sub.1-R.sub.5-N(CHR.sub.2--OH).sub.2).sup.+,
--COO.sup.-(NH.sub.2R.sub.1-R.sub.5-N=R.sub.2H).sup.+, or a mixture
thereof If the terminal RI of the group of formula
--COO.sup.-(NH.sub.2R.sub.6-R.sub.5-NHR.sub.1).sup.+is alkyl, the
polymeric sorbent after exposure to the aldehyde R.sub.2--(CO)--H
can have groups of formula
--COO.sup.-(NH.sub.2R.sub.6-R.sub.5-NR.sub.I-CHR.sub.2--OH).sup.+.
Likewise, if the terminal R.sub.6 of the group of formula
--COO.sup.-(NH.sub.2R.sub.1-R.sub.5-NHR.sub.6).sup.+is alkyl, the
polymeric sorbent after exposure to the aldehyde R.sub.2--(CO)--H
can have groups of formula
--COO.sup.-(NH.sub.2R.sub.1-R.sub.5-NR.sub.6-CHR.sub.2--OH).sup.+.
Additional amounts of aldehyde can react with any remaining primary
amino group or secondary amino group.
[0135] In yet other embodiments, the polymeric sorbent is formed
using a compound of Formula (V-4) as the nitrogen-containing
compound.
NH.sub.2--(C=NH)--HN-R.sub.5-NHR.sub.1 (V-4)
The resulting polymeric sorbent can have nitrogen-containing groups
of formula
--COO.sup.-(NH.sub.3--(C=NH)--NH-R.sub.5-NHR.sub.1).sup.+,
--COO.sup.-(NH.sub.2R.sub.1-R.sub.5-NH--(C=NH)--NH.sub.2).sup.+, or
both. If the terminal R.sub.1 of the group of formula --COO.sup.31
(NH.sub.3-(C=NH)--NH-R.sub.5-NHR.sub.1).sup.+ is hydrogen, the
polymeric sorbent after exposure to the aldehyde R.sub.2--(CO)--H
can have groups of formula --COO.sup.31
(NH.sub.3--(C=NH)--NH-R.sub.5--NH--CHR.sub.2--OH).sup.+,
--COO.sup.31
(NH.sub.3--(C=NH)--NH-R.sub.5--N(CHR.sub.2--OH)2).sup.+,
--COO.sup.31 (NH.sub.3--(C=NH)--NH-R.sub.5--N=CR.sub.2H).sup.+, or
a mixture thereof. If the terminal R.sub.1 of the group of formula
--COO.sup.31 (NH.sub.3--(C=NH)--NH-R.sub.5--NHR.sub.1).sup.+ is an
alkyl, the polymeric sorbent after exposure to the aldehyde
R.sub.2--(CO)--H can have groups of formula --COO.sup.31
(NH.sub.3--(C=NH)--NH--R.sub.5-NR.sub.1--CHR.sub.2--OH).sup.+. If
the polymeric sorbent has groups of formula --COO.sup.31
(NH.sub.2R.sub.1-R.sub.5--NH--(C=NH)--NH.sub.2).sup.+, the
polymeric sorbent after exposure to the aldehyde R.sub.2--(CO)--H
can have groups of formula --COO.sup.31
(NH.sub.2R.sub.1-R.sub.5--NH--(C=NH)--NH--CHR.sub.2--OH).sup.+,
--COO.sup.31
(NH.sub.2R.sub.1-R.sub.5--NH--(C=NH)--N(CHR.sub.2--OH).sub.2).sup.+,
--COO.sup.31
(NH.sub.2R.sub.1-R.sub.5--NH--(C=NH)--N=CR.sub.2H).sup.+, or a
mixture thereof. Additional amounts of aldehyde can react with any
remaining primary amino group or secondary amino group.
[0136] In yet further embodiments, the polymeric sorbent is formed
using a compound of Formula (V-5)
H.sub.2N--(C=NH)--NHR.sub.1 (V-5)
as the nitrogen-containing compound. The resulting polymeric
sorbent can have nitrogen-containing groups of formula --COO.sup.31
(NH.sub.3--(C=NH)--NHR.sub.1).sup.+, --COO.sup.31
(NH.sub.2R.sub.1-(C=NH)-NH.sub.2).sup.+, or both. If the terminal
R.sub.1 of the group of formula --COO.sup.31
(NH.sub.3--(C=NH)--NHR.sub.1).sup.+is hydrogen, the polymeric
sorbent after exposure to the aldehyde R.sub.2--(CO)--H can have
groups of formula --COO.sup.31
(NH.sub.3--(C=NH)--NH--CHR.sub.2--OH).sup.+, --COO.sup.31
(NH.sub.3--(C=NH)--N(CHR.sub.2--OH).sub.2).sup.+, --COO.sup.31
(NH.sub.3-(C=NH)-N=CR.sub.2H).sup.+, or a mixture thereof If the
terminal Ri of the group of formula --COO.sup.31
(NH.sub.3--(C=NH)--NHR.sub.1).sup.+ is alkyl, the polymeric sorbent
after exposure to the aldehyde R.sub.2--(CO)--H can have groups of
formula --COO.sup.31
(NH.sub.3--(C=NH)--NR.sub.1--CHR.sub.2--OH).sup.+. If the polymeric
sorbent has groups of formula --COO.sup.31
(NH.sub.2R.sub.1--(C=NH)--NH.sub.2).sup.+, the polymeric sorbent
after exposure to the aldehyde R.sub.2--(CO)--H can have groups of
formula --COO.sup.31
(NH.sub.2R.sub.1--(C=NH)--NH--CHR.sub.2--OH).sup.+, --COO.sup.31
(NH.sub.2R.sub.1--(C=NH)--N(CHR.sub.2--OH).sub.2).sup.+,
--COO.sup.31 (NH.sub.2R.sub.1--(C=NH)--N=CR.sub.2H).sup.+, or a
mixture thereof. Additional amounts of aldehyde can react with any
remaining primary amino group or secondary amino group.
[0137] In still further embodiments, the polymeric sorbent is
formed using a compound of Formula (VI) as the nitrogen-containing
compound.
R.sub.7-(NHR.sub.1).sub.z (VI)
[0138] The resulting polymeric sorbent can have nitrogen-containing
groups of formula --COO.sup.31
(NH.sub.2R.sub.1-R.sub.7-(NHR.sub.1).sub.z-1).sup.+. If one of the
terminal R.sub.1 of the group of formula
--COO.sup.-(NH.sub.2R.sub.1-R.sub.7--(NHR.sub.z-1).sup.+ is
hydrogen, the polymeric sorbent after exposure to the aldehyde
R.sub.2--(CO)--H can have groups of formula --COO.sup.31
(NH.sub.2R.sub.1-R.sub.7-(NHR.sub.1).sub.z-2(NH--CHR.sub.2OH)).sup.+,
--COO.sup.31
(NH.sub.2R.sub.1-R.sub.7--(NHR.sub.1).sub.z-2(N(CHR.sub.2OH).sub.2)).sup.-
+, --COO.sup.31
(NH.sub.2R.sub.1-R.sub.7-(NHR.sub.1).sub.z-2(N=CR.sub.2H)).sup.+,
or a mixture thereof. If one of the terminal R.sub.1 of the group
of formula --COO.sup.31
(NH.sub.2R.sub.1-R.sub.7-(NHR.sub.1).sub.z-1).sup.+ is alkyl, the
polymeric sorbent after exposure to the aldehyde R.sub.2--(CO)--H
can have groups of formula --COO.sup.31
(NH.sub.2R.sub.1-R.sub.7-(NHR.sub.1).sub.z-2(NR.sub.1--CHR.sub.2OH)).sup.-
+. In some of these embodiments, more than one terminal --NHR.sub.1
group can react with the aldehyde. In addition to the terminal
groups, the aldehyde can react with any other primary and/or
secondary amino group on the polymeric sorbent.
[0139] The amount of aldehyde sorbed by the polymeric sorbent at
room temperature (e.g., 25.degree. C.) and standard pressure is
often at least 0.5 mmoles/gram (i.e., at least 0.5 mmoles of
aldehyde per gram of polymeric sorbent). For example, the amount of
aldehyde sorbed can be at least 1 mmole/gram, at least 1.5
mmoles/gram, at least 2 mmoles/gram, at least 2.5 mmoles/gram, at
least 3 mmoles/gram, at least 3.5 mmoles/gram, at least 4
mmoles/gram, at least 4.5 mmoles/gram, or at least 5 mmoles/gram.
The amount sorbed can be up to 15 mmoles/gram, up to 12 mmoles/gram
or even higher, up to 10 mmoles/gram, up to 9 mmoles/gram, up to 8
mmoles/gram, or up to 7 mmoles/gram. The amount sorbed is often in
a range of 0.5 to 12 mmoles/gram, in a range of 1 to 12
mmoles/gram, in a range of 2 to 12 mmoles/gram, in a range of 1 to
10 mmoles/gram, in a range of 2 to 10 mmoles/gram, in a range of 3
to 12 mmoles/gram, in a range of 3 to 10 mmoles/gram, or in a range
of 3 to 8 mmoles/gram.
[0140] Various embodiments are provided that are a polymeric
sorbent, a method of preparing a polymeric sorbent, a method of
sorbing aldehyde on a polymeric sorbent, a composition comprising a
polymeric sorbent and aldehyde sorbed on the polymeric sorbent, or
composite granules containing the polymeric sorbent.
[0141] Embodiment 1A is a polymeric sorbent comprising a reaction
product of a) a hydrolyzed divinylbenzene/maleic anhydride
polymeric material having carboxylic acid groups and b) a
nitrogen-containing compound having at least two amino groups of
formula --NHR, wherein R is hydrogen or alkyl and wherein the
nitrogen-containing compound is attached to the hydrolyzed
divinylbenzene/maleic anhydride polymeric material with an ionic
bond.
[0142] Embodiment 2A is the polymeric sorbent of embodiment 1A,
wherein the hydrolyzed divinylbenzene/maleic anhydride polymeric
material is a hydrolyzed product of a divinylbenzene/maleic
anhydride precursor material, the divinylbenzene/maleic anhydride
precursor material being formed from a polymerizable composition
comprising 1) 8 to 65 weight percent maleic anhydride based on the
total weight of monomers in the polymerizable composition, 2) 30 to
85 weight percent divinylbenzene based on the total weight of
monomers in the polymerizable composition, and 3) 0 to 40 weight
percent of a styrene-type monomer based on the total weight of
monomers in the polymerizable composition, wherein the styrene-type
monomer is styrene, an alkyl-substituted styrene, or a combination
thereof.
[0143] Embodiment 3A is the polymeric sorbent of embodiment 1A or
2A, wherein the polymerizable composition comprises 15 to 65 weight
percent maleic anhydride, 30 to 85 weight percent divinylbenzene,
and 0 to 40 weight percent of a styrene-type monomer based on the
total weight of monomers in the polymerizable composition.
[0144] Embodiment 4A is the polymeric sorbent of any one of
embodiments 1A to 3A, wherein the polymerizable composition
comprises 25 to 65 weight percent maleic anhydride, 30 to 75 weight
percent divinylbenzene, and 1 to 20 weight percent styrene-type
monomer based on the total weight of monomers in the polymerizable
composition.
[0145] Embodiment 5A is the polymeric sorbent of any one of
embodiments 1A to 4A, wherein the polymerizable composition
comprises 30 to 65 weight percent maleic anhydride, 30 to 70 weight
percent divinylbenzene, and 1 to 20 weight percent styrene-type
monomer based on the total weight of monomers in the polymerizable
composition.
[0146] Embodiment 6A is the polymeric sorbent of any one of
embodiments 1A to 5A, wherein the nitrogen-containing compound is
of Formula (V)
R.sub.4NHR.sub.1 (V)
wherein R.sub.1 is hydrogen or an alkyl. R.sub.4 is a group of
formula -R.sub.5-NHR.sub.6, or --(C=NH)--NH.sub.2. R.sub.5 is an
alkylene, a (hetero)arylene, a (hetero)aralkylene, a heteroalkylene
having one or more oxy (--O--) groups, or a heteroalkylene having
one or more --NH-groups. R.sub.6 is hydrogen, alkyl, or
--(C=NH)--NH.sub.2.
[0147] Embodiment 7A is the polymeric sorbent of embodiment 6A,
wherein the polymeric sorbent has ionic groups of formula
--COO.sup.31 (NH.sub.2R.sub.1R4).sup.+.
[0148] Embodiment 8A is the polymeric sorbent of embodiment 6A,
wherein the nitrogen-containing compound is of Formula (V-1).
R.sub.6HN-R.sub.5-NHR.sub.1 (V-1)
In Formula (V-1), R.sub.1 is hydrogen or an alkyl; R.sub.5 is an
alkylene, a (hetero)arylene, a (hetero)aralkylene, a heteroalkylene
having one or more oxy (--O--) groups, or a heteroalkylene having
one or more --NH-groups, wherein the (hetero)arylene and
(hetero)aralkylene is optionally substituted with a primary amino
group and/or a secondary amino group; and R.sub.6 is hydrogen,
alkyl, or --(C=NH)--NH.sub.2.
[0149] Embodiment 9A is the polymeric sorbent of embodiment 8A,
wherein the polymeric sorbent has ionic groups of formula
--COO.sup.31 (NH.sub.2R.sub.6-R.sub.5-NHR.sub.1).sup.+,
--COO.sup.31 (NH.sub.2R.sub.1-R.sub.5-NHR.sub.6).sup.+, or
both.
[0150] Embodiment 10A is the polymeric sorbent of embodiment 8A or
9A, wherein R.sub.5 is an alkylene and the nitrogen-containing
compound is an alkylene diamine. Example alkylene diamines include,
but are not limited to, methylene diamine, ethylene diamine,
propylene diamine, butylene diamine, and N,N'-dimethylethylene
diamine.
[0151] Embodiment 11A is the polymeric sorbent of embodiment 8A or
9A, wherein R.sub.5 is a (hetero)arylene that is optionally
substituted with a primary amino group and/or a secondary amino
group. Example nitrogen-containing compounds are phenylene diamine
and melamine.
[0152] Embodiment 12A is the polymeric sorbent of embodiment 8A or
9A, wherein R.sub.5 is a heteroalkylene and the nitrogen-containing
compound is of Formula (V-2) or Formula (V-3).
R.sub.6HN-R.sub.a-[O-R.sub.b].sub.n-NHR.sub.1 (V-2)
R.sub.6HN-R.sub.a-[NH-R.sub.b].sub.n-NHR.sub.1 (V-3)
In these formulas, R.sub.a is an alkylene; R.sub.b is an alkylene;
and n is an integer in a range of 1 to 50.
[0153] Embodiment 13A is the polymeric sorbent of embodiment 12A,
wherein the nitrogen-containing compound is of Formula (V-2) and is
a polyethylene glycol diamine or a polypropylene glycol
diamine.
[0154] Embodiment 14A is the polymeric sorbent of embodiment 12A,
wherein the nitrogen-containing compound is of Formula (V-3) and is
diethylene triamine, triethylene tetramine, or tetraethylene
pentamine.
[0155] Embodiment 15A is the polymeric sorbent of embodiment 8A,
wherein the nitrogen-containing compound of Formula (V-1) is of
Formula (V-4).
NH.sub.2--(C=NH)--HN-R.sub.5--NHR.sub.1 (V-4)
[0156] Embodiment 16A is the polymeric sorbent of embodiment 15A,
wherein the polymeric sorbent has ionic groups of formula
--COO.sup.31 (NH.sub.3--(C=NH)--NH-R.sub.5-NHR.sub.1).sup.+,
--COO.sup.-(NH.sub.2R.sub.1-R.sub.5-NH--(C=NH)--NH.sub.2).sup.+, or
both.
[0157] Embodiment 17A is the polymeric sorbent of embodiment 15A or
16A, wherein R.sub.5 is an alkylene.
[0158] Embodiment 18A is the polymeric sorbent of any one of
embodiments 15A to 17A, wherein the nitrogen-containing compound is
agmatine.
[0159] Embodiment 19A is the polymeric sorbent of embodiment 8A,
wherein the nitrogen-containing compound of Formula (V-1) is of
Formula (V-5).
H.sub.2N--(C=NH)--NHR.sub.1 (V-5)
[0160] Embodiment 20A is the polymeric sorbent of embodiment 19A,
wherein the polymeric sorbent has ionic groups of formula
--COO.sup.-(NH.sub.3--(C=NH)--NHR.sub.1).sup.+, --COO.sup.31
(NH.sub.2R.sub.1--(C=NH)--NH.sub.2).sup.+, or both.
[0161] Embodiment 21A is the polymeric sorbent of embodiment 19A or
20A, wherein the nitrogen-containing compound is guanidine.
[0162] Embodiment 22A is the polymeric sorbent of any one of
embodiments 1A to 5A, wherein the nitrogen-containing compound is
of Formula (VI).
R.sub.7-(NHR.sub.1).sub.z (VI)
[0163] Group R.sub.7 is a z-valent radical of an alkane or a
z-valent radical of a heteroalkane. Group R.sub.1 is hydrogen or
alkyl. The variable z is an integer in a range of 3 to 10.
[0164] Embodiment 23A is the polymeric sorbent of embodiment 22A,
wherein the polymeric sorbent has ionic groups of formula
--COO.sup.31
(NH.sub.2R.sub.1-R.sub.7--(NHR.sub.1).sub.z-1).sup.+.
[0165] Embodiment 24A is the polymeric sorbent of any one of
embodiments 1A to 23A, wherein the nitrogen-containing compound has
a molecular weight no greater than 2000 Daltons.
[0166] Embodiment 25A is the polymeric sorbent of any one of
embodiments 1A to 24A, wherein the polymeric sorbent further
comprises an acid-base dye.
[0167] Embodiment 26A is the polymeric sorbent of embodiment 25A,
wherein the acid-base dye has a lower pK.sub.b than the
nitrogen-containing compound.
[0168] Embodiment 27A is the polymeric sorbent of embodiment 25A or
26A, wherein a difference between the pK.sub.b of the
nitrogen-containing compound and the pK.sub.b of the acid-base dye
is equal to at least 2.
[0169] Embodiment 28A is the polymeric sorbent of any one of
embodiments 1A to 27A, wherein the hydrolyzed divinylbenzene/maleic
anhydride polymeric material has a BET specific surface area of at
least 50 m.sup.2/g.
[0170] Embodiment 1B is a method of sorbing an aldehyde on a
polymeric sorbent. The method includes providing a polymeric
sorbent of any one of embodiments 1A to 28A and sorbing an aldehyde
on the polymeric sorbent. The aldehyde is of Formula (I)
R.sub.2-(CO)--H (I)
wherein R.sub.2 is hydrogen, alkyl, vinyl, or aryl. The molecular
weight of the aldehyde of Formula (I) is no greater than 200
grams/mole.
[0171] Embodiment 2B is the method of embodiment 1B, wherein
R.sub.2 is hydrogen (the aldehyde is formaldehyde) or methyl (the
aldehyde is acetaldehyde).
[0172] Embodiment 3B is the method of embodiment 1B or 2B, wherein
the polymeric sorbent sorbs an amount of aldehyde in a range of 0.5
to 15 millimoles per gram based on the weight of the polymeric
sorbent.
[0173] Embodiment 4B is the method of any one of embodiments 1B to
3B, wherein the polymeric sorbent comprises an acid-base dye and
wherein the acid-base dye changes color when the aldehyde sorption
capacity of the polymeric sorbent is reached or is close to being
reached.
[0174] Embodiment 1C is a composition comprising (a) a polymeric
sorbent of any one of embodiments 1A to 28A and (b) an aldehyde
sorbed on the polymeric sorbent. The aldehyde is of Formula
(I).
R.sub.2-(CO)--H (I)
In Formula (I), R.sub.2 is hydrogen, alkyl, vinyl, or aryl. The
molecular weight of the aldehyde of Formula (I) is no greater than
200 grams/mole.
[0175] Embodiment 2C is the composition of embodiment 1C, wherein
R.sub.2 is hydrogen (the aldehyde is formaldehyde) or methyl (the
aldehyde is acetaldehyde).
[0176] Embodiment 3C is the composition of embodiment 1C or 2C,
wherein the polymeric sorbent sorbs an amount of aldehyde in a
range of 0.5 to 15 millimoles per gram based on the weight of the
polymeric sorbent.
[0177] Embodiment 4C is the composition of any one of embodiments
1C to 3C, wherein the polymeric sorbent comprises an acid-base dye
and wherein the acid-base dye changes color when the aldehyde
sorption capacity of the polymeric sorbent is reached or is close
to being reached.
[0178] Embodiment 1D is a method of preparing a polymeric sorbent.
The method includes providing a divinylbenzene/maleic anhydride
precursor polymeric material, hydrolyzing the divinylbenzene/maleic
anhydride precursor polymeric material to form a hydrolyzed
divinylbenzene/maleic anhydride polymeric material having
carboxylic acid groups, and reacting the hydrolyzed
divinylbenzene/maleic anhydride polymeric material with a
nitrogen-containing compound having at least two amino groups of
formula --NHR wherein R is hydrogen or alkyl to form the polymeric
sorbent, wherein the polymeric sorbent has an ionically attached
nitrogen-containing group.
[0179] Embodiment 2D is the method of embodiment 1D, wherein the
divinylbenzene/maleic anhydride precursor material is a polymerized
product formed of a polymerizable composition comprising:
[0180] 1) 8 to 65 weight percent maleic anhydride based on the
total weight of monomers in the polymerizable composition;
[0181] 2) 30 to 85 weight percent divinylbenzene based on the total
weight of monomers in the polymerizable composition; and
[0182] 3) 0 to 40 weight percent of a styrene-type monomer based on
the total weight of monomers in the polymerizable composition,
wherein the styrene-type monomer is styrene, an alkyl-substituted
styrene, or a combination thereof.
[0183] Embodiment 3D is the method of embodiment 1D or 2D, wherein
the polymerizable composition comprises 15 to 65 weight percent
maleic anhydride, 30 to 85 weight percent divinylbenzene, and 0 to
40 weight percent of a styrene-type monomer based on the total
weight of monomers in the polymerizable composition.
[0184] Embodiment 4D is the method of any one of embodiments 1D to
3D, wherein the polymerizable composition comprises 25 to 65 weight
percent maleic anhydride, 30 to 75 weight percent divinylbenzene,
and 1 to 20 weight percent styrene-type monomer based on the total
weight of monomers in the polymerizable composition.
[0185] Embodiment 5D is the method of any one of embodiments 1D to
4D, wherein the polymerizable composition comprises 30 to 65 weight
percent maleic anhydride, 30 to 70 weight percent divinylbenzene,
and 1 to 20 weight percent styrene-type monomer based on the total
weight of monomers in the polymerizable composition.
[0186] Embodiment 6D is the method of any one of embodiments 1D to
5D, wherein the nitrogen-containing compound has a molecular weight
no greater than 2000 Daltons.
[0187] Embodiment 7D is the method of any one of embodiments 1D to
6D, wherein the nitrogen-containing compound is of Formula (V).
R.sub.4NHR.sub.1 (V)
Group RI is hydrogen or an alkyl. R.sub.4 is a group of formula
--R.sub.5-NHR.sub.6, or --(C=NH)--NH.sub.2. R.sub.5 is an alkylene,
a (hetero)arylene, a (hetero)aralkylene, a heteroalkylene having
one or more oxy (--O--) groups, or a heteroalkylene having one or
more --NH-groups, wherein the (hetero)arylene and
(hetero)aralkylene is optionally substituted with a primary amino
group and/or a secondary amino group. R.sub.6 is hydrogen, alkyl,
or --(C=NH)--NH.sub.2.
[0188] Embodiment 8D is the method of embodiment 7D, wherein the
polymeric sorbent has ionic groups of formula --COO.sup.31
(NH.sub.2R.sub.1R.sub.4).sup.+.
[0189] Embodiment 9D is the method of embodiment 7D, wherein the
nitrogen-containing compound is of Formula (V-1).
R.sub.6HN--R.sub.5-NHR.sub.1 (V-1)
[0190] In Formula (V-1), R.sub.1 is hydrogen or an alkyl; R.sub.5
is an alkylene, a (hetero)arylene, a (hetero)aralkylene, a
heteroalkylene having one or more oxy (--O--) groups, or a
heteroalkylene having one or more --NH-groups, wherein the
(hetero)arylene and (hetero)aralkylene is optionally substituted
with a primary amino group and/or a secondary amino group; and
R.sub.6 is hydrogen, alkyl, or --(C=NH)--NH.sub.2.
[0191] Embodiment 10D is the method of embodiment 9D, wherein the
polymeric sorbent has ionic groups of formula --COO.sup.31
(NH.sub.2R.sub.6-R.sub.5--NHR.sub.1).sup.+, --COO.sup.31
(NH.sub.2R.sub.1-R.sub.5-NHR6).sup.+, or both.
[0192] Embodiment 11D is the method of embodiment 9D or 10D,
wherein R.sub.5 is an alkylene and the nitrogen-containing compound
is an alkylene diamine. Example alkylene diamines include, but are
not limited to, methylene diamine, ethylene diamine, propylene
diamine, butylene diamine, and N,N'-dimethylethylene diamine.
[0193] Embodiment 12D is the method of embodiment 9D or 10D,
wherein R.sub.5 is a (hetero)arylene that is optionally substituted
with a primary amino group and/or a secondary amino group. Example
nitrogen-containing compounds are phenylene diamine and
melamine.
[0194] Embodiment 13D is the method of embodiment 9D or 10D,
wherein R.sub.5 is a heteroalkylene and the nitrogen-containing
compound is of Formula (V-2) or Formula (V-3).
R.sub.6HN--R.sub.a-[O--R].sub.n-NHR.sub.1 (V-2)
R.sub.6HN--R.sub.a-[NH-R.sub.b].sub.n-NHR.sub.1 (V-3)
In these formulas, R.sub.a is an alkylene; R.sub.b is an alkylene;
and n is an integer in a range of 1 to 50.
[0195] Embodiment 14D is the method of embodiment 13D, wherein the
nitrogen-containing compound is of Formula (V-2) and is a
polyethylene glycol diamine or a polypropylene glycol diamine.
[0196] Embodiment 15D is the method of embodiment 14D, wherein the
nitrogen-containing compound is of Formula (V-3) and is diethylene
triamine, triethylene tetramine, or tetraethylene pentamine.
[0197] Embodiment 16D is the method of embodiment 9D, wherein the
nitrogen-containing compound of Formula (V-1) is of Formula
(V-4).
NH.sub.2--(C=NH)---N--R.sub.5-NHR.sub.1 (V-4)
[0198] Embodiment 17D is the method of embodiment 16D, wherein the
polymeric sorbent has ionic groups of formula --COO.sup.31
(NH.sub.3--(C=NH)---H-R.sub.5-NHR.sub.1).sup.+, --COO.sup.31
(NH.sub.2R.sub.1-R.sub.5--NH--(C=NH)--NH.sub.2).sup.+, or both.
[0199] Embodiment 18D is the method of embodiment 16D or 17D,
wherein R.sub.5 is an alkylene.
[0200] Embodiment 19D is the method of any one of embodiments 16D
to 18D, wherein the nitrogen-containing compound is agmatine.
[0201] Embodiment 20D is the method of embodiment 9D, wherein the
nitrogen-containing compound of Formula (V-1) is of Formula
(V-5).
H.sub.2N--(C=NH)--NHR.sub.1 (V-5)
[0202] Embodiment 21D is the method of embodiment 20D, wherein the
polymeric sorbent has ionic groups of formula
--COO.sup.-(NH.sub.3--(C=NH)--NHR.sub.1).sup.+, --COO.sup.31
(NH.sub.2R.sub.1--(C=NH)--NH.sub.2).sup.+, or both.
[0203] Embodiment 22D is the method of embodiment 20D or 21D,
wherein the nitrogen-containing compound is guanidine.
[0204] Embodiment 23D is the method of any one of embodiments 1D to
6D, wherein the nitrogen-containing compound is of Formula
(VI).
R.sub.7-(NHR.sub.1).sub.z (VI)
Group R.sub.7 is a z-valent radical of an alkane or a z-valent
radical of a heteroalkane. R.sup.1 is hydrogen or alkyl. The
variable z is an integer in a range of 3 to 10.
[0205] Embodiment 24D is the method of embodiment 23D, wherein the
polymeric sorbent has ionic groups of formula --COO.sup.31
(NH.sub.2R.sub.1-R.sub.7--(NHR.sub.1).sub.z-1).sup.+.
[0206] Embodiment 25D is the method of any one of embodiments 1D to
24D, wherein the nitrogen-containing compound has a molecular
weight no greater than 2000 Daltons.
[0207] Embodiment 26D is the method of any one of embodiments 1D to
25D, wherein the polymeric sorbent further comprises an acid-base
dye.
[0208] Embodiment 27D is the method of embodiment 26D, wherein the
acid-base dye has a lower pK.sub.b than the nitrogen-containing
compound.
[0209] Embodiment 28D is the method of embodiment 26D or 27D,
wherein a difference between the pK.sub.b of the
nitrogen-containing compound and the pK.sub.b of the acid-base dye
is equal to at least 2.
[0210] Embodiment 29D is the method of any one of embodiments 1D to
28D, wherein the hydrolyzed divinylbenzene/maleic anhydride
polymeric material has a BET specific surface area of equal to at
least 50 m.sup.2/grams.
[0211] Embodiment 1E is a composite granule that includes (a) a
polymeric sorbent of any one of embodiments 1A to 28A and (b) a
binder.
[0212] Embodiment 2E is the composite granules of embodiment 1E,
wherein the composite granules comprise 1 to 30 weight percent
binder and 70 to 99 weight percent polymeric sorbent based on the
total weight of the composite granules.
[0213] Embodiment 3E is the composite granules of embodiment 1E or
2E, wherein the composite granules comprise 1 to 25 weight percent
binder and 75 to 99 weight percent polymeric sorbent based on the
total weight of the composite granules.
[0214] Embodiment 4E is the composite granules of any one of
embodiments 1E to 3E, wherein the composite granules comprise 1 to
20 weight percent binder and 80 to 99 weight percent polymeric
sorbent based on the total weight of the composite granules.
[0215] Embodiment 5E is the composite granules of any one of
embodiments 1E to 4E, wherein the binder comprises metal
hydroxides, metal oxides, or combinations thereof.
[0216] Embodiment 6E is the composite granules of any one of
embodiments 1E to 4E, wherein the binder comprises a salt (e.g., a
metal salt) or a polymer.
[0217] Embodiment 7E is the composite granules of embodiment 1E,
wherein the binder comprises a silicate (e.g., a metal
silicate).
[0218] Embodiment 8E is the composite granules of embodiment 7E,
wherein the silicate comprises sodium silicate, potassium silicate,
calcium silicate, magnesium silicate, sodium metasilicate, or a
mixture thereof.
[0219] Embodiment 9E is the composite granules of embodiment 8E,
wherein the silicate comprises sodium metasilicate.
[0220] Embodiment 10E is the composite granules of any one of
embodiments 1E to 4E, wherein the binder comprises a
polyorganozirconate, polyorganoaluminate, polysiloxane, polysilane,
polysilazane, polycarbosilane, polyborosilane, zirconium
dimethacrylate, zirconium tetramethacrylate, zirconium
2-ethylhexanoate, aluminum butoxide, aluminum diisopropoxide
ethylacetoacetate, tetramethyldisiloxane,
tristrimethylsilylphosphate, tristrimethylsiloxyboron, or a mixture
thereof.
[0221] Embodiment 11E is the composite granules of any one of
embodiments lE to 4E, wherein the binder comprises a carboxylate
salt.
[0222] Embodiment 12E is the composite granules of embodiment 11E,
wherein the carboxylate anion has at least 10 carbon atoms.
[0223] Embodiment 13E is the composite granules of embodiment 11E
or 12E, wherein the carboxylate salt comprises magnesium
stearate.
[0224] Embodiment 14E is the composite granules of any one of
embodiments 1E to 4E, wherein the binder comprises a thermoplastic
polymer.
[0225] Embodiment 15E is the composite granules of any one of
embodiments 1E to 4E, wherein the binder comprises a thermoset
polymer. Embodiment 16E is the composite granules of any one of
embodiments 1E to 4E, wherein the binder comprises an
elastomer.
[0226] Embodiment 17E is the composite granules of any one of
embodiments 1E to 4E, wherein the binder comprises a naturally
occurring polymer.
[0227] Embodiment 18E is the composite granules of embodiment 17E,
wherein the naturally occurring polymer is a cellulosic resin.
[0228] Embodiment 19E is the composite granules of any one of
embodiments 1E to 4E, wherein the binder comprises an electrically
conductive polymer.
[0229] Embodiment 20E is the composite granules of any one of
embodiments 1E to 4E, wherein the binder comprises a gelling
material, an absorbent material, or mixture thereof.
[0230] Embodiment 21E is the composite granules of embodiment 20E,
wherein the binder comprises a superabsorbent material comprising
polyacrylic acid, polyacrylamide, polyalcohol, polyamine,
polyethylene oxide, cellulose including carboxymethyl cellulose,
chitin, gelatin, starch, polyvinyl alcohol, polyacrylonitrile,
alginic acid, carrageenan isolated from seaweed, polysaccharide,
pectin, xanthan, polydiallyldimethylammonium chloride,
polyvinylpyridine, polyvinylbenzyltrimethylammonium salt,
polyvinyacetate, polylactic acid, or mixture thereof.
[0231] Embodiment 1F is a method of making composite granules. The
method includes preparing a polymeric sorbent according to any one
of embodiments 1D to 29D. The method still further includes
blending the polymeric sorbent with a binder to form a blended
material and preparing the composite granules from the blended
material.
[0232] Embodiment 2F is the method of embodiment 1F, wherein
preparing the composite granules from the blended material
comprises forming pellets or disks from the blended material,
milling the pellets or disks to form a milled product, and sieving
the milled product to collect a sieved product.
[0233] Embodiment 1G is a method of sorbing (i.e., capturing) an
aldehyde. The method includes providing composite granules of any
one of embodiments 1E to 21E. The method further includes exposing
the composite granules to an aldehyde and sorbing the aldehyde on
the polymeric sorbent. The aldehyde is of Formula (I)
R.sub.2-(CO)--H (I)
wherein R.sub.2 is hydrogen, alkyl, vinyl, or aryl. The molecular
weight of the aldehyde of Formula (I) is no greater than 200
grams/mole.
EXAMPLES
[0234] Materials:
[0235] The materials with their sources were as listed in Table 1.
Unless otherwise indicated, all materials were purchased from
commercial sources and used as received.
TABLE-US-00001 TABLE 1 List of materials. Chemical Name Chemical
Supplier Divinylbenzene (DVB) (80% technical Sigma-Aldrich,
Milwaukee, WI grade), which contained 80 weight percent DVB and 20
weight percent styrene-type monomers. The calculation of moles of
DVB used to prepare the polymeric material takes into account the
purity. Maleic anhydride (MA) Alfa Aesar, Ward Hill, MA
2,2'-azobis(2,4-dimethyl-pentanenitrile) E. I. du Pont de Nemours,
(available under the trade designation Wilmington, DE VAZO 52 from
E. I. du Pont de Nemours) Benzoyl peroxide (BPO) Sigma-Aldrich,
Milwaukee, WI Ethyl acetate (EtOAc) EMD Millipore Chemicals,
Billerica, MA Sodium hydroxide (NaOH) EMD Millipore Chemicals,
Billerica, MA Concentrated hydrochloric acid, 37% EMD Millipore
Chemicals, (HCl) Billerica, MA Ethyl alcohol (EtOH), denatured, EMD
Millipore Chemicals, anhydrous Billerica, MA Ethylenediamine, 99%
(EDA) Alfa Aesar, Ward Hill, MA Polyethyleneimine, 600 MW (PEI)
Polysciences, Warrington, PA Diethylenetriamine, 99% (DETA) Alfa
Aesar, Ward Hill, MA Isonicotinic acid hydrazide (IAH) TCI,
Portland, OR
[0236] Gas Sorption Analysis:
[0237] Porosity and gas sorption experiments were performed using
an Accelerated Surface Area and Porosimetry (ASAP) 2020 system from
Micromeritics Instrument Corporation (Norcross, Ga.). The
adsorbates were of ultra-high purity. The following is a typical
method used for the characterization of the porosity within the
exemplified materials. In a Micromeritics half inch (1.3 cm)
diameter sample tube, 50-250 milligrams (mg) of material was
degassed by heating under ultra-high vacuum (3-7 micrometers Hg) on
the analysis port of the ASAP 2020 to remove residual solvent and
other adsorbates. The degas procedure for the precursor polymeric
material was 3 hours at 150.degree. C.
[0238] Nitrogen adsorption isotherms at 77 K for the precursor
polymeric material were obtained using low pressure dosing (5
cm.sup.3/g) at a relative pressure)(p/p.degree. less than 0.1 and a
pressure table of linearly spaced pressure points from a
p/p.degree. in a range from 0.1 to 0.98. The method for all
isotherms made use of the following equilibrium intervals: 90
seconds at p/p.degree. less than 10.sup.-5, 40 seconds at
p/p.degree. in a range of 10.sup.-5 to 0.1, and 20 seconds at
p/p.degree. greater than 0.1. Helium was used for the free space
determination, after nitrogen adsorption analysis, both at ambient
temperature and at 77 K. BET specific surface areas (SABET) were
calculated from nitrogen adsorption data by multipoint
Brunauer-Emmett-Teller (BET) analysis. Apparent micropore
distributions were calculated from nitrogen adsorption data by
density functional theory (DFT) analysis using the standard
nitrogen at 77 K DFT model. Total pore volume was calculated from
the total amount of nitrogen adsorbed at a p/p.degree. equal to
approximately 0.98. BET, DFT and total pore volume analyses were
performed using Micromeritics MicroActive Version 4.04
software.
[0239] Formaldehyde Capacity Test:
[0240] A simple flow-through custom built delivery system was used
to deliver known concentrations of formaldehyde to the sample for
measurement. Plastic tubing was used throughout the delivery
system, with the portions downstream of the formaldehyde generation
being fluoropolymer tubing. Formaldehyde was generated by
delivering a 4.86 weight percent solution of paraformaldehyde in
water using a 2.5 milliliter (mL) GASTIGHT syringe (product number
81420, Hamilton Company, Reno, Nev.). This syringe was driven at a
specific rate by a syringe pump, model 780200-V (KD Scientific,
Holliston, Mass.). By knowing the paraformaldehyde concentration in
solution, and the cross-sectional area of the syringe, a precise
rate of paraformaldehyde solution could be delivered. This solution
was delivered onto a piece of hot gold foil in a flask which served
to decompose the paraformaldehyde and vaporize the resulting
formaldehyde. Through this flask, 250 mL/minute of nitrogen gas was
passed, controlled by an analog mass flow controller, model GFC17,
with a range of 0-500 mL/min (Aalborg, Orangeburg, N.Y.). This
controller was calibrated by placing a model 800286 GILIBRATOR soap
bubble flow meter with a 20-6000 mL calibration cell (Sensidyne,
St. Petersburg, Fla.) at the output of the controller. The
GILIBRATOR flow meter was used to measure a range of flows from
each flow controller that was used to generate calibration curves.
The evaporation of the formaldehyde served to create a 250 parts
per million (ppm) concentration of formaldehyde in the nitrogen.
Water was also evaporated into the nitrogen which humidified the
stream to approximately 50% relative humidity. Using these
calibration curves, the mass flow controllers were set to deliver
the desired formaldehyde concentration (250 ppm formaldehyde) and
humidity (50% relative humidity) at the desired gas flow rate (250
mL/minute).
[0241] The formaldehyde removal capacity for a test material was
determined by adding the test material to a tared test tube until
the bed depth in the tube was 1.0 cm after being tamped. The inner
diameter of the test tube was 1.0 cm. The mass of the test material
was then determined by weighing the test materials in the test
tube. The test tube was then connected in line with the system,
allowing the 250 ppm formaldehyde gas stream to flow through the
test material. To the downstream side of the test tube, tubing was
connected that led to a gas chromatograph instrument (SRI 8610C,
SRI Instruments, Torrance, Calif.). At the time the formaldehyde
gas stream began to pass through the test sample, the test was
considered started, and a timer was started. The gas chromatograph
then periodically sampled the gas stream and passed the sample
through a 15 meter long RT-U-BOND column with an inner diameter of
0.53 millimeters (Restek Corporation, Bellefonte, Pa.). The gas
chromatograph software recorded the timestamp of every data point
taken.
[0242] The effluent from this column was then passed through a
methanizer equipped with a flame ionization detector (FID). The
methanizer converted the formaldehyde to methane, which was then
ionized and detected by the FID. This signal was subsequently
reported and recorded in the data acquisition software provided
with the device. It was observed that good detection of
formaldehyde vapor was found when the gas chromatograph sampled the
gas stream for 6 seconds, allowed the sample to pass through the
column for 144 seconds and then allowed 60 seconds to flush out the
sample before it drew in the next sample to be analyzed.
[0243] Prior to testing, different rates of formaldehyde were
delivered into the nitrogen gas stream to calibrate the gas
chromatograph software. In this way, a signal to concentration
curve could be made so that any level of signal on the gas
chromatograph could be correlated to a concentration of
formaldehyde.
[0244] The end point of the formaldehyde capacity test was defined
as the point corresponding to the time at which the formaldehyde
effluent passing through the bed of the test material produced a
signal on the FID detector that exceeded the signal corresponding
to 1 ppm. The performance of each test material was reported as the
number of minutes until 1 ppm breakthrough was observed performing
the test as described above. In addition, the area under the curve
of the breakthrough plot until 1 ppm breakthrough coupled with the
known mass of the test material used in this fixed volume test was
used to calculate a millimole/gram (mmol/g) capacity for each test
material using a sum of least squares equation.
[0245] Preparatory Example 1: Preparation of Precursor Polymeric
Material
[0246] In a 2 liter (L) Parr stainless steel pressure vessel,
177.11 grams (g) (1.09 moles) divinylbenzene (DVB, 80 weight %
technical grade), 240.05 g (2.45 moles) of maleic anhydride (MA),
and 4.17 g (16.8 mmol) of 2,2'-azobis(2,4-dimethyl-pentanenitrile)
(VAZO 52) were dissolved in 625.92 g of ethyl acetate (EtOAc). The
polymerizable composition had 40.0 weight % solids in EtOAc and
contained a monomer mixture (34.0 weight % DVB, 57.5 weight % MA,
and 8.5 weight % styrene-type monomers) and 1 weight % VAZO 52
(based on total weight of monomers). The polymerizable composition
was bubbled with nitrogen for 15 minutes. The pressure vessel was
then sealed and placed in a water bath at 60.degree. C. The
polymerizable composition was heated at this elevated temperature
for 18 hours. A white precipitate that had formed was isolated by
vacuum filtration and washed with EtOAc. The solid was placed in a
4 L Erylenmeyer flask and 2.0 L of EtOAc was added to the flask.
The solid was allowed to stand in EtOAc for one hour at room
temperature. The solid was again isolated by vacuum filtration and
washed with EtOAc. The solid was placed in a 4 L Erylenmeyer flask
and 2.0 L of EtOAc was added to the flask. The solid was allowed to
stand in EtOAc overnight. The solid was again isolated by vacuum
filtration and washed with EtOAc. The solid was then dried in a
batch oven at 100.degree. C. for 18 hours. This precursor polymeric
material had a SA.sub.BET of 343.3 m.sup.2/gram and a total pore
volume of 0.593 cm.sup.3/gram (p/p.degree. equal to 0.979) as
determined by nitrogen adsorption.
[0247] Preparatory Example 2: Preparation of Hydrolyzed Precursor
Polymeric Material
[0248] The precursor polymeric material described in Preparatory
Example 1 was treated with a hydrolyzing agent (sodium hydroxide
(NaOH)). More specifically, 58.8 g (1.47 moles) of NaOH was
dissolved in 490 mL of deionized water within a 1 L jar. To this
solution was added 50.0 g of the precursor polymeric material which
had been ground and sieved to a particle size range of 40.times.80
mesh by isolation using USA standard test No. 40 and 80 wire mesh
sieves (ASTM E-11 standard; Hogentogler and Co., Inc., Columbia,
Md.) and a Meinzer II Sieve Shaker (CSC Scientific Company, Inc.,
Fairfax, Va.) operated for 15 minutes before the separated material
was collected.
[0249] The jar was then capped and placed on a jar roller. This
suspension was allowed to roll at room temperature for 18 hours.
The solid was isolated by vacuum filtration and washed with
deionized water. The solid was returned to the 1 L jar, and to the
jar was added 515 mL of 2.1 Molar (M) aqueous hydrochloric acid
(HCl) (80 mL of concentrated HCl added to 435 mL of deionized
water). The jar was capped and placed back onto a jar roller where
it was allowed to roll overnight at room temperature. The solid was
again isolated by vacuum filtration and washed with deionized
water. The solid was then dried under high vacuum at 95.degree. C.
for eight hours.
Examples 1-7:
[0250] The following examples were prepared by reacting the
hydrolyzed precursor polymeric material of Preparatory Example 2
with a nitrogen-containing compound (e.g., amine compound)
containing two or more amino groups in ethanol (EtOH). The identity
of the amine compound, the amount of amine compound reacted with
the hydrolyzed precursor polymeric material, the equivalents of the
amine compound per MA and the concentration of the amine compound
in the amine/EtOH solution used for the reaction are summarized in
Table 2. More specifically, the amine compound was dissolved into
enough EtOH to prepare each amine solution with the concentrations
listed in Table 2. To each of these solutions was added 3.0 g
(40.times.80 mesh, obtained as described previously) of the
hydrolyzed precursor polymeric material of Preparatory Example 2.
The hydrolyzed precursor polymeric material was allowed to soak in
each amine solution at room temperature for 18 hours. The solids
were each isolated by vacuum filtration and washed with EtOH. Each
solid was then put back in an 8 ounce (oz.) jar containing 200 mL
of EtOH. The solids were allowed to soak in the EtOH for 18 hours.
The solids were isolated by vacuum filtration and washed with EtOH.
The solid material was then dried in an oven under high vacuum at
90.degree. C. for 18 hours. The resulting amine salt functional
polymeric sorbents (40 x 80 mesh, obtained as described previously)
were used to perform the formaldehyde capacity test, as described
above, to determine the formaldehyde capacity of each amine salt
functional polymeric sorbent. The mass of sample used for the test,
the number of minutes each test lasted and the calculated mmol/g
capacity (mmoles of formaldehyde per gram of polymeric sorbent) are
shown in Table 3.
TABLE-US-00002 TABLE 2 Type, amount, equivalents, and concentration
of amine solution used in the functionalization step to prepare
each polymeric sorbent. Equivalents Concentration Amine Amine of
Amine of Amine Compound Compound Compound Compound in Example #
Type Amount per MA EtOH (mol/L) Example 1 EDA 2.0 mL 2 1.5 Example
2 EDA 20 mL 17 neat Example 3 PEI 10 mL 1 0.86 Example 4 PEI 20 mL
2 0.86 Example 5 PEI 40 mL 3 0.86 Example 6 DETA 1.9 mL 1 1.2
Example 7 DETA 3.8 mL 2 1.2
Comparative Example 1
[0251] The material of Comparative Example 1 was an activated
carbon (which had been sieved to a particle size range of
32.times.60 mesh by isolation utilizing USA standard test No. 32
and 60 wire mesh sieves (ASTM E-11 standard; Hogentogler and Co.,
Inc., Columbia, Md.) and a Meinzer II Sieve Shaker (CSC Scientific
Company, Inc., Fairfax, Va.) operated for 15 minutes before the
separated material was collected) used in the commercially
available 3M GAS AND VAPOUR FILTERS 6000 SERIES cartridges (3M,
Maplewood, Minn.) rated for formaldehyde and organic vapors. The
formaldehyde capacity of this carbon arises from its impregnation
with a half neutralized aqueous solution of sulfamic acid. The
impregnated carbon was used to perform the formaldehyde capacity
test, as described above, to determine the formaldehyde capacity of
this impregnated carbon. The mass of sample used for the test, the
number of minutes the test lasted and the calculated mmol/g
capacity (mmoles of formaldehyde per gram of comparative sorbent)
are shown in Table 3.
Comparative Example 2
[0252] The material of Comparative Example 2 contained a
comparative sorbent prepared by reacting the hydrolyzed precursor
polymeric material, described in Preparatory Example 2, with
isonicotinic acid hydrazide (IAH). More specifically, 2.42 g (17.6
mmol) of IAH was dissolved in 36 mL of EtOH within a 4 oz. jar
while being heated in a sand bath to 80.degree. C. To this, 3.0 g
of the hydrolyzed precursor polymeric material was added. The
hydrolyzed precursor polymeric material was allowed to react while
heated at 80.degree. C. for 18 hours. The solid was then isolated
by vacuum filtration and washed with EtOH. The solid was placed
back in a 4 oz. jar and 50 mL of EtOH was added to the jar. The jar
was returned to the sand bath, and the solid was allowed to stand
in EtOH overnight at 80.degree. C. The solid was again isolated by
vacuum filtration and washed with EtOH. The solid was then dried in
an oven under high vacuum at 90.degree. C. for eight hours. The
resulting comparativesorbent (which had been sieved to a particle
size range of 40.times.80 mesh by isolation utilizing USA standard
test No. 40 and 80 wire mesh sieves (ASTM E-11 standard;
Hogentogler and Co., Inc., Columbia, Md.) and a Meinzer II Sieve
Shaker (CSC Scientific Company, Inc., Fairfax, Va.) operated for 15
minutes before the separated material was collected) was used to
perform the formaldehyde capacity test, as described above, to
determine the formaldehyde capacity of this comparative sorbent.
The mass of sample used for the test, the number of minutes the
test lasted and the calculated mmol/g capacity (mmoles of
formaldehyde per gram of comparative sorbent) are shown in Table
3.
Comparative Example 3
[0253] The material of Comparative Example 3 contained a
comparative sorbent prepared by reacting a hydrolyzed precursor
polymeric material, described in Preparatory Example 2, with
isonicotinic acid hydrazide (IAH). More specifically, 4.83 g (35.2
mmol) of IAH was dissolved in 72 mL of EtOH within an 8 oz. jar
while being heated in a sand bath to 80.degree. C. To this, 3.0 g
of the hydrolyzed precursor polymeric material was added. The
hydrolyzed precursor polymeric material was allowed to react while
heated at 80.degree. C. for 18 hours. The solid was then isolated
by vacuum filtration and washed with EtOH. The solid was placed
back in an 8 oz. jar and 50 mL of EtOH was added to the jar. The
jar was returned to the sand bath, and the solid was allowed to
stand in EtOH overnight at 80.degree. C. The solid was again
isolated by vacuum filtration and washed with EtOH. The solid was
then dried in an oven under high vacuum at 90.degree. C. for eight
hours. The resulting comparativesorbent (which had been sieved to a
particle size range of 40.times.80 mesh by isolation utilizing USA
standard test No. 40 and 80 wire mesh sieves (ASTM E-llstandard;
Hogentogler and Co., Inc., Columbia, MD) and a Meinzer II Sieve
Shaker (CSC Scientific Company, Inc., Fairfax, Va.) operated for 15
minutes before the separated material was collected) was used to
perform the formaldehyde capacity test, as described above, to
determine the formaldehyde capacity of this comparative sorbent.
The mass of sample used for the test, the number of minutes the
test lasted and the calculated mmol/g capacity (mmoles of
formaldehyde per gram of comparative sorbent) are shown in Table
3.
TABLE-US-00003 TABLE 3 Formaldehyde Capacity Test results for the
sorbents of Examples 1-7 and Comparative Examples 1-3. Test Minutes
until 1 ppm material 1 ppm Breakthrough mass Breakthrough Capacity
Example # (g) (min) (mmol/g) Example 1 0.330 655 4.95 Example 2
0.302 531 4.40 Example 3 0.327 332 2.54 Example 4 0.385 604 3.92
Example 5 0.346 439 3.17 Example 6 0.321 693 5.41 Example 7 0.311
828 6.66 Comparative 0.443 117 1.00 Example 1 Comparative 0.305 61
0.50 Example 2 Comparative 0.309 76 0.62 Example 3
* * * * *