Environment purifying material

• US 5,997,829 A
• Filed: 11/26/1997
• Issued: 12/07/1999
• Est. Priority Date: 05/26/1995
• Status: Expired due to Term

• Current Assignee: Hitachi Chemical Company Limited (Resonac Holdings Corp.)
• Original Assignee: Hitachi Chemical Company Limited (Resonac Holdings Corp.)
• Inventors: Kawada, Hiroyuki, Senda, Takayuki, Sekine, Yoshika, Tonoki, Kenji, Uchida, Tatsuya, Miyadera, Yasuo
• Primary Examiner(s): Straub, Gary P.
• Assistant Examiner(s): Vanoy, Timothy C
• Application Number:
  US08/973,001
• Time in Patent Office: 741 Days
• Field of Search: 502/402, 502/507, 502/406, 502/416, 502/417, 502/428, 502/514, 502/439, 502/527, 502/527.14, 502/527.15, 502/527.2, 502/300, 502/307, 502/312, 502/325, 502/324 , 502/331, 502/345, 502/335, 502/309, 423/210, 423/230, 423/237, 423/245.1, 423/247, 423/219, 423/239.1, 210/749
• US Class Current: 423/210
• CPC Class Codes: B01D 2253/102 Carbon
• CPC Class Codes: B01D 2253/104 Alumina
• CPC Class Codes: B01D 2253/106 Silica or silicates
• CPC Class Codes: B01D 2253/108 Zeolites
• CPC Class Codes: B01D 2253/11 Clays
• CPC Class Codes: B01D 2253/112 Metals or metal compounds not provided for in B01D2253/104 or B01D2253/106
• CPC Class Codes: B01D 2253/202 Polymeric adsorbents
• CPC Class Codes: B01D 2253/304 Linear dimensions, e.g. particle shape, diameter
• CPC Class Codes: B01D 2253/3425 Honeycomb shape
• CPC Class Codes: B01D 2257/90 Odorous compounds not provided for in groups B01D2257/00 - B01D2257/708
• CPC Class Codes: B01D 53/02 by adsorption, e.g. preparative gas chromatography solid sorbent compositions B01J20/00, preparation of inorganic compounds or elements C01
• CPC Class Codes: B01D 53/86 Catalytic processes
• CPC Class Codes: B01J 20/28004 Sorbent size or size distribution, e.g. particle size
• CPC Class Codes: B01J 20/28028 Particles immobilised within fibres or filaments
• CPC Class Codes: B01J 20/28033 Membrane, sheet, cloth, pad, lamellar or mat
• CPC Class Codes: B01J 20/28045 Honeycomb or cellular structures; Solid foams or sponges
• CPC Class Codes: B01J 2231/70 Oxidation reactions, e.g. epoxidation, (di)hydroxylation, dehydrogenation and analogues
• CPC Class Codes: B01J 31/06 containing polymers organometallic polymers B01J31/123; polymer-bound organometallic complexes B01J31/165; coordination polymers B01J31/1691
• CPC Class Codes: B01J 35/58 Fabrics or filaments
• CPC Class Codes: Y10S 502/507 Synthetic resin, natural resin, polysaccaride, or polypeptide

Abstract

The present invention is directed to a sheet-form environment purifying material comprising particles of metal and/or metal oxide consisting essentially of at least one member being selected from the group consisting of manganese, copper, zinc, iron, vanadium, nickel, titanium, palladium, platinum, manganese oxide, copper oxide, zinc oxide, iron oxide, vanadium oxide, nickel oxide, titanium oxide, palladium oxide, and platinum oxide, adsorbent particles consisting essentially of at least one member selected from the group consisting of activated carbon, zeolite, silica gel, sepiolite, activated alumina and activated clay, thermoplastic resin particles being selected from ultrahigh-molecular weight polyethylene, polyethylene, polycarbonate, polyamide acrylonitrile-butadiene-styrene resins, polyimide, polyvinyl chloride, cellulose acetate, polysulfone, polystyrene phthalate and polypropylene, and an air-permeable sheet of fibrous. The metal and/or metal oxide particles and the adsorbent particles are respectively bound to the thermoplastic resin particles while retaining their inherent surface areas and performances without being covered by the thermoplastic resin layers, and the thermoplastic resin particles are joined to the fibrous substrate. The present invention is also directed to a process for making the environment purifying material which comprises the steps of mixing all the particles and heating the mixture at a temperature not lower than the melting point of the thermoplastic resin and not higher than the thermal decomposition temperature thereof. The environment purifying material of the present invention is useful as deodorizers and harmful gas removers.

Claims

1. An environment purifying material comprising:

(a) particles consisting essentially of at least one being selected from the group consisting of manganese, copper, zinc, iron, vanadium, nickel, titanium, palladium, platinum, manganese oxide, copper oxide, zinc oxide, iron oxide, vanadium oxide, nickel oxide, titanium oxide, palladium oxide, and platinum oxide;

(b) adsorbent particles consisting essentially of at least one selected from the group consisting of activated carbon, silica gel and sepiolite; and

(c) thermoplastic resin particles;

wherein said component-(a) particles and said component-(b) particles are respectively bound to said component-(c) particles, and said component-(c) particles are joined to each other.

2. The environment purifying material according to claim 1, wherein;

said component-(c) particles are selected from the group consisting of ultrahigh-molecular weight polyethylene, polyethylene, polycarbonate, polyamide acrylonitrile-butadiene-styrene resins, polyimide, polyvinyl chloride, cellulose acetate, polysulfone, polystyrene phthalate and polypropylene.

3. The environment purifying material according to claim 2, wherein;

said component-(a) particles are manganese dioxide and cupric oxide;

said component-(b) particles are activated carbon; and

said component-(c) particles are ultrahigh-molecular weight polyethylene having an average molecular weight of from 1,000,000 to 9,000,000 as measured by viscometry.

4. The environment purifying material according to claim 1, wherein;

said component-(a) particles have an average particle diameter of from 0.1 μ

m to 10 μ

m;

said component-(b) adsorbent particles contain particles that pass a sieve of 48 meshes (300 μ

m), in an amount not less than 50% by weight based on the total weight of the adsorbent particles; and

said component-(c) particles have an average particle diameter of from 20 μ

m to 150 μ

m.

5. The environment purifying material according to claim 1, wherein said component-(c) particles are contained in an amount of from 10 to 80 parts by weight based on 100 parts total weight, the total weight being defined by the sum of from 90 parts by weight to 10 parts by weight of said component-(a) particles and from 10 parts by weight to 90 parts by weight of said component-(b) adsorbent particles.

6. The environment purifying material according to claim 1, wherein the environment purifying material is formed in any shape of grains, pellets, balls and a plate.

7. A process for producing the environment purifying material according to claim 1 comprising the steps of mixing;

(a) particles of metal and/or metal oxide;

(b) adsorbent particles; and

(c) thermoplastic resin particles;

and heating the mixture at a temperature not lower than the melting point of the thermoplastic resin and not higher than the thermal decomposition temperature thereof.

8. A process for producing the environment purifying material according to claim 7, wherein said mixture is heated under application of pressure.

9. A method of purifying the environment for removing pollutive substances contained in polluted air or water by contacting the objects to be purified with said environment purifying materials according to either one of claims 1 and 2.

10. The environment purifying materials according to claim 1, further comprising particles (e) consisting essentially of magnesium oxide, wherein particles (a), (b) and (e) are respectively bound to particles (c), and particles (c) are joined to each other.

13. The sheet-form environment purifying material according to claim 9, wherein;

said component-(a) particles are manganese dioxide and cupric oxide;

said component-(b) particles are activated carbon;

said component-(c) particles are ultrahigh-molecular weight polyethylene having an average molecular weight of from 1,000,000 to 9,000,000 as measured by viscometry; and

said component-(d) fibrous substrate is a non-woven glass fabric having a void volume of from 60% to 98%.

18. A sheet-form environment purifying material comprising a sheet consisting of an environment purifying material according to claim 9, and an air-permeable surface protector covering at least one surface of said sheet.

11. A sheet-form environment purifying material comprising;

(a) particles consisting essentially of at least one being selected from the group consisting of manganese, copper, zinc, iron, vanadium, nickel, titanium, palladium, platinum, manganese oxide, copper oxide, zinc oxide, iron oxide, vanadium oxide, nickel oxide, titanium oxide, palladium oxide, and platinum oxide;

(b) adsorbent particles consisting essentially of at least one selected from the group consisting of activated carbon, silica gel and sepiolite;

(c) thermoplastic resin particles; and

(d) an air-permeable sheet of fibrous substrate;

wherein said component-(a) particles and said component-(b) particles are respectively bound to said component-(c) particles, and

said component-(c) particles are joined to said component-(d) fibrous substrate.

12. The sheet-form environment purifying material according to claim 11, wherein:

said component-(c) particles are selected from the group consisting of ultrahigh-molecular weight polyethylene, polyethylene, polycarbonate, polyamide acrylonitrile-butadiene-styrene resins, polyimide, polyvinyl chloride, cellulose acetate, polysulfone, polystyrene phthalate and polypropylene; and

said component-(d) fibrous substrate is a fibrous substrate having a void volume of from 60% to 98%.

14. The sheet-form environment purifying material according to claim 11, wherein;

said component-(a) particles have an average particle diameter of from 0.1 μ

m to 10 μ

m;

said component-(b) adsorbent particles contain particles that pass a sieve of 48 meshes (300 μ

m), in an amount not less than 50% by weight based on the total weight of the adsorbent particles; and

said component-(c) particles have an average particle diameter of from 20 μ

m to 150 μ

m.

15. The sheet-form environment purifying material according to claim 11, wherein mixed particles of said components-(a) to (c) are in a weight of (a)+(b)+(c), of from 40 to 200 parts by weight based on 100 parts by weight of said component-(d) an air-permeable sheet fibrous substrate.

16. A multi-layer sheet-form environment purifying material comprising a plurality of environment purifying materials according to claim 11 which are superposed in layers.

17. The multi-layer sheet-form environment purifying material according to claim 16, wherein at least two layers thereof respectively contain the component-(a) particles or component-(b) adsorbent particles of different types.

19. A honeycomb type environment purifying material comprising said sheet-form environment purifying material according to claim 11, having been formed in a honeycomb shape.

20. The environment purifying materials according to claim 11, further comprising particles (e) consisting essentially of magnesium oxide, wherein particles (a), (b) and (e) are respectively bound to particles (c), and particles (c) are joined to the fibrous substrate (d).