Adsorption filter material with high adsorption capacity and low breakthrough behavior

• US 7,160,369 B2
• Filed: 04/16/2004
• Issued: 01/09/2007
• Est. Priority Date: 04/17/2003
• Status: Active Grant

• Current Assignee: BLÜCHER GmbH
• Original Assignee: BLÜCHER GmbH
• Inventors: Bohringer, Bertram, von Blucher, Hasso, Moskopp, Michael, Kamper, Stefan, de Ruiter, Ernest, Ouvry, Ludovic
• Primary Examiner(s): LAWRENCE JR, FRANK M
• Application Number:
  US10/825,745
• Publication Number:
  US 20040237790A1
• Time in Patent Office: 998 Days
• Field of Search: 95/90, 952/73, 952/85, 96/4, 96/11, 961/21, 961/31, 961/32, 961/34, 961/35, 961/53, 961/54, 553/15, 553/18, 555/27, 55D/IG.33
• US Class Current: 96/132
• CPC Class Codes: A62D 5/00 Composition of materials for coverings or clothing affording protection against harmful chemical agents
• CPC Class Codes: B01D 2239/0407 comprising particulate additives, e.g. adsorbents apparatus incorporating gas filtering material B01D46/0036
• CPC Class Codes: B01D 2239/0464 Impregnants
• CPC Class Codes: B01D 2239/0654 Support layers
• CPC Class Codes: B01D 2239/083 Binders between layers of the filter
• CPC Class Codes: B01D 2239/1233 Fibre diameter
• CPC Class Codes: B01D 2239/1241 Particle diameter
• CPC Class Codes: B01D 2239/1258 Permeability
• CPC Class Codes: B01D 2239/1291 Other parameters
• CPC Class Codes: B01D 39/1615 of natural origin
• CPC Class Codes: B01D 39/18 the material being cellulose or derivatives thereof cork or peat B01D39/1646 ; making filter paper D21F11/14
• CPC Class Codes: B01D 39/2062 Bonded, e.g. activated carbon blocks
• CPC Class Codes: B01D 39/2065 the material being fibrous
• CPC Class Codes: B01J 20/20 comprising free carbon; comprising carbon obtained by carbonising processes
• CPC Class Codes: B01J 20/28004 Sorbent size or size distribution, e.g. particle size
• CPC Class Codes: B01J 20/28016 Particle form
• CPC Class Codes: B01J 20/28019 Spherical, ellipsoidal or cylindrical
• CPC Class Codes: B01J 20/28023 Fibres or filaments fibres or filaments in the form of membranes B01J20/28038; B01J20/28007 takes precedence
• 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 20/28038 : Membranes or mats made from fibers or filaments
• CPC Class Codes: B01J 20/28057 : Surface area, e.g. B.E.T specific surface area
• CPC Class Codes: B01J 21/18 : Carbon
• CPC Class Codes: B01J 23/06 : of zinc, cadmium or mercury
• CPC Class Codes: B01J 23/38 : of noble metals
• CPC Class Codes: B01J 23/72 : Copper
• CPC Class Codes: B01J 35/59 : Membranes
• CPC Class Codes: B32B 2250/05 : 5 or more layers
• CPC Class Codes: B32B 2255/02 : on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/04 : on a particulate layer
• CPC Class Codes: B32B 2255/24 : Organic non-macromolecular coating
• CPC Class Codes: B32B 2262/062 : Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2262/106 : Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2264/0235 : Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2264/105 : Metal
• CPC Class Codes: B32B 2264/108 : Carbon, e.g. graphite particles
• CPC Class Codes: B32B 23/00 : Layered products comprising a layer of cellulosic plastic substances , i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose
• CPC Class Codes: B32B 23/04 : comprising such cellulosic plastic substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a glass layer B32B17/08
• CPC Class Codes: B32B 23/10 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 23/12 : next to a particulate layer
• CPC Class Codes: B32B 2307/308 : Heat stability dimensional stability B32B2307/734
• CPC Class Codes: B32B 2307/554 : Wear resistance
• CPC Class Codes: B32B 2307/558 : Impact strength, toughness
• CPC Class Codes: B32B 2307/714 : Inert, i.e. inert to chemical degradation, corrosion
• CPC Class Codes: B32B 2307/7145 : Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2307/724 : Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/7242 : Non-permeable
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2437/00 : Clothing anti-ballistic clothing B32B2571/02
• CPC Class Codes: B32B 2437/02 : Gloves, shoes
• CPC Class Codes: B32B 2459/00 : Nets, e.g. camouflage nets
• CPC Class Codes: B32B 2571/02 : defensive, e.g. armour plates, anti-ballistic clothing camouflage nets B32B2459/00
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/14 : next to a particulate layer
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 3/20 : of hollow pieces, e.g. tubes; of pieces with channels or cavities
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/16 : characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 5/30 : one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: B32B 7/02 : Physical, chemical or physicochemical properties
• CPC Class Codes: Y10S 55/33 : Gas mask canister

Abstract

An adsorption filter material used especially for producing protective materials, such as NBC protective suits, has a first layer, a second layer, and an adsorption layer arranged between the first layer and the second layer. The adsorption layer has a first activated carbon layer with granular or spherical activated carbon particles. The first activated carbon layer additionally contains activated carbon fibers and/or the adsorption layer additionally contains a second activated carbon layer with activated carbon fibers.

Claims

1. An adsorption filter material for producing protective materials, comprising:

first and second layers;

an adsorption layer arranged between said first and second layers, wherein the adsorption layer includes a first activated carbon layer having activated carbon particles comprising at least one of granules and spherules of activated carbon, said adsorption layer further comprising activated carbon fibers; and

at least one barrier layer between said adsorption layer and at least one of said first and second layers, wherein said barrier layer is designed to be permeable to water vapor and essentially impermeable to gas and air.

2. The adsorption filter material of claim 1, wherein said adsorption layer further comprises a second activated carbon layer, said activated carbon fibers being arranged in said second activated carbon layer.

3. The adsorption filter material of claim 1, wherein said activated carbon fibers are arranged in said first activated carbon layer.

4. The adsorption filter material of claim 1, wherein said activated carbon particles are produced by carbonization and subsequent activation of suitable granular or spherical organic starting materials.

5. The adsorption filter material of claim 1, wherein said activated carbon particles of said first activated carbon layer have a mean particle diameter of 0.05 to 1 mm.

6. The adsorption filter material of claim 1, wherein said activated carbon particles have a specific surface (BET) of at least 800 m²/g, and up to 1,500 m²/g.

7. The adsorption filter material of claim 1, wherein said activated carbon fibers are produced by carbonization and subsequent activation of suitable organic starting fibers.

8. The adsorption filter material of claim 7, wherein said organic starting fibers are selected from the group comprising cellulose fibers, fibers based on cellulose derivatives, phenol resin fibers, polyvinyl alcohol fibers, pitch fibers, acrylic resin fibers, polyacrylonitrile fibers, aromatic polyamide fibers, formaldehyde resin fibers, divinylbenzene-crosslinked polystyrene fibers, lignin fibers, cotton fibers, and hemp fibers.

9. The adsorption filter material of claim 1, wherein said activated carbon fibers comprise an activated carbon fiber textile material.

10. The adsorption filter material of claim 1, wherein said activated carbon fibers have a mean fiber diameter of 1–

25 μ

m.

11. The adsorption filter material of claim 1, wherein said activated carbon fibers have a length-specific weight (titer) of 1–

10 dtex.

12. The adsorption filter material of claim 1, wherein the mean particle diameter of said activated carbon particles is at least three times greater than the mean fiber diameter of the activated carbon fibers.

13. The adsorption filter material of claim 1, wherein a total amount of activated carbon in said activated carbon particles and said activated carbon fibers in said adsorption filter material is 25–

300 g/m².

14. The adsorption filter material of claim 2, wherein said first activated carbon layer and said second activated carbon layer are arranged relative to each other such that they border directly on each other or are arranged one directly above the other.

15. The adsorption filter material of claim 1, wherein at least one of said activated carbon particles and said activated carbon fibers are impregnated with a catalyst.

16. The adsorption filter material of claim 15, wherein said catalyst is selected from among metals and metal compounds, said metals being selected from the group comprising copper, cadmium, silver, platinum, palladium, zinc, and mercury, and their compounds.

17. The adsorption filter material of claim 15, wherein said catalyst is impregnated by an amount equal to 0.01 to 15 wt. % of said at least one of said activated carbon particles and said activated carbon fibers.

18. The adsorption filter material of claim 1, wherein at least one of said first layer and said second layer is an air-permeable textile material.

19. The adsorption filter material of claim 1, wherein at least one of said first layer and said second layer is rendered oleophobic.

20. The adsorption filter material of claim 1, wherein at least one of said first layer and said second layer is a support layer for said adsorption layer.

21. The adsorption filter material of claim 2, wherein one of said first layer and said second activated carbon layer comprises a support layer for said first activated carbon layer, and wherein one of said second layer and said first activated carbon layer comprises a support layer for said second activated carbon layer.

22. The adsorption filter material of claim 1, wherein said adsorption filter material is formed as an air-permeable multilayer composite material that comprises several layers joined together.

23. The adsorption filter material of claim 1, wherein said adsorption filter material has a total weight of 75–

1,000 g/m².

24. The adsorption filter material of claim 1, wherein said adsorption filter material is gas-permeable and air-permeable, and the gas-permeability and air-permeability of said adsorption filter material is greater than 50 L·

m<sup>−

2</sup>·

s<sup>−

1</sup>, and as high as 10,000 L·

m<sup>−

2</sup>·

s<sup>−

1</sup>.

25. The adsorption filter material of claim 1, wherein said adsorption filter material has a water vapor permeability of at least 5 L/m² per 24 h.

26. The adsorption filter material of claim 1, wherein said barrier layer is at least essentially impermeable to or at least retards passage of toxic chemical agents and chemical warfare agents.

27. The adsorption filter material of claim 1, wherein said barrier layer is at least essentially impermeable to or at least retards the passage of liquids and aerosols.

28. The adsorption filter material of claim 1, wherein said barrier layer is applied as a continuous closed layer on one of said first and second layers.

29. The adsorption filter material of claim 1, wherein a thickness of said barrier layer is 5–

500 μ

m.

30. The adsorption filter material of claim 1, wherein said barrier layer comprises at least one of a plastic and an organic polymer.

34. The adsorption filter material of claim 1, wherein said adsorption filter material is thermally stable.

35. Use of the adsorption filter material of claim 1 for producing protective materials.

36. The use of the adsorption filter material of claim 35, wherein said protective materials are selected from the group consisting of protective suits for civilian or military use, protective gloves and protective covers.

37. Use of the adsorption filter material of claim 1 for producing filters and filter materials for the removal of noxious substances, foul-smelling substances, and toxic substances of all types from air and gas flows, the filters and filter materials being selected from the group consisting of gas mask filters, deodorant filters, surface filters, air filters, filters for room air purification, adsorptive support structures, and filters or filter materials for medical applications.

38. A protective material including one of a protective suit, a protective glove, and a protective cover, produced using said adsorption filter material of claim 1 and including said adsorption filter material.

31. An adsorption filter material for producing protective materials, comprising:

first and second layers;

an adsorption layer arranged between said first and second layers, wherein the adsorption layer includes a first activated carbon layer having activated carbon particles comprising at least one of granules and spherules of activated carbon, said adsorption layer further comprising activated carbon fibers; and

at least one barrier layer between said adsorption layer and at least one of said first and second layers, wherein said barrier layer comprises one of a multilayer laminate and a multilayer composite comprising several layers of plastic or polymer.

32. An adsorption filter material for producing protective materials comprising:

first and second layers;

an adsorption layer arranged between said first and second layers, wherein the adsorption layer includes a first activated carbon layer having activated carbon particles comprising at least one of granules and spherules of activated carbon, said adsorption layer further comprising activated carbon fibers; and

at least one barrier layer between said adsorption layer and at least one of said first and second layers, wherein said adsorption filter material has a water vapor permeability of at least 10 L/m² per 24 h with said barrier layer at a thickness of 50 μ

m.

33. An adsorption filter material for producing protective materials comprising:

first and second layers; and

an adsorption layer arranged between said first and second layers, wherein the adsorption layer includes a first activated carbon layer having activated carbon particles comprising at least one of granules and spherules of activated carbon, and a second activated carbon layer comprising activated carbon fibers arranged in said second activated carbon layer; and

wherein said adsorption filter material is a composite material with several successive layers bonded to one another, wherein said adsorption filter material contains the following layers in sequence;

said first layer, wherein said first layer comprises a textile that has been rendered oleophobic;

a water vapor-permeable and at least essentially gas-impermeable and air-impermeable barrier layer;

said adsorption layer, wherein said adsorption layer comprises said first activated carbon layer with said activated carbon particles and said second activated carbon layer with activated carbon fibers; and

said second layer, wherein said second layer comprises a textile layer.