Methods for preparing highly porous microfibrous media with functional particles immobilized inside
First Claim
1. A method for preparing porous mesh media comprising fibers and functional particles, the method comprising:
- (a) dispersing the fibers in a liquid suspension, wherein the fibers are kinked, bent, or curved prior, during, or after dispersing the fibers in the suspension;
(b) applying the dispersion in step (a) on a sheet former to minimize the compression of the media;
(c) removing the solvent in step (b) to form green media without compressing the green media;
(d) drying and pre-oxidizing the green media in step (c);
(e) sintering the dried media in step (d) in a reducing environment to form fiber-fiber junctions, wherein the void space is from about 85 to about 99.5% in the porous mesh media; and
(f) loading the functional particles into the porous mesh media.
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Abstract
Improved methods for preparing highly porous mesh media and loading functional particles into the media are described herein. The highly porous media can be used as supports for catalyst materials for a variety of applications, such as desulfurization. Pre-manufactured catalyst can be loaded into the sintered open media. Thus, the contamination issues associated wetlay paper making and pre-oxidation, the deactivation issues associated with the sintering and pre-oxidation steps, and the corrosion issues associated with the catalyst formation step can be avoided. The methods described herein result in the formation of highly porous media with functional particles immobilized inside.
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Citations
20 Claims
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1. A method for preparing porous mesh media comprising fibers and functional particles, the method comprising:
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(a) dispersing the fibers in a liquid suspension, wherein the fibers are kinked, bent, or curved prior, during, or after dispersing the fibers in the suspension; (b) applying the dispersion in step (a) on a sheet former to minimize the compression of the media; (c) removing the solvent in step (b) to form green media without compressing the green media; (d) drying and pre-oxidizing the green media in step (c); (e) sintering the dried media in step (d) in a reducing environment to form fiber-fiber junctions, wherein the void space is from about 85 to about 99.5% in the porous mesh media; and (f) loading the functional particles into the porous mesh media. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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Specification