US5401706A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Desiccant-coated substrate and method of manufacture
Assignee: Semco Inc
•
Filing: 1993-01-06
•
Granted: 1995-03-28
•
Expires: 2013-01-06
Abstract
Abstract Desiccant-coated substrates, regeneratable rotary dehumidification wheels and other devices for gas (e.g., air) treatment using those substrates, and processes for making them are disclosed. The substrates may have coatings in thicknesses of from about 2 to about 10 mils containing particles of one or more adsorbent desiccants and an organic water-based binder. The desiccant particles retain a high fraction of their original adsorption capacity because the pores of the desiccant particles contain a pore-clearing agent prior to the binder setting and the pore-clearing agent leaves the pores during the manufacturing process to prevent the binder from blocking the pores. In preferred embodiments a mixture of different desiccants is used and a particle suspending agent keeps the particles well-mixed so that the desiccant particles in the coated substrate will be as well-mixed as possible. The suspending agent may also function as the pore-clearing agent. A pH-adjusting agent may be used to control the pH of the coating if the binder or another constituent of the coating is pH-sensitive.
Inventors
- 👤 John C. Fischer
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 08:38
CPC Classifications
B; B01; B01J; B01J20/00; B01J20/28; B01J20/28014; B01J20/2803; B01D; B01D53/00; B01D53/26; B01D53/261; B01D53/28; B01J20/28042; B01J20/28045; F; F24; F24F; F24F3/00; F24F3/12; F24F3/14; F24F3/1411; F24F3/1423; F24F2203/00; F24F2203/10; F24F2203/1032; F24F2203/1036; Y; Y10; Y10S; Y10S95/00; Y10S95/90; Y10S95/902
Claims Analysis
Total Claims: 51
Claim 1
Independent Claim
270 words
A process for making a desiccant-coated substrate capable of being used at temperatures over 150 degrees Fahrenheit, the desiccant being in the form of particles and the particles having pores and being adhered to the substrate by a binder, the coated substrate being sufficiently flexible and the coating having sufficient adherence to the substrate so that the coated substrate can be formed into corrugated shapes, the desiccant particles in the coated substrate having at least 60% of their original adsorption capacity and the binder having good breathability; said process comprising the steps: (a) forming an aqueous suspension comprising particles of one or more desiccants, a water-based organic binder, a suspending agent to help maintain the desiccant particles in suspension, and an organic pore-clearing agent at least some of which enters at least some of the pores of the desiccant particles; (b) depositing the suspension on the substrate; and (c) causing the binder of the deposited suspension to set so that the deposited desiccant particles adhere to the substrate and causing at least some of the pore-clearing agent to leave the pores of the desiccant particles to prevent the binder from occluding at least some of the pores of the adhered desiccant particles, thereby to form a desiccant-coated substrate capable of being used at temperatures over 150 degrees Fahrenheit and of sufficient flexibility and having a coating having sufficient adherence to the substrate so that the desiccant-coated substrate can be formed into corrugated shapes and in which the desiccant particles in the coated substrate have at least 60% of their original adsorption capacity and in which the binder has good breathability.
Claim 2
Dependent Claim
270 words
A process for making a desiccant-coated substrate capable of being used at temperatures over 150 degrees Fahrenheit, the desiccant being in the form of particles and the particles having pores and being adhered to the substrate by a binder, the coated substrate being sufficiently flexible and the coating having sufficient adherence to the substrate so that the coated substrate can be formed into corrugated shapes, the desiccant particles in the coated substrate having at least 60% of their original adsorption capacity and the binder having good breathability; said process comprising the steps: (a) forming an aqueous suspension comprising particles of one or more desiccants, a water-based organic binder, a suspending agent to help maintain the desiccant particles in suspension, and an organic pore-clearing agent at least some of which enters at least some of the pores of the desiccant particles; (b) depositing the suspension on the substrate; and (c) causing the binder of the deposited suspension to set so that the deposited desiccant particles adhere to the substrate and causing at least some of the pore-clearing agent to leave the pores of the desiccant particles to prevent the binder from occluding at least some of the pores of the adhered desiccant particles, thereby to form a desiccant-coated substrate capable of being used at temperatures over 150 degrees Fahrenheit and of sufficient flexibility and having a coating having sufficient adherence to the substrate so that the desiccant-coated substrate can be formed into corrugated shapes and in which the desiccant particles in the coated substrate have at least 60% of their original adsorption capacity and in which the binder has good breathability.
Claim 3
Dependent Claim
14 words
The process of claim 1 wherein the suspending agent is also the pore-clearing agent.
Claim 4
Dependent Claim
17 words
The process of claim 1 wherein the suspending agent is also the pore-clearing agent and is N-methyl-2-pyrrolidone.
Claim 5
Dependent Claim
12 words
The process of claim 1 wherein the binder is a polyurethane binder.
Claim 6
Dependent Claim
19 words
The process of claim 1 wherein the adhered desiccant coating on the substrate is at least 2 mils thick.
Claim 7
Dependent Claim
19 words
The process of claim 1 wherein the adhered desiccant coating on the substrate is at least 3 mils thick.
Claim 8
Dependent Claim
23 words
The process of claim 1 wherein the one or more desiccants are selected from the group consisting of molecular sieves and silica gels.
Claim 9
Dependent Claim
16 words
The process of claim 1 wherein the one or more desiccants comprise at least two desiccants.
Claim 10
Dependent Claim
63 words
The process of claim 1 wherein step (a) comprises forming an aqueous suspension comprising the particles of one or more desiccants, a suspending agent to help maintain the desiccant particles in suspension, and an organic pore-clearing agent at least some of which enters at least some of the pores of the desiccant particles and thereafter adding to the suspension a water-based organic binder.
Claim 11
Dependent Claim
70 words
The process of claim 1 wherein step (a) comprises forming an aqueous suspension comprising the particles of at least two desiccants; a suspending agent to help maintain the desiccant particles in suspension; a pH-adjusting agent to adjust the pH; and an organic pore-clearing agent at least some of which enters at least some of the pores of the desiccant particles; and thereafter adding to the suspension a water-based organic binder.
Claim 12
Dependent Claim
12 words
The process of claim 10 wherein the pH-adjusting agent is ammonium hydroxide.
Claim 13
Dependent Claim
21 words
The process of claim 1 wherein step (b) comprises using a double helically wound rod to deposit suspension on the substrate.
Claim 14
Dependent Claim
57 words
The process of claim 1 wherein step (c) comprises heating the suspension deposited on the substrate to cause the binder to set and to cause at least some of the pore-clearing agent to leave the pores of the desiccant particles to prevent the binder from occluding at least some of the pores of the adhered desiccant particles.
Claim 15
Dependent Claim
35 words
The process of claim 1 wherein the substrate has two major faces and steps (b) and (c) are carried out for each major face of the substrate, thereby adhering a desiccant coating to each face.
Claim 16
Dependent Claim
51 words
The process of claim 1 wherein step (c) comprises causing the pore-clearing agent to leave the pores of the desiccant particles to prevent the binder from occluding pores of the adhered desiccant particles so that the desiccant particles in the coated substrate have at least 75% of their original adsorption capacity.
Claim 17
Dependent Claim
51 words
The process of claim 1 wherein step (c) comprises causing the pore-clearing agent to leave the pores of the desiccant particles to prevent the binder from occluding pores of the adhered desiccant particles so that the desiccant particles in the coated substrate have at least 90% of their original adsorption capacity.
Claim 18
Dependent Claim
36 words
The process of claim 1 further comprising preloading the particles of desiccant with water before step (a) so that the water in the particles will be approximately in equilibrium with respect to water in the suspension.
Claim 19
Dependent Claim
53 words
The process of claim 1 wherein step (a) comprises forming an aqueous mixture of some of the particles of the one or more desiccants, thereafter adding the suspending agent and the organic pore-clearing agent, thereafter adding more of the particles of the one or more desiccants, and thereafter adding the water-based organic binder.
Claim 20
Dependent Claim
281 words
A process for making a desiccant-coated substrate capable of being used at temperatures over 150 degrees Fahrenheit, the desiccant being in the form of particles and the particles having pores and being adhered to the substrate by a binder, the coated substrate being sufficiently flexible and the coating having sufficient adherence to the substrate so that the coated substrate can be formed into corrugated shapes, the desiccant particles in the coated substrate having at least 75% of their original adsorption capacity and the binder having good breathability; said process comprising the steps: (a) forming an aqueous suspension comprising particles of one or more desiccants, a suspending agent to help maintain the desiccant particles in suspension, and an organic pore-clearing agent at least some of which enters at least some of the pores of the desiccant particles; (b) adding a water-based organic binder to the suspension; (c) depositing the suspension on the substrate in a thickness of at least 2 mils; and (d) causing the binder of the deposited suspension to set so that the deposited desiccant particles adhere to the substrate and causing at least some of the pore-clearing agent to leave the pores of the desiccant particles to prevent the binder from occluding at least some of the pores of the adhered desiccant particles, thereby to form a desiccant-coated substrate capable of being used at temperatures over 150 degrees Fahrenheit and of sufficient flexibility and having a coating having sufficient adherence to the substrate so that the desiccant-coated substrate can be formed into corrugated shapes and in which the desiccant particles in the coated substrate have at least 75% of their original adsorption capacity and the binder has good breathability.
Claim 21
Dependent Claim
281 words
A process for making a desiccant-coated substrate capable of being used at temperatures over 150 degrees Fahrenheit, the desiccant being in the form of particles and the particles having pores and being adhered to the substrate by a binder, the coated substrate being sufficiently flexible and the coating having sufficient adherence to the substrate so that the coated substrate can be formed into corrugated shapes, the desiccant particles in the coated substrate having at least 75% of their original adsorption capacity and the binder having good breathability; said process comprising the steps: (a) forming an aqueous suspension comprising particles of one or more desiccants, a suspending agent to help maintain the desiccant particles in suspension, and an organic pore-clearing agent at least some of which enters at least some of the pores of the desiccant particles; (b) adding a water-based organic binder to the suspension; (c) depositing the suspension on the substrate in a thickness of at least 2 mils; and (d) causing the binder of the deposited suspension to set so that the deposited desiccant particles adhere to the substrate and causing at least some of the pore-clearing agent to leave the pores of the desiccant particles to prevent the binder from occluding at least some of the pores of the adhered desiccant particles, thereby to form a desiccant-coated substrate capable of being used at temperatures over 150 degrees Fahrenheit and of sufficient flexibility and having a coating having sufficient adherence to the substrate so that the desiccant-coated substrate can be formed into corrugated shapes and in which the desiccant particles in the coated substrate have at least 75% of their original adsorption capacity and the binder has good breathability.
Claim 22
Dependent Claim
14 words
The process of claim 19 wherein the suspending agent is also the pore-clearing agent.
Claim 23
Dependent Claim
17 words
The process of claim 19 wherein the suspending agent is also the pore-clearing agent and is N-methyl-2-pyrrolidone.
Claim 24
Dependent Claim
12 words
The process of claim 19 wherein the binder is a polyurethane binder.
Claim 25
Dependent Claim
30 words
The process of claim 19 wherein the one or more desiccants comprise at least two desiccants, the desiccants being selected from the group consisting of silica gels and molecular sieves.
Claim 26
Dependent Claim
28 words
The process of claim 19 wherein the water-based organic binder is pH-sensitive and step (a) further comprises adding a pH-adjusting agent to adjust the pH of the suspension.
Claim 27
Dependent Claim
12 words
The process of claim 24 wherein the pH-adjusting agent is ammonium hydroxide.
Claim 28
Dependent Claim
57 words
The process of claim 19 wherein step (d) comprises heating the suspension deposited on the substrate to cause the binder to set and to cause at least some of the pore-clearing agent to leave the pores of the desiccant particles to prevent the binder from occluding at least some of the pores of the adhered desiccant particles.
Claim 29
Dependent Claim
36 words
The process of claim 19 further comprising preloading the particles of desiccant with water before step (a) so that the water in the particles will be approximately in equilibrium with respect to water in the suspension.
Claim 30
Dependent Claim
28 words
The process of claim 1 wherein the corrugated shapes result from a corrugation process using corrugation gears having pressure angles of from about 7 to about 60 degrees.
Claim 31
Dependent Claim
29 words
The process of claim 1 wherein the corrugated shapes have a bend angle measured at the interior of the apex of the bend of at least about 14 degrees.
Claim 32
Dependent Claim
17 words
The process of claim 1 wherein the corrugated shapes have hydraulic diameters of at least 0.5 millimeters.
Claim 33
Dependent Claim
28 words
The process of claim 19 wherein the corrugated shapes result from a corrugation process using corrugation gears having pressure angles of from about 7 to about 60 degrees.
Claim 34
Dependent Claim
29 words
The process of claim 19 wherein the corrugated shapes have a bend angle measured at the interior of the apex of the bend of at least about 14 degrees.
Claim 35
Dependent Claim
17 words
The process of claim 19 wherein the corrugated shapes have hydraulic diameters of at least 0.5 millimeters.
Claim 36
Dependent Claim
112 words
A desiccant-coated substrate comprising a coating layer and a substrate, the coating layer being from about 2 mils to about 10 mils thick and comprising a water-based organic binder and at least 75% by weight desiccant, the desiccant being in the form of particles and the particles having pores, the coated substrate being sufficiently flexible and the coating layer having sufficient adherence to the substrate so that the coated substrate can be formed into corrugated shapes, the desiccant particles in the desiccant-coated substrate having at least 75% of their original adsorption capacity, the binder having good breathability, and the desiccant-coated substrate being able to be used at temperatures over 150 degrees Fahrenheit.
Claim 37
Dependent Claim
112 words
A desiccant-coated substrate comprising a coating layer and a substrate, the coating layer being from about 2 mils to about 10 mils thick and comprising a water-based organic binder and at least 75% by weight desiccant, the desiccant being in the form of particles and the particles having pores, the coated substrate being sufficiently flexible and the coating layer having sufficient adherence to the substrate so that the coated substrate can be formed into corrugated shapes, the desiccant particles in the desiccant-coated substrate having at least 75% of their original adsorption capacity, the binder having good breathability, and the desiccant-coated substrate being able to be used at temperatures over 150 degrees Fahrenheit.
Claim 38
Dependent Claim
23 words
The desiccant-coated substrate of claims 34 wherein the desiccant particles in the coated substrate have at least 90% of their original adsorption capacity.
Claim 39
Dependent Claim
19 words
The desiccant-coated substrate of claim 35 wherein the desiccant comprises at least 85% by weight of the coating layer.
Claim 40
Dependent Claim
19 words
The desiccant-coated substrate of claim 34 wherein the coating layer is from about 3 mils to 8 mils thick.
Claim 41
Dependent Claim
19 words
The desiccant-coated substrate of claim 37 wherein the desiccant comprises at least 85% by weight of the coating layer.
Claim 42
Dependent Claim
23 words
The desiccant-coated substrate of claim 38 wherein the desiccant particles in the coated substrate have at least 90% of their original adsorption capacity.
Claim 43
Dependent Claim
11 words
The desiccant-coated substrate of claim 34 wherein the binder is polyurethane.
Claim 44
Dependent Claim
19 words
The desiccant-coated substrate of claim 40 wherein the desiccant comprises at least 85% by weight of the coating layer.
Claim 45
Dependent Claim
23 words
The desiccant-coated substrate of claim 41 wherein the desiccant particles in the coated substrate have at least 90% of their original adsorption capacity.
Claim 46
Dependent Claim
19 words
The desiccant-coated substrate of claim 34 wherein it is capable of being used at temperatures over 200 degrees Fahrenheit.
Claim 47
Dependent Claim
10 words
A desiccant-coated substrate made by the process of claim 1.
Claim 48
Dependent Claim
10 words
A desiccant-coated substrate made by the process of claim 19.
Claim 49
Dependent Claim
29 words
The desiccant-coated substrate of claim 34 wherein the corrugated shapes result from a corrugation process using corrugation gears having pressure angles of from about 7 to about 60 degrees.
Claim 50
Dependent Claim
30 words
The desiccant-coated substrate of claim 34 wherein the corrugated shapes have a bend angle measured at the interior of the apex of the bend of at least about 14 degrees.
Claim 51
Dependent Claim
18 words
The desiccant-coated substrate of claim 34 wherein the corrugated shapes have hydraulic diameters of at least 0.5 millimeters.
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| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 1998-03-27 | 1998-09-26 | 1999-03-28 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2002-03-27 | 2002-09-26 | 2003-03-28 | $3760.00 | Window Closed / Lapsed |
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