US 12,083,495 B2
Monolithic trace-contaminant sorbents fabricated from 3D-printed polymer precursors
Joseph E. Cosgrove, Colombia, CT (US); Marek A. Wójtowicz, East Hartford, CT (US); Michael A. Serio, Sturbridge, MA (US); and Andrew E. Carlson, Higganum, CT (US)
Assigned to Advanced Fuel Research, Inc, East Hartford, CT (US)
Filed by ADVANCED FUEL RESEARCH, INC., East Hatford, CT (US)
Filed on Jul. 3, 2020, as Appl. No. 16/920,538.
Claims priority of provisional application 62/871,106, filed on Jul. 6, 2019.
Claims priority of provisional application 62/870,718, filed on Jul. 4, 2019.
Prior Publication US 2021/0001305 A1, Jan. 7, 2021
Int. Cl. B01J 20/20 (2006.01); B01D 53/04 (2006.01); B01J 20/28 (2006.01); B01J 20/30 (2006.01); B33Y 10/00 (2015.01); B33Y 70/00 (2020.01); B33Y 80/00 (2015.01); C01B 32/318 (2017.01); C01B 32/336 (2017.01)
CPC B01J 20/20 (2013.01) [B01D 53/04 (2013.01); B01J 20/28042 (2013.01); B01J 20/3007 (2013.01); B01J 20/3078 (2013.01); B01J 20/3085 (2013.01); B33Y 10/00 (2014.12); B33Y 70/00 (2014.12); B33Y 80/00 (2014.12); C01B 32/318 (2017.08); C01B 32/336 (2017.08); B01D 2253/102 (2013.01); B01D 2253/304 (2013.01); B01D 2253/306 (2013.01); B01D 2253/308 (2013.01); B01D 2253/3425 (2013.01); B01D 2257/406 (2013.01); B01D 2257/70 (2013.01); B01D 2259/40083 (2013.01); B01D 2259/4575 (2013.01)] 12 Claims
OG exemplary drawing
 
1. A method for the production of a carbon sorbent monolith for removing at least one gas from a gaseous environment in which the at least one gas is contained, comprising the steps:
3D-printing of a polymer monolith from a polymer precursor;
carbonizing said polymer monolith so as to produce a high-purity carbon monolith by exposure to elevated temperatures of at least 500° C. in a non-oxidative atmosphere; and
activating said high-purity carbon monolith by exposure to an oxidizing environment under conditions sufficient to produce a microporous sorbent monolith with a surface area of at least 100 m2/g, with the majority of pores being smaller than 2 nm.