3D-Printed Polymeric Filter Structure for High Sorbent Loading
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Solution Overview
Problem
Conventional filtration devices face issues such as insufficient sorbent loading, irregular pore sizes, delamination of sorbent from the support material, high energy usage, and high production costs, along with a cumbersome production process involving multiple steps.
Innovation Solution
A polymeric structure composed of stacked layers formed by 3D-printed polymeric material with interlaced strands, where sorbent is integrated into the spaces between the strands, allowing for high sorbent loading and improved retention, and produced through a single 3D printing operation with a solvent-based emulsion application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional support material with sorbent is used, then filtration function is provided, but sorbent loading is insufficient
Solution Approach 1:
The patent employs a 3D-printed porous support structure with controlled pore sizes and distributions that enables high sorbent loading capacity while maintaining structural integrity. The porous architecture provides extensive surface area and internal volume for sorbent placement, resolving the contradiction between loading quantity and retention reliability.
Solution Approach 2:
The patent creates a composite structure combining the 3D-printed porous support material with sorbent materials. This composite approach allows the support structure to provide mechanical strength and pore architecture while the sorbent provides filtration function, achieving both high sorbent loading and reliable retention through synergistic material combination.
2Ease of manufacture
If conventional production process is used, then support material is produced, but energy usage is high
Solution Approach 1:
The patent utilizes 3D printing technology which operates at lower temperatures and energies compared to conventional support material production methods. By changing the manufacturing parameters from high-energy processes to additive manufacturing, the patent achieves ease of manufacture with significantly reduced energy consumption.
3Ease of manufacture
If conventional production process is used, then support material is produced, but production cost is high
Solution Approach 1:
The patent employs 3D printing technology which reduces production costs by enabling direct fabrication of complex porous structures without expensive tooling or multiple assembly steps. The additive manufacturing process changes the economic parameters of production, making it more cost-effective than conventional methods.
4Productivity
If conventional production process is used, then support material and sorbent are assembled, but production efficiency is low
Solution Approach 1:
The patent merges the support structure fabrication and sorbent placement into a single integrated 3D printing process. The support material is printed with built-in pore structures that simultaneously serve as the framework and the sorbent housing, eliminating separate assembly steps and大幅提高 production efficiency while reducing process complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables high sorbent loading (up to 250 g/m²) with enhanced retention, efficient contaminant removal, reduced energy and cost, and streamlined production, preventing delamination and ensuring consistent pore sizes for effective filtration.
Implementation Method 1
a first layer comprising a first plurality of strands that are positioned substantially parallel to each other in a first direction and a second layer comprising a second plurality of strands that are positioned substantially parallel to each other in a second direction
Implementation Method 2
produced through a single 3D printing operation with a solvent-based emulsion application
Implementation Method 3
The sorbent may have an activity for sorbing, such as absorbing or adsorbing, a particular component, e.g., a contaminant, from a medium
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2A~2B
AI summary
The present invention provides a polymeric structure including a plurality of stacked layers formed of 3D-printed polymeric material, a plurality of spaces formed in the plurality of stacked layers; and a sorbent positioned in the plurality of spaces having a mass per m2 of a surface area of the polymeric structure that is at least 200 g/m2; and a method of producing the polymeric structure as well as a filter device including a plurality of polymeric structures as defined herein.