3D-Printed Membrane Structure for Uniform Pore Filtration
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Solution Overview
Problem
Existing nano-membranes have wide pore size distributions, limiting selectivity, and are costly to produce due to the restrictive use of laser-etched methods, which are applicable only to materials with excellent thermal and chemical resistance, making them unsuitable for widespread use.
Innovation Solution
A membrane with uniform pore size and arrangement is manufactured using 3D printing, allowing for the use of various materials and reducing costs by shortening the manufacturing time, achieved through 3D printing of pore structures followed by application of a membrane-forming solution and heat treatment, with pore structures removed using water or an acidic solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser or ion beam etching is used to create narrow pore size distribution, then selectivity is improved, but manufacturing cost increases and material selection is restricted
Solution Approach 1:
The patent replaces the mechanical/thermal laser or ion beam etching process with a chemical self-organization process. The block copolymer spontaneously forms ordered nanodomains through phase separation, creating uniform pores without requiring high-energy beam irradiation. This substitution eliminates the need for expensive equipment and reduces manufacturing costs while maintaining narrow pore size distribution.
Solution Approach 2:
The patent changes the fundamental approach from top-down etching to bottom-up self-organization. By controlling polymer composition, molecular weight, and processing conditions (temperature, solvent), the system naturally forms uniform nanoscale structures. This parameter-based control achieves precise pore size distribution without the high costs associated with beam etching.
2Manufacturing precision
If laser or ion beam etching is used to create narrow pore size distribution, then selectivity is improved, but material selection is restricted to materials with excellent thermal and chemical resistance
Solution Approach 1:
The patent transforms the material selection constraint into an advantage by using diverse block copolymers with different compositions, molecular weights, and phase separation behaviors. Each polymer system can be tuned to produce specific pore sizes and structures, expanding material versatility while maintaining uniform pore distribution that laser etching cannot achieve with restricted materials.
Solution Approach 2:
The patent employs block copolymer systems consisting of different polymer blocks that self-assemble into ordered structures. These composite polymer systems provide both the structural framework and the pore-forming mechanism, allowing selection from a wide range of polymer combinations while achieving narrow pore size distribution without requiring extreme thermal or chemical resistance.
3Quantity of substance
If multiple laser or ion beam irradiations are applied to achieve high porosity, then pore density increases, but processing time and cost increase proportionally
Solution Approach 1:
The patent performs preliminary self-organization of the block copolymer into ordered nanodomains before any pore formation step. This pre-formed template structure allows subsequent pore creation to occur in a single step rather than requiring multiple iterative irradiations. The self-assembled structure is already optimized for high porosity, enabling direct conversion to the final porous membrane in one processing cycle.
Solution Approach 2:
The patent replaces the time-consuming iterative laser or ion beam irradiation process with a single chemical etching step that removes the sacrificial polymer domains. The self-organized template guides this single-step etching to create high porosity uniformly throughout the membrane, eliminating the need for repeated processing cycles and dramatically improving productivity.
4Ease of manufacture
If conventional membrane manufacturing is used, then manufacturing is simple, but pore size distribution is wide and selectivity is limited
Solution Approach 1:
The patent maintains manufacturing simplicity by using solution casting and standard etching procedures, but changes the critical parameter of pore formation from random to self-organized. The block copolymer's inherent phase separation behavior creates uniform nanodomains during processing, and subsequent etching of these domains produces narrow pore size distribution. The process remains simple and solution-based, avoiding complex equipment while achieving precision pore control.
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 3D printed membrane achieves improved filtration performance and fouling resistance with uniform porosity, reducing manufacturing costs by more than three times compared to conventional methods.
Implementation Method 1
utilizing the self-assembly of block copolymers through phase separation
Implementation Method 2
etching the polymer domains to form a porous structure
Implementation Method 3
applying a membrane-forming solution between the plurality of pore structures and performing heat treatment
Data Source
AI summary
The present disclosure relates to a membrane having uniform pore size and pore arrangement. The present disclosure provides a membrane including a plurality of pores, wherein the diameter of the plurality of pores is 100 μm or less, the porosity is 20 to 80%, the thickness is 3 to 500 μm, and the membrane is a single layer membrane.