3D-Printed Single-Layer Membrane With Uniform Pore Structure
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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 use of laser or ion beam etching, which is restrictive to specific materials and requires multiple irradiations for high porosity.
Innovation Solution
A membrane with uniform pore size and arrangement is manufactured using 3D printing, allowing for various materials and reduced costs through a method involving 3D printing of pore structures, application of a membrane-forming solution, and removal of these structures via heat treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser or ion beam etching is used to create nano-membranes with narrow pore size distribution, then selectivity is improved, but manufacturing cost increases and material versatility is limited
Solution Approach 1:
The patent replaces the optical/physical etching methods (laser or ion beam) with a 3D printing-based mechanical formation method. Pore structures are formed through additive manufacturing processes, allowing precise control of pore size and distribution without the high costs and material limitations of beam-based etching. This substitution enables broader material selection while maintaining manufacturing precision.
Solution Approach 2:
The patent utilizes 3D printing technology to precisely control and vary parameters such as pore size, pore distribution, and membrane thickness during the manufacturing process. By adjusting print resolution, layer thickness, and material properties, the patent achieves narrow pore size distributions (improving selectivity) while maintaining cost-effectiveness and material versatility, thus resolving the contradiction between precision and ease of manufacture.
2Reliability
If multiple laser or ion beam irradiations are performed to achieve high porosity, then filtration performance is improved, but processing time and cost increase
Solution Approach 1:
The patent incorporates pore structure formation directly into the initial 3D printing process, creating the porous architecture during manufacturing rather than requiring subsequent multiple irradiation steps. This preliminary action establishes the necessary porosity and pore distribution in one integrated process, significantly reducing processing time while maintaining high filtration performance through controlled pore geometry and distribution.
3Manufacturing precision
If conventional nano-membrane manufacturing methods are used, then selectivity is limited by wide pore size distribution, but achieving narrow distribution requires restrictive and expensive processes
Solution Approach 1:
The patent employs 3D printing technology as a universal manufacturing platform that can work with various materials (polymers, metals, ceramics) while maintaining precise control over pore structure. This multi-functional approach allows the same manufacturing process to produce nano-membranes with narrow pore size distributions across different material systems, greatly enhancing material selection flexibility without sacrificing manufacturing precision.
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 uniform porosity and improved filtration performance with reduced fouling resistance, and manufacturing costs are significantly lower compared to conventional methods.
Implementation Method 1
applying a membrane-forming solution between the plurality of pore structures and performing heat treatment
Data Source
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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.