3D Porous Sorbent Structure via Phase Inversion Drying

The patent changes the thermal processing parameters by replacing conventional calcination (high temperature, prolonged heating) and sintering with a milder drying process at lower temperatures. This parameter change allows the green body to achieve sufficient mechanical strength without the harmful thermal effects that block pores and reduce sorbent accessibility.

The patent converts the typically harmful effect of thermal treatment (which causes pore blocking and sorbent deactivation) into a beneficial process. By using controlled drying instead of calcination and sintering, the process achieves mechanical strengthening while preserving pore structure and sorbent activity, effectively turning a harmful thermal process into a beneficial low-temperature drying process.

The patent fundamentally changes the temperature and time parameters of the thermal processing step. Instead of conventional calcination (high temperature, prolonged heating) and sintering, the invention uses a drying process at significantly lower temperatures, dramatically reducing energy consumption while still achieving the required mechanical strength.

The patent employs a temporary organic binder that is removed during the drying process, replacing the need for expensive and energy-intensive calcination and sintering operations. This approach uses a disposable, easily removable binder instead of permanent ceramic binders that require high-energy processing.

The patent creates a composite structure combining inorganic sorbent particles with an organic binder matrix. This composite approach allows the formation of complex 3D structures with high mechanical strength, as the organic binder provides flexibility and toughness while the inorganic particles provide functional sorption properties.

The patent changes the material state and processing parameters by using a viscous paste composition that can be 3D-printed into complex geometries. The organic binder material and solvent system allow for flexible formability of complex structures without the brittleness associated with conventional inorganic 3D printing, as the organic component provides ductility.

The patent converts the typically harmful thermal decomposition process (calcination) into a beneficial controlled drying process. This eliminates carbon residue formation while still achieving the removal of the organic binder, thereby preserving sorbent activity and preventing the deactivation that would occur with conventional thermal treatment.

The patent fundamentally changes the temperature and atmospheric conditions of the binder removal process. Instead of high-temperature calcination in an oxidizing atmosphere that produces carbon residues, the invention uses low-temperature drying that removes the organic binder through evaporation and decomposition without forming harmful carbon deposits, thus preserving sorbent activity.