Additive Ceramic Membrane Manufacturing via Layered Consolidation
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Solution Overview
Problem
Conventional membrane filtration processes are limited by the need for multiple sintering operations, which can lead to design defects and reduced profitability, and lack flexibility in shape and channel variability.
Innovation Solution
A method for manufacturing membranes using an additive technique, where a three-dimensional ceramic porous support is formed by depositing and consolidating powdered material layer by layer, allowing for controlled pore size and shape variability, and enabling the deposition of a filtration separator layer with a smaller pore diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional extrusion and sintering methods are used to manufacture membrane supports, then the manufacturing process is well-established and reliable, but the process requires multiple sintering operations which reduces productivity and increases complexity
Solution Approach 1:
The invention combines the support structure manufacturing and channel formation into a single additive manufacturing step, eliminating the need for separate extrusion and multiple sintering operations. The support with integrated channels is built layer-by-layer directly, merging what were previously separate manufacturing processes into one unified operation.
Solution Approach 2:
The invention changes the manufacturing parameters from conventional extrusion-sintering parameters to additive manufacturing parameters (layer thickness 10-100 μm, controlled consolidation patterns). This parameter change enables single-step manufacturing of complex 3D structures with internal channels, improving productivity while maintaining reliability through precise digital control.
2Ease of manufacture
If conventional extrusion methods are used, then the manufacturing process is straightforward, but the shape and channel design variability is limited
Solution Approach 1:
The invention introduces dynamic design capabilities through computer-controlled additive manufacturing, allowing channel patterns, cross-sectional shapes, and three-dimensional configurations to be dynamically adjusted via software. The consolidation pattern can be programmatically changed layer-by-layer, enabling complex variable geometries that are impossible with fixed extrusion dies.
Solution Approach 2:
The invention transitions from two-dimensional extrusion profiles to three-dimensional additive construction, enabling channels to be positioned and shaped in all three spatial dimensions. This dimensional expansion allows for complex internal geometries, varying cross-sections, and optimized fluid flow paths that cannot be achieved with conventional extrusion.
3Strength
If multiple sintering operations are performed, then the support achieves required solidity, but design defects increase and profitability decreases
Solution Approach 1:
The invention performs preliminary consolidation of the ceramic powder during the additive manufacturing process itself, building the support with integrated strength from the first layer. The layer-by-layer consolidation ensures progressive strength development without requiring subsequent sintering operations, preventing defects that arise from repeated thermal processing.
Solution Approach 2:
The invention extracts the multiple sintering operations from the manufacturing process, replacing them with a single additive manufacturing process that achieves both shape formation and consolidation in one step. This elimination of redundant thermal cycles removes the source of many manufacturing defects while maintaining support solidity.
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
This approach enhances reliability and production rate, allows for greater variability in membrane shape and structure, and reduces design defects, resulting in improved membrane performance and efficiency.
Implementation Method 1
step b) is carried out by a supply of energy. The location of the consolidation is controlled automatically. More precisely, the points of application of the energy supply or the liquid projection are controlled by computer.
Implementation Method 2
Consolidation is carried out by supply of energy, in particular by laser, UV, electron beam treatment.
Implementation Method 3
Consolidation is carried out by supply of energy, in particular by laser, UV, electron beam treatment.
Data Source
Figure 1~2C
Figure 2D~2E
Figure 2F~3
AI summary
The present invention relates to a method for manufacturing a membrane for filtering a fluid, said membrane comprising: a substrate having a three-dimensional structure and consisting of an one-piece ceramic porous body; and at least one separating filtering layer having a porosity that is lower than that of the substrate, in which the three-dimensional structure of the substrate is produced by forming elemental layers that are stacked and connected in series with one another, by repeating the following steps: a) depositing a continuous bed of powder at least partially consisting of a powder intended for forming the ceramic porous body, the bed having a constant thickness across a surface area greater than the section of said porous body measured at the layer; b) locally consolidating, according to a pattern determined for each layer, part of the deposited material such as to create the elemental layer, and simultaneously linking the elemental layer thus formed with the preceding layer such as to gradually grow the desired three-dimensional shape. The invention also relates to the membranes obtained by such a method.