Breached Glass Bubble Porous Structure for Low-Cost CO2 Filters
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Solution Overview
Problem
Existing ceramic filters do not effectively capture CO2 from ambient air due to their high thermal shocks and high thermal shocks, and they are not optimized for CO2 capture applications, and they are not optimized for CO2 capture applications, and they are not optimized for low-cost honeycomb filters with properties and performance optimized for CO2 capture application.
Innovation Solution
The development of porous structures made from glass bubbles that are breached and bonded to form interconnected cavities, with a composition comprising at least 7.3 wt % Na2O and 10 vol % MgO, allowing for efficient CO2 capture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ceramic honeycomb filters are used for CO2 capture from ambient air, then filtration capability is provided, but the high thermal shock resistance and high temperature withstand properties make the structure complex and costly, and the material composition is not optimized for CO2 capture
Solution Approach 1:
The patent changes the material composition parameters from traditional ceramic (Cordierite-based) to glass-based material with specific composition (SiO2: 70-80 wt%, Na2O: 10-20 wt%, CaO: 1-5 wt%, MgO: 1-5 wt%). This parameter change enables lower manufacturing cost while maintaining CO2 capture effectiveness through optimized pore structure and surface area
Solution Approach 2:
The patent creates a composite porous structure by combining glass bubbles with binder material and undergoing controlled breaching. The resulting composite structure has both the structural integrity of glass and the porosity needed for CO2 capture, achieving cost-effectiveness without sacrificing reliability
2Reliability
If glass bubbles are kept intact to maintain low weight-to-volume ratio, then structural integrity is preserved, but porosity is reduced and CO2 capture capability is compromised
Solution Approach 1:
The patent intentionally creates porous materials by breaching glass bubbles to form interconnected pore networks. The controlled breaching process maintains structural integrity through the glass skeleton while creating the necessary porosity (30-70% pore volume) for CO2 capture efficiency
Solution Approach 2:
The patent performs preliminary actions by forming glass bubbles with controlled thickness and composition before the breaching step. The glass bubbles are pre-formed with specific wall thickness (5-50 μm) and chemical composition to ensure they maintain structural integrity during handling but can be reliably breached to create the desired porous structure
3Productivity
If glass bubbles are breached to create open porosity, then CO2 capture capability is improved, but structural strength is reduced
Solution Approach 1:
The patent applies local quality by creating different properties in different regions: the glass bubble walls maintain their original strength where intact, while the interior creates porosity where breached. The resulting structure has localized strength in the glass skeleton and localized porosity in the bubble interiors, optimizing both structural strength and CO2 capture efficiency
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 porous structures achieve high porosity and structural integrity, enabling effective CO2 capture with low material and energy costs.
Implementation Method 1
the glass bubbles are sintered to one another such that adjoining glass bubbles are physically bonded directly to one another
Data Source
AI summary
A method of making a porous structure configured for use in a particulate filter includes bonding a plurality of glass bubbles to one another, and breaching the plurality of glass bubbles. Voids within individual breached glass bubbles open into one another to form cavities that extend through the porous structure.