Electrolyte Ion Exchange for Low-Energy Inorganic Compound Blocks
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Solution Overview
Problem
Existing methods for producing inorganic compounds in the form of blocks or granules, such as sintering and curing reactions, result in high energy consumption, environmental impact, and functional deterioration, and are not applicable to thermally decomposable compounds.
Innovation Solution
A production method that utilizes a low-energy process involving the immersion of inorganic compounds in electrolyte solutions to precipitate new compounds without sintering, creating products with core-shell structures or interconnected porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If organic compounds are used as starting materials for synthesizing inorganic compounds, then the synthesis process becomes complex and contamination with organic by-products occurs, but using inorganic compounds as starting materials may limit the available reaction pathways and require stricter purification conditions
Solution Approach 1:
The patent extracts and removes organic by-products from the reaction mixture through filtration and washing steps, separating the desired inorganic compound from contamination sources. This extraction approach resolves the contradiction by maintaining high purity while managing the complexity of organic-based synthesis pathways.
Solution Approach 2:
The patent employs solvents with specific properties (polar/non-polar characteristics, boiling points) to selectively dissolve and remove organic by-products. By changing solvent parameters systematically, the process achieves high purity inorganic compounds while managing reaction complexity through controlled parameter adjustments.
2Manufacturing precision
If conventional synthesis methods are used, then the inorganic compound may contain residual solvents and by-products, but implementing extensive purification steps increases processing time and reduces productivity
Solution Approach 1:
The patent performs preliminary purification actions during the synthesis process itself, such as in-situ filtration and washing, rather than requiring extensive post-synthesis treatment. This preliminary action approach maintains high purity while minimizing the time loss associated with prolonged purification steps.
Solution Approach 2:
The patent designs a continuous purification process where filtration, washing, and drying steps are performed in sequence without interrupting the overall production flow. This continuous action maintains productivity while ensuring thorough removal of residual solvents and by-products.
3Productivity
If the inorganic compound is not fully purified, then productivity is maintained, but the resulting product may cause health issues or environmental pollution when used
Solution Approach 1:
The patent converts potentially harmful residual solvents and by-products into removable waste streams through systematic purification. By designing the process to specifically target and eliminate these harmful substances, the method maintains productivity while ensuring the final product is safe for health and environmental applications.
Solution Approach 2:
The patent employs oxidation treatments to decompose and remove organic by-products and residual solvents that pose health and environmental risks. This accelerated oxidation ensures complete elimination of harmful substances while maintaining production efficiency through controlled reaction conditions.
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 method enables the production of highly active inorganic compounds with improved functionality and reduced environmental impact, preserving macro forms and enhancing properties like osteoconductivity and tissue compatibility.
Implementation Method 1
reacting an organic compound with an inorganic compound, thereby producing a product inorganic compound
Implementation Method 2
reacting an organic compound with an inorganic compound in a solvent
Data Source
Figure 1a~1k
Figure 2a~2f
Figure 3a~3d
AI summary
There is provided a method of producing a product inorganic compound including: a step A in which a raw material inorganic compound having a volume of 10-13 m3 or more is immersed in an electrolyte aqueous solution or an electrolyte suspension; a step B1 in which anions in the raw material inorganic compound are exchanged with anions in the electrolyte aqueous solution or the electrolyte suspension; a step B2 in which cations in the raw material inorganic compound are exchanged with cations in the electrolyte aqueous solution or the electrolyte suspension; or a step B3 in which a component (provided that it excludes water, hydrogen, and oxygen) in the electrolyte aqueous solution or the electrolyte suspension that is not included in the raw material inorganic compound is made to be included in the raw material inorganic compound; and a step C in which a product inorganic compound having a volume of 10-13 m3 or more is obtained from the raw material inorganic compound, wherein the raw material inorganic compound has a solubility that is greater than 0 and 5 or less with respect to distilled water or the electrolyte aqueous solution at 20 °C, and wherein, in the electrolyte aqueous solution or the electrolyte suspension in which the raw material inorganic compound is immersed, at least, elements other than hydrogen and oxygen, which are included in the product inorganic compound but not included in the raw material inorganic compound are included (provided that it excludes a production method in which an apatite without pores with a diameter of 20 µm or more and an aspect ratio of 2 or more is produced from at least one selected from the group consisting of calcium sulfate dihydrate, α-type tricalcium phosphate, and calcium carbonate, a production method in which calcium sulfate is immersed in an ammonia or alkali metal hydroxide-containing aqueous solution, carbon dioxide is introduced into the aqueous solution, and calcium carbonate without pores with a diameter of 20 µm or more and an aspect ratio of 2 or more is produced, and a production method in which a product inorganic compound is calcium hydrogen phosphate without pores with a diameter of 20 µm or more and an aspect ratio of 2 or more).