Mixed-Porosity Glass Bubble Substrate for Low-Energy CO2 Capture

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Solution Overview

Problem

Existing ceramic honeycomb structures for CO2 capture are inefficient and costly due to high thermal energy input for desorption, and there is a need for lightweight, low-density structures that can effectively capture CO2 from ambient air or flue gas.

Innovation Solution

A porous structure composed of sintered glass bubbles with a high proportion of closed voids and mixed porosity, where at least 50% of the glass bubbles are closed, providing at least 10% closed porosity and 40% open porosity, with a bulk density ranging from 0.4 to 0.6 g/cm3, and a cellular honeycomb geometry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If ceramic honeycomb structures are used for CO2 capture, then CO2 capture capability is improved, but thermal energy input for desorption increases significantly

Engineering Contradiction:

ImproveCO2 capture capabilityVSAvoidthermal energy input for desorption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent employs a porous glass structure with controlled porosity (50-90% void volume) to create a high-surface-area substrate for CO2 adsorbent. The porous architecture enables efficient CO2 capture while the glass material's thermal properties allow for reduced thermal energy input during desorption compared to traditional ceramic honeycomb structures.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent changes the material parameter from ceramic to glass, and adjusts the porosity parameter to 50-90% void volume. This parameter change in material composition and structural density enables the structure to achieve both high CO2 capture capability and reduced thermal energy requirements for desorption.

Inventive Principle:

Principle #35Parameter changes

2Strength

If traditional ceramic honeycomb structures are used, then structural strength is maintained, but weight and density increase

Engineering Contradiction:

Improvestructural strengthVSAvoidweight and density

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent uses a porous glass structure with 50-90% void volume, which dramatically reduces the material density compared to solid ceramic honeycomb structures. The porous architecture maintains sufficient structural strength through the glass matrix while minimizing weight, making the CO2 capture system more energy-efficient and easier to deploy.

Inventive Principle:

Principle #31Porous materials

3Ease of manufacture

If glass bubbles are used as filler in composite structures, then material cost is reduced and weight is adjusted, but mechanical integrity is compromised

Engineering Contradiction:

Improvematerial cost reductionVSAvoidmechanical integrity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

Instead of using glass bubbles as filler within a continuous matrix material (traditional approach), the patent inverts the structure by making the glass bubbles themselves form the continuous structural framework. The glass bubbles are sintered together to create an interconnected porous structure where the bubbles provide both structural support and the desired low-density properties, eliminating the need for additional matrix material.

Inventive Principle:

Principle #13The other way round (Inversion)

4Productivity

If porous structures with high open porosity are created for CO2 capture, then CO2 access is improved, but structural stability decreases

Engineering Contradiction:

ImproveCO2 capture efficiencyVSAvoidstructural stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The patent creates a porous glass structure with 50-90% void volume that maintains structural stability through the interconnected glass matrix. The porous architecture provides excellent CO2 access and capture efficiency while the glass material's inherent stability ensures the structure maintains its integrity under operating conditions.

Inventive Principle:

Principle #31Porous materials

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 structure achieves efficient CO2 capture with reduced thermal energy input and lower material costs, enabling scalable CO2 capture systems.

Implementation Method 1

the glass bubbles are sintered to one another such that adjoining glass bubbles are physically bonded directly to one another

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS20250382218A1Light weight substrate with glass bubble skeleton having mixed porosity for carbon capture and method of making

Publication Date: 2025.12.18 CORNING INC

AI summary

A porous structure includes a plurality of glass bubbles that are sintered to one another such that adjoining glass bubbles are physically bonded directly to one another. The glass bubbles have surfaces that define interstices throughout the porous structure. The interstices include closed interstices that do not open to surfaces of the porous structure. At least 50% of the glass bubbles are closed glass bubbles with each closed glass bubble defining a sealed void therein. The porous structure has at least 10% closed porosity and at least 40% open porosity. The closed porosity includes the sealed voids and the closed interstices. A method for making the porous structure includes heating the glass bubbles. Prior to the heating, substantially all of the glass bubbles are closed glass bubbles. At least 50% of the glass bubbles remain closed after the heating such that the sintered, closed glass bubbles form the porous structure.