3D Printed Inorganic Filter Support with Non-Rectilinear Channels
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Solution Overview
Problem
Existing methods for manufacturing filtration membranes require multiple sintering operations and are cumbersome, especially when creating non-rectilinear channels, which complicates the process and increases costs due to the need for adjusting powder fluidity and removing unconsolidated powder.
Innovation Solution
A 3D printing method is used to create a manipulable three-dimensional green structure from an inorganic composition, which is then sintered, allowing for the production of monolithic porous supports with varied shapes and porosity suitable for filtration, including non-rectilinear channels without the need for supporting means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional extrusion and sintering methods are used to manufacture porous supports, then rectilinear channels can be produced, but the process requires multiple sintering operations and is cumbersome for non-rectilinear channels
Solution Approach 1:
The patent combines the support structure and channel geometry into a single monolithic piece manufactured by 3D printing, eliminating the need for separate assembly steps and multiple sintering operations. The entire porous support with integrated channels is created in one additive manufacturing process followed by a single sintering step.
Solution Approach 2:
The patent changes the manufacturing approach from subtractive/conventional methods to additive manufacturing, enabling complex non-rectilinear channel geometries that cannot be achieved by traditional extrusion. This parameter change in the manufacturing process allows freedom in channel design without increasing process complexity.
2Shape
If additive technique with continuous powder bed deposition is used, then non-rectilinear channels can be created, but powder fluidity must be adjusted and unconsolidated powder removal is time-consuming
Solution Approach 1:
The patent uses a bindable composition that temporarily holds the green structure together during manufacturing, then is completely removed during sintering. This disposable binding approach eliminates the need for time-consuming powder removal operations while enabling complex channel shapes.
Solution Approach 2:
The patent applies a bindable composition to the deposited powder layers before sintering to create a manipulable green structure. This preliminary binding action stabilizes the structure during and after deposition, eliminating the need for subsequent powder removal operations.
3Length of stationary object
If large-dimension monolithic porous supports are manufactured by conventional methods, then production is limited in size, but additive techniques currently on market cannot produce supports greater than certain dimensions
Solution Approach 1:
The patent uses additive manufacturing to build supports layer by layer in the vertical dimension, enabling production of large-dimension monolithic supports that exceed the capabilities of conventional horizontal manufacturing methods. The layer-by-layer approach allows continuous growth in size without tooling constraints.
4Ease of manufacture
If conventional extrusion method is used, then support structure can be manufactured, but organic binders must be completely removed during sintering which affects mechanical properties
Solution Approach 1:
The patent changes the binder from organic to inorganic composition that matches the support material chemistry. This parameter change allows the binder to become part of the final sintered structure rather than being completely removed, preserving mechanical strength while maintaining ease of manufacture.
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 rapid and cost-effective production of mechanically resistant, homogeneous porous supports with controlled porosity and shape, suitable for large-scale filtration membranes, including tangential filtration, with improved mechanical strength and reduced production time.
Implementation Method 1
a second phase in the form of a matrix, comprising at least one hot-melt polymer
Implementation Method 2
placing this manipulable three-dimensional green structure in a heat treatment furnace in order to carry out a sintering operation at a temperature comprised between 0.5 and 1 times the melting temperature of at least one material forming the powdery solid inorganic phase
Data Source
AI summary
The present invention relates to a method for manufacturing at least one monolithic inorganic porous support (1) having a porosity comprised between 10% and 60% and an average pore diameter ranging from 0.5 μm to 50 μm, using a 3D printer type machine (I) to build, in accordance with a 3D digital model, a manipulable three-dimensional green structure (2) intended to form, after sintering, the monolithic inorganic porous support(s) (1).