3D Printed Inorganic Filter Support for Complex Geometries

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Solution Overview

Problem

Conventional 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 monolithic inorganic porous support by extruding a string of inorganic composition, allowing for the formation of complex geometries without supporting means, followed by sintering to achieve a mechanically resistant and porous structure suitable for filtration membranes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional extrusion method is used to manufacture porous support, then rectilinear channels can be obtained, but the process requires multiple sintering operations and is cumbersome for non-rectilinear channels

Engineering Contradiction:

Improveease of manufactureVSAvoidprocess complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The invention changes the manufacturing approach from conventional extrusion with multiple sintering operations to 3D printing with a single sintering operation. This parameter change in the manufacturing process enables complex geometries including non-rectilinear channels while reducing process complexity and eliminating the need for multiple sintering cycles.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Instead of using extrusion to create rectilinear channels and then modifying them, the invention inverts the approach by using 3D printing to directly create the desired complex geometries in a single step, including non-rectilinear channels, eliminating the need for subsequent modifications or multiple operations.

Inventive Principle:

Principle #13The other way round (Inversion)

2Shape

If additive technique with continuous powder bed deposition is used, then complex geometries can be achieved, but powder fluidity must be adjusted and unconsolidated powder must be removed

Engineering Contradiction:

Improvegeometry complexityVSAvoidproduction efficiency

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The invention uses 3D printing to directly copy the desired complex geometry from a digital model, building the structure layer by layer with precise material deposition. This eliminates the need for powder fluidity adjustments and removal of unconsolidated powder, as the material is deposited in a controlled, consolidated form that maintains structural integrity throughout the building process.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The 3D printing process performs preliminary consolidation of the material during the deposition process itself, rather than requiring subsequent removal and recycling of unconsolidated powder. The structure is built in a manipulable state with adequate mechanical strength, eliminating post-processing steps and improving production efficiency.

Inventive Principle:

Principle #10Preliminary action

3Shape

If 3D printing is used to create manipulable three-dimensional raw structure, then complex geometries and large dimensions can be achieved, but consolidation must be accelerated during extrusion

Engineering Contradiction:

Improvegeometry complexityVSAvoidenergy consumption

Core Design Contradiction:

ShapeVSUse of energy by moving object

Solution Approach 1:

The invention applies periodic or continuous energy input during the 3D printing process to accelerate consolidation of the material as it is being extruded and deposited. This energy input, in the form of heating or other consolidation mechanisms, ensures that each layer maintains adequate mechanical strength before the next layer is deposited, enabling the construction of large-dimensional structures with complex geometries without requiring supporting means.

Inventive Principle:

Principle #19Periodic action

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, open, and interconnected porous supports with varied geometries, including non-rectilinear channels, with porosity between 10% and 60% and average pore diameters ranging from 0.5 μm to 50 μm, suitable for tangential filtration membranes.

Implementation Method 1

supplying an extrusion head of the 3D printing machine with the inorganic composition and causing its extrusion to form a string

Methodology Applied

Scientific EffectExtrusion: Extrusion

Implementation Method 2

placing the manipulable three-dimensional raw structure in a heat treatment furnace in order to carry out a sintering operation at a temperature comprised between 0.5 and 1 time the melting temperature of at least one material forming the powdery solid inorganic phase

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS11806893B2Method for material additive manufacturing of an inorganic filter support and resulting membrane

Publication Date: 2023.11.07 TECHNOLOGIES AVANCEES ET MEMBRANES INDUSTRIELLES SA

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 raw structure (2) intended to form, after sintering, the monolithic inorganic porous support(s) (1).