Isolated Porous Material via Dynamic Bubble Templating
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Solution Overview
Problem
Existing methods for producing porous materials result in them being bonded to a substrate, limiting their applications and making detachment challenging due to structural fragility.
Innovation Solution
A method involving dynamic bubble templating (DHBT) with an electrically conductive intermediate layer applied on a substrate, followed by removing the intermediate layer to produce an isolated, self-standing porous material with interconnected primary and secondary pores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If porous material is deposited onto a substrate using DHBT method, then the porous material can be formed with controlled pore structure, but the porous material becomes bonded to the substrate making detachment challenging
Solution Approach 1:
The patent introduces an intermediate layer between the substrate and the porous material, segmenting the bonding interface. This allows the porous material to be deposited on the intermediate layer rather than directly on the substrate, enabling subsequent detachment of the porous material while leaving the substrate intact. The intermediate layer acts as a sacrificial or releasable interface that facilitates separation.
Solution Approach 2:
The intermediate layer serves as a mediator between the substrate and the porous material. It provides a temporary bonding surface during deposition but allows for controlled detachment afterward. This intermediary layer resolves the contradiction by enabling both precise deposition and easy detachment through its special properties (such as being soluble, decomposable, or having controlled adhesion).
2Ease of manufacture
If the porous material structure is made fragile to enable detachment from substrate, then detachment becomes easier, but the structural integrity and strength of the porous material deteriorates
Solution Approach 1:
By segmenting the system into substrate-intermediate layer-porous material layers, the weakness is localized to the intermediate layer rather than the porous material itself. The porous material maintains its full structural integrity while the intermediate layer provides the necessary weakness for detachment.
Solution Approach 2:
The intermediate layer acts as a sacrificial mediator that absorbs the detachment stress. Its designed weakness or solubility enables easy separation without applying stress to the porous material structure, thus preserving the porous material's strength and integrity.
3Adaptability or versatility
If the porous material is isolated from substrate, then applications as diffusion media and filters are enabled, but additional processing steps are required to achieve isolation
Solution Approach 1:
The intermediate layer is applied in advance during the deposition process, preparing the system for future isolation. This preliminary action embeds the isolation mechanism within the deposition step itself, so that the porous material is deposited on a pre-configured releasable layer, simplifying subsequent isolation steps.
Solution Approach 2:
The intermediate layer provides a built-in isolation mechanism that enables versatile applications. By using a material that can be selectively removed or that provides controlled release, the system achieves easy isolation without requiring complex additional processing equipment or procedures.
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 method enables the production of a free-standing porous material with improved permeability and flexibility, allowing for a wide range of applications including diffusion media, filters, and catalysts.
Implementation Method 1
applying an electrically conductive intermediate layer on at least part of a surface of the substrate
Implementation Method 2
The fundamental idea of DHBT is that the generated H2 bubbles disrupt the growth of the metal layer, acting as a dynamic template for the electrodeposition process
Implementation Method 3
forming a surface layer on the intermediate layer by electrodeposition using dynamic bubble templating
Data Source
AI summary
The present invention relates to a porous material comprising a porous wall structure defining and separating primary pores that are interconnected across its thickness dimension. The primary pores have a diameter greater than 5 μm and less than 1000 μm. The diameter of the primary pores gradually increases across its thickness dimension while their number decreases in its thickness dimension. The porous wall structure comprises or consists of secondary pores that are interconnected throughout the material. The secondary pores have a diameter smaller than 5 μm. The present invention further relates to a method of manufacturing an isolated porous material comprising the steps of: providing a substrate; applying an electrically conductive intermediate layer on at least part of a surface of the substrate; forming a surface layer on the intermediate layer by electrodeposition using dynamic bubble templating; and removing the intermediate layer from the porous surface layer to obtain the isolated porous material; wherein the step of removing the intermediate layer takes place during or after deposition of the porous surface layer. The present invention further relates to a porous material obtainable with a method of manufacturing according to the second aspect. The present invention further relates to the use of a porous material according to the first or third aspect in a chemical or electrochemical system.