3D-Printed Metallic Filter Structure for Low Pressure Drop
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Solution Overview
Problem
Current protective masks, such as surgical and FFP2 masks, are disposable and non-reusable, leading to significant ecological issues and health risks due to their ephemeral nature and the accumulation of soiled wastes. Additionally, existing metallic filters are expensive, complex to produce, and have heterogeneous porosity, resulting in high pressure drops and limited efficiency.
Innovation Solution
A manufacturing method using additive manufacturing techniques to create functional parts with metallic filtering media. This method involves successive layer deposition of metallic material, controlled by a computer database to achieve a coalescent network of connecting strands with a homogeneous pore distribution, allowing for high efficiency and low pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If disposable masks are used to ensure high filtering efficiency, then filtering performance is improved, but ecological impact and waste accumulation worsen
Solution Approach 1:
The patent applies this principle in reverse by creating durable reusable metallic filters instead of disposable masks. The metallic filter structure can be sterilized and reused multiple times, eliminating waste accumulation while maintaining high filtering efficiency through its permanent porous structure.
2Reliability
If metallic filters are manufactured by sintering powders to achieve high filtering efficiency, then porosity control is improved, but manufacturing complexity and cost worsen
Solution Approach 1:
The patent changes the manufacturing parameters from traditional sintering processes to additive manufacturing (3D printing). This allows precise control of porosity and pore distribution through digital modeling and layer-by-layer construction, simplifying the manufacturing process while achieving homogeneous pore structures that traditional sintering cannot produce.
3Reliability
If filtering efficiency is increased to achieve very high efficiency filters, then particle removal rate is improved, but pressure drop worsens
Solution Approach 1:
The patent applies local quality by creating regions of different porosity within the filter structure. The additive manufacturing process enables varying pore density and strand thickness in different zones, allowing high filtration efficiency in critical areas while maintaining lower pressure drop in other regions, optimizing the balance between efficiency and flow resistance.
4Productivity
If traditional sintering processes are used to manufacture metallic filters, then production capability is improved, but porosity homogeneity worsens
Solution Approach 1:
The patent applies preliminary action by pre-designing the exact pore distribution and strand configuration through 3D digital modeling before manufacturing. The additive manufacturing process then precisely reproduces this predetermined structure layer by layer, ensuring homogeneous porosity distribution that cannot be achieved with conventional sintering methods.
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 produces reusable filtering media with high durability and efficiency, achieving filtration rates higher than 99% for particles larger than 100 nm while maintaining a low pressure drop. It also reduces environmental impact and manufacturing costs, enabling the production of complex shapes and large exchange surfaces.
Implementation Method 1
each pass comprising the deposition of at least one layer of said metallic material, the deposited material adhering to the metallic material of at least one layer deposited before
Implementation Method 2
The deposition of the metallic material at the level of each layer is controlled at each pass such that the stack of the metallic material deposited during said successive passes constitutes said functional part
Data Source
AI summary
A manufacturing method enables the obtainment of a functional part essentially formed in a metallic material, all or part of the functional part delimiting a filtering medium permeable to a fluid and delimiting first and second main faces for a preferred circulation of said gas through the filtering medium. The method includes a main phase consisting of an additive manufacturing method in successive passes from a support tray. Each pass comprises the deposition of at least one layer of said metallic material, the deposited material adhering to the metallic material of at least one layer deposited before. The deposition is controlled at each pass such that the stack of the metallic material deposited during the successive passes constitutes the functional part. The filtering medium includes a coalescent network of connecting strands interconnected according to a three-dimensional spatial distribution between the first and second main faces.