Topologically Optimized Sorbent for CO2 Capture

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Solution Overview

Problem

Existing carbon capture technologies are not cost-effective for widespread industry adoption due to high costs and inefficiencies in direct air capture (DAC) of carbon dioxide (CO2).

Innovation Solution

The development of topologically optimized sorbents with hierarchical pores, produced using binder jetting additive manufacturing, which are designed to efficiently capture and release CO2 and water from gases.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional DAC technologies are used, then CO2 capture can be achieved, but the cost is high and not cost-effective for industry adoption

Engineering Contradiction:

ImproveCO2 capture efficiencyVSAvoidcost-effectiveness

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent employs porous sorbent materials with hierarchical pore structures (micro-, meso-, and macropores) to enhance CO2 adsorption capacity and efficiency. The porous structure provides large surface area and optimized mass transport pathways, enabling effective CO2 capture at lower costs compared to conventional dense materials.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention uses composite sorbent materials combining different functional components within a hierarchical pore structure. These composites integrate materials with complementary properties to achieve both high CO2 capture efficiency and cost-effectiveness, resolving the trade-off between performance and economy.

Inventive Principle:

Principle #40Composite materials

2Productivity

If sorbent-based DAC is used, then CO2 capture efficiency can be improved, but the system complexity increases

Engineering Contradiction:

ImproveCO2 capture efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The sorbent structure is segmented into hierarchical pore levels (micro-, meso-, macropores) that perform specialized functions. This segmentation enables optimized mass transport and adsorption while maintaining a relatively simple overall system architecture that can be manufactured using additive manufacturing techniques.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent optimizes sorbent parameters including pore size distribution, surface area, and material composition to maximize CO2 capture efficiency. By carefully controlling these parameters during manufacturing, the system achieves high productivity without proportionally increasing complexity.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If thermal energy is used for CO2 desorption, then CO2 can be released from the sorbent, but energy consumption increases

Engineering Contradiction:

ImproveCO2 desorption rateVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent utilizes phase transition phenomena in the sorbent material to enable CO2 desorption. The hierarchical pore structure facilitates phase changes that allow CO2 release at lower temperatures compared to conventional methods, reducing the thermal energy required while maintaining high desorption rates.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The sorbent system operates in periodic cycles of adsorption and desorption. The hierarchical pore structure enables rapid mass transport during desorption cycles, allowing efficient CO2 release with minimized energy input by optimizing the timing and duration of each cycle.

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 solution reduces the energy needed for CO2 adsorption and desorption, achieves cost-effective CO2 capture, and allows for scalable and location-independent operations while avoiding thermal and chemical degradation issues.

Implementation Method 1

at least one chamber configured to collect water from the gas accepted via the inlet; at least one chamber configured to collect carbon dioxide from the gas accepted via the inlet; wherein the at least one chamber configured to collect water and the at least one chamber configured to collect carbon dioxide each comprise a topologically optimized sorbent with hierarchical pores

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

the at least one chamber configured to collect water and the at least one chamber configured to collect carbon dioxide are each configured to respectively release the collected water and the collected carbon dioxide

Methodology Applied

Scientific EffectDesorption: Desorption

Data Source

PatentUS20250135391A1Systems and Methods for Extracting A Component From A Gas

Publication Date: 2025.05.01 OMEGA DAC INC

AI summary

Systems and methods for extracting components from a gas. A chamber to collect water and another chamber to collect carbon dioxide from a gas are each configured with topologically optimized sorbents. A DAC method for extracting components from a gas includes water and carbon dioxide chambers configured with topologically optimized sorbents to respectively capture water and carbon dioxide.