3D Printed Plastic Catalytic Support for Photocatalysis
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Solution Overview
Problem
Ceramic catalytic supports used in industrial processes are heavy, fragile, and limited in geometric design, making them difficult to produce and use in photocatalysis due to their opacity, which restricts light penetration and catalyst activation.
Innovation Solution
A catalytic support made from lightweight plastic materials using three-dimensional printing techniques, allowing for flexible geometry and transparency or translucency to enhance light penetration and catalyst contact, with a honeycomb structure and non-parallel conduits for increased reaction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If ceramic materials are used for catalytic supports, then adequate porosity and catalytic activity are achieved, but specific weight becomes excessive
Solution Approach 1:
The patent changes the material parameter from ceramic to plastic, fundamentally altering the density and weight characteristics while maintaining the required porosity structure for catalytic function
Solution Approach 2:
The patent uses composite plastic materials that can incorporate catalyst particles within the matrix, creating a composite structure that combines the lightweight properties of plastic with the catalytic functionality previously provided by ceramic materials
2Stability of the object's composition
If ceramic materials are used for catalytic supports, then structural stability is achieved, but impact resistance deteriorates
Solution Approach 1:
The patent changes the material phase from brittle ceramic to ductile plastic, fundamentally altering the mechanical response to impact while maintaining structural integrity through appropriate plastic material selection and formulation
3Ease of manufacture
If extrusion process is used for manufacturing, then production simplicity is achieved, but geometrical freedom deteriorates
Solution Approach 1:
The patent replaces the traditional extrusion mechanical process with 3D printing technology, which uses additive manufacturing principles to build complex geometries layer by layer, eliminating the geometric constraints of extrusion while maintaining manufacturing efficiency
Solution Approach 2:
The patent transitions from two-dimensional extrusion profiles to three-dimensional additive manufacturing, enabling complex internal and external geometries that cannot be achieved through conventional extrusion methods
4Power
If ceramic materials are used for photocatalysis, then catalytic activity is achieved, but light penetration deteriorates
Solution Approach 1:
The patent changes the optical parameter of the support material from opaque (ceramic) to transparent or translucent (plastic), enabling light penetration while maintaining catalytic activity through appropriate material selection and catalyst distribution
Solution Approach 2:
The patent applies the catalyst selectively within the plastic matrix at locations where light activation is required, ensuring that the catalytic activity is concentrated in the regions most effective for photocatalysis while the plastic support provides optimal light transmission
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 solution results in a lighter, more durable catalytic support with increased geometric freedom and photocatalysis performance, optimizing light activation and catalyst contact, thereby enhancing the efficiency of catalysis reactions.
Implementation Method 1
a catalytic support (1) made of plastic material, in particular made by means of a three-dimensional printing process
Implementation Method 2
If the catalysis process comprises a photocatalysis... i ceramic supports have a further major limitation in terms of performance caused by the impossibility to make them transparent or translucent
Data Source
AI summary
A catalytic support for catalysis processes including a main body, at least one conduit made in said main body, said conduit having an inlet portion made on a first surface of said main body and an outlet portion made on a second surface of said main body, said first surface being opposite said second surface said main body includes a plurality of layers at least partially superposed and mutually adherent, said layers forming a plurality of recesses at the intersections and superposition of said layers, said recesses being configured to house particles of at least one catalyst element.