Porous Ceramic Particles via Electrospraying for Fluid Absorption
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Solution Overview
Problem
Existing ceramic membranes and granules are difficult to handle and ineffective for removing fluids from surfaces, and existing methods for producing ceramic particles do not efficiently enhance absorption capabilities.
Innovation Solution
A process involving the preparation of a ceramic dispersion solution with specific components, electrostatic spraying to form droplets, coagulation in a non-solvent bath to create porous particles, and sintering to remove residual components, resulting in ceramic particles with increased absorption properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If ceramic membranes are used for fluid removal, then fluid absorption capability is improved, but ease of operation deteriorates due to difficult handling
Solution Approach 1:
The ceramic membrane is segmented into individual granular particles of sizes 0.1-2.0 mm, transforming the continuous membrane structure into discrete, easily handled units that can be freely applied to surfaces while maintaining fluid absorption capability
Solution Approach 2:
A polymeric binder forms a flexible coating around the ceramic particles, creating a thin film structure that binds particles together into applicable granules while preserving porosity and fluid absorption properties
2Ease of operation
If large particle ceramic granules are used for sewage absorption, then ease of operation is improved, but manufacturing precision deteriorates due to irregular shapes
Solution Approach 1:
Spherical ceramic particles are prepared in advance with controlled sizes and uniform shapes through controlled precipitation and drying processes before being coated with polymeric binder, ensuring both handling ease and manufacturing precision
Solution Approach 2:
A composite structure is created by coating spherical ceramic particles with a polymeric binder layer, combining the shape control of ceramic spheres with the binding properties of polymer to achieve uniform, handleable granules
3Quantity of substance
If ceramic particles are made with higher porosity for increased absorption, then fluid absorption capability is improved, but strength deteriorates
Solution Approach 1:
A polymeric binder forms a flexible protective shell around the porous ceramic particles, reinforcing the particle structure and compensating for strength losses due to high porosity while maintaining fluid absorption capability
Solution Approach 2:
The composite structure of porous ceramic core with polymeric binder shell combines the high absorption capability of porous ceramic with the mechanical strength of polymer, achieving both high fluid absorption and adequate particle strength
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 process produces ceramic particles with enhanced fluid absorption capabilities, particularly for water and oil, suitable for surface treatment and industrial applications without health risks.
Implementation Method 1
an electrical potential is applied between the coagulation bath and the syringe or the nozzle at the tip of the syringe which is conductive. Therefore, an electric field is generated around the liquid. As the electric field strength increases, the surface tension of the liquid is overcome at the tip of the nozzle, therefore forming a cone-like shape called the Taylor cone. As soon as the electric field reaches and passes a critical strength, a jet formed at the tip of the Taylor cone breaks up into fine droplets due to the electrostatic force acting on the nozzle.
Implementation Method 2
the polymeric binder in the mixture ensures that the droplets leave the nozzle with the necessary cohesive strength
Implementation Method 3
During the journey from the nozzle to the coagulation bath the solvent inside the fine droplets starts to evaporate.
Implementation Method 4
Upon landing on the surface of the non-solvent bath and inside the bath the droplets flatten.
Implementation Method 5
This exchange additionally creates pores throughout the particles. During this process the unstructured polymeric binder within the particles maintains a dynamic equilibrium between dissolving and precipitating out. As all the solvent diffuses into the non-solvent of the coagulation bath, the non-solvent solidifies the shape of the particles
Implementation Method 6
As all the solvent diffuses into the non-solvent of the coagulation bath, the non-solvent solidifies the shape of the particles resulting in the formation of solid particles
Implementation Method 7
the filtered and shaped particles are sintered in order to remove the residual binder component respective to burn out any residual (organic) components from the shaped solid ceramic particles
Data Source
Figure 1
Figure 2~3
AI summary
The present invention is directed to a process to make fluid absorbing ceramic particles (4) comprising the following steps: preparing a ceramic dispersion solution using at least a ceramic, a solvent and a polymeric binder; using the electro spraying method to direct fine droplets of the dispersion solution leaving a nozzle (2) in a mainly vertical jet to a coagulation bath (3) containing a non-solvent liquid with respect to the electro-sprayed solution; flattening the droplets inside the coagulation bath (3) with the non-solvents solidifying to the shape of the particles (4); finally filtering and sintering the solid particles (4).