Printed Porous Structure via Multi-Step Absorption Photopolymerization
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Solution Overview
Problem
Existing techniques for manufacturing complex porous structures are limited by production speed, cost, and material choices, making it difficult to achieve accurate and efficient production of three-dimensional porous structures.
Innovation Solution
The use of multi-step absorption (MSA) process in conjunction with advanced manufacturing equipment that employs photon sources, galvanic reflective mirrors, and controlled polymerization methods to create complex porous structures layer-by-layer, allowing for precise control over pore size and structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional printing techniques are used to manufacture porous structures, then material choices are limited, but production speed is slow and costs are high
Solution Approach 1:
The invention changes the chemical parameters of the printing system by using photopolymerization reactions initiated by light sources. This allows a wide range of photopolymerizable materials to be used, expanding material choices while maintaining fast printing speeds through chemical curing mechanisms
Solution Approach 2:
The invention replaces mechanical printing and drying processes with photopolymerization-based printing. Light sources initiate chemical reactions that rapidly solidify materials layer-by-layer, eliminating slow mechanical drying steps and enabling both high productivity and material versatility
2Manufacturing precision
If conventional printing techniques are used to manufacture porous structures, then production costs are high, but manufacturing precision can be achieved
Solution Approach 1:
The invention replaces expensive mechanical printing and post-processing equipment with a photopolymerization-based system. Light sources and photopolymerizable materials enable direct printing of precise porous structures without costly mechanical drying, curing ovens, or multiple processing steps
Solution Approach 2:
The invention changes the curing mechanism from thermal or mechanical processes to photopolymerization initiated by light. This allows precise control of structure formation through light patterning while reducing equipment costs and simplifying the manufacturing process
3Manufacturing precision
If complex porous structures are manufactured using existing techniques, then production speed is slow, but manufacturing precision can be maintained
Solution Approach 1:
The invention replaces slow mechanical layer-by-layer construction with photopolymerization-based printing. Light sources rapidly cure photopolymerizable materials to form precise porous structures, achieving both high production speed and accurate pore size control through optical patterning
Solution Approach 2:
The invention enables continuous printing and curing operations by maintaining photopolymerization reactions throughout the printing process. Light sources continuously initiate polymerization as material is deposited, eliminating interruptions and enabling rapid production of complex porous structures with precise geometry
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 approach enables the rapid and cost-effective production of complex porous structures with precise control over pore size and structure, improving production speed, reducing costs, and expanding material choices.
Implementation Method 1
The photon source(s) 202 may provide coherent photons/beams, partially coherent photons/beams, super-luminescent photons/beams and/or incoherent photons/beams. Such photons/beams may be continuous wave and/or pulsed. The photons provided may include one or more of: infrared, near-infrared, visible and/or ultraviolet photons, etc. Furthermore, the photons may be of substantially the same wavelength. They may also be of different wavelengths.
Implementation Method 2
two galvanic reflective mirrors 204 and 206 each operable under the influence of a controller 250. The photon source 202 in the manufacturing equipment 200 is oriented to propagate a beam of photons L toward two galvanic reflective mirrors 204 and 206
Implementation Method 3
An adjustable objective lens or lenses 208, again under the influence of the controller 250 is used to focus the beam L to an exact polymerisation point P in a bath 100, for polymerisation of a photo-activatable composition that is provided therein.
Data Source
AI summary
A printed porous structure (500) fabricated using a multi-step absorption, MSA, process, said printed porous structure (500) comprising a support layer (520) that supports a filtration membrane (510), wherein said support layer (520) and said filtration membrane (510) are integrally formed.