Additively Manufactured Reactive Structure Using Solid Metal Oxide Particles
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Solution Overview
Problem
Current additive manufacturing processes for structures used in reactionary processes, such as catalytic and adsorption processes, are limited by the poor rheological behavior of metal oxide precursor materials, particularly dissolved nitrate salts, which restrict the loading of active agents and efficiency of these structures.
Innovation Solution
The development of a method involving the formation of an ink from metal or metal oxide particles, a dispersion solvent, and a binder, which is deposited and cured to create structures that can withstand higher active agent loadings, enabling more efficient catalytic and adsorption processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dissolved nitrate salts are used as metal oxide precursors in additive manufacturing, then the structures can be formed using additive manufacturing processes, but the rheological behavior deteriorates and nitrate loading is limited to below 10 weight percentage
Solution Approach 1:
The patent changes the physical state parameter of the metal oxide precursor from dissolved nitrate salt to solid metal or metal oxide particles. This parameter change fundamentally alters the rheological properties of the ink, enabling higher loadings of active agent (up to 80 wt% or more) while maintaining printability and avoiding the hydrophobic behavior and shear thickening issues associated with dissolved nitrate salts.
Solution Approach 2:
The patent creates a composite ink formulation consisting of solid metal or metal oxide particles suspended in a binder matrix with dispersion solvent. This composite approach allows the active agent particles to be distributed throughout the binder, achieving high loadings while the binder provides structural integrity and rheological control during the additive manufacturing process.
2Productivity
If higher active agent loadings are used in the structures, then catalytic and adsorption performance improves, but rheological behavior deteriorates making additive manufacturing difficult
Solution Approach 1:
The patent changes the form of the active agent from dissolved precursor to solid particles, which fundamentally improves rheological behavior at high loadings. Solid particles maintain suspension stability and prevent the hydrophobic effects and paste spreading issues that occur with dissolved nitrate salts at high concentrations, enabling both high productivity and ease of manufacture.
Solution Approach 2:
The binder acts as an intermediary material that facilitates the incorporation of high concentrations of metal or metal oxide particles into the additive manufacturing ink. The binder provides a compatible matrix that maintains proper rheology, enables deposition, and allows the high loading of active agent particles without compromising processability or catalytic performance.
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 allows for the creation of structures with higher active agent loadings and improved performance in catalytic and adsorption reactions, overcoming the limitations of traditional methods by providing enhanced catalytic conversion and adsorption capacities.
Implementation Method 1
forming an ink from metal or metal oxide particles, a dispersion solvent, and a binder
Implementation Method 2
depositing the ink onto a build platform and curing the ink to form a structure
Data Source
AI summary
A method of additively manufacturing a structure for use in a reactionary process includes forming a material from metal or metal oxide particles, a dispersion solvent, and a binder. The method also includes depositing the material onto a build platform and curing the material to form a structure for use in a reactionary process. The structure includes the metal or metal oxide particles and is configured to provide a reaction when exposed to a reactant.