Porous ceramics for additive manufacturing, filtration, and membrane applications

Patent metadata

Field	Value
Publication number	US-12303863-B2
Application number	US-202318124979-A
Country	US
Kind code	B2
Filing date	Mar 22, 2023
Priority date	Jun 23, 2017
Publication date	May 20, 2025
Grant date	May 20, 2025

Abstract

An ink for three dimensional printing a ceramic material includes metal oxide nanoparticles and a polymer resin, where a concentration of the metal oxide nanoparticles is at least about 50 wt % of a total mass of the ink. A method of forming a porous ceramic material includes obtaining an ink, where the ink comprises a mixture of metal oxide nanoparticles and a polymer, forming a body from the ink, curing the formed body, heating the formed body for removing the polymer and for forming a porous ceramic material from the metal oxide nanoparticles. The forming the body includes an additive manufacturing process with the ink.

First claim

What is claimed is:

1. An ink for three dimensional printing a ceramic material, the ink comprising:
metal oxide nanoparticles, a polymer resin, and a cross-linking agent, wherein a concentration of the metal oxide nanoparticles is at least about 50 wt % of a total mass of the ink.

2. The ink as recited in claim 1 , wherein the ink includes metal oxide nanoparticles in a range of about 50 wt % to about 80 wt % of the total mass of the ink.

3. The ink as recited in claim 1 , wherein a concentration of the metal oxide nanoparticles is about 60 wt % of the total mass of the ink.

4. The ink as recited in claim 1 , wherein a concentration of the metal oxide nanoparticles is about 70 wt % of the total mass of the ink.

5. The ink as recited in claim 1 , wherein the metal oxide nanoparticles comprise Y 2 O 3 -doped ZrO 2 .

6. The ink as recited in claim 5 , wherein the metal oxide nanoparticles comprising Y 2 O 3 -doped ZrO 2 have an average diameter in a range of at least about 20 nanometers to about 600 nanometers.

7. A method of forming a porous ceramic material using the ink as recited in claim 1 , the method comprising:
forming a body from the ink, wherein forming the body comprises an additive manufacturing process with the ink;
curing the formed body; and
heating the formed body for removing polymer and for forming a porous ceramic material from the metal oxide nanoparticles.

8. The method as recited in claim 7 , wherein the porous ceramic material has an open cell structure with a plurality of pores, wherein pores of the ceramic material form continuous channels through the ceramic material from one side of the ceramic material to an opposite side of the ceramic material.

9. The method as recited in claim 8 , wherein an average diameter of the pores is in a range of about 50 nanometers to about 500 nanometers.

10. The method of claim 7 , wherein the additive manufacturing process is direct ink writing, wherein the ink is extruded through a nozzle.

11. The method of claim 10 , wherein features of the formed body have an average diameter of at least a diameter of the nozzle.

12. The method of claim 7 , wherein the ink includes a photoinitiator and an inhibitor, wherein the additive manufacturing is projection micro-stereolithography.

13. The method as recited in claim 12 , wherein features of the formed body have an average length of at least about ten microns.

14. The method as recited in claim 7 , wherein the formed body is a free standing porous structure, wherein the formed body has an average diameter of greater than one centimeter.

Assignees

• L Livermore Nat Security Llc

Inventors

• Campbell Patrick
• Baker Sarah
• Ceron Hernandez Maira R
• Knipe Jennifer Marie
• Stolaroff Joshuah K

Classifications

• B01D67/00793

  Dispersing a component, e.g. as particles or powder, in another component · CPC title

• B01D69/14111

  with nanoscale dispersed material, e.g. nanoparticles · CPC title

• B01J20/3293

  Coatings on a core, the core being particle or fiber shaped, e.g. encapsulated particles, coated fibers · CPC title

• B01J20/3085

  Chemical treatments not covered by groups B01J20/3007 - B01J20/3078 · CPC title

• B01J20/3042

  Use of binding agents; addition of materials ameliorating the mechanical properties of the produced sorbent · CPC title