Porous ceramics for additive manufacturing, filtration, and membrane applications

Patent metadata

Field	Value
Publication number	US-2023219058-A1
Application number	US-202318124979-A
Country	US
Kind code	A1
Filing date	Mar 22, 2023
Priority date	Jun 23, 2017
Publication date	Jul 13, 2023
Grant date	—

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 and a polymer resin, 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 , comprising a cross-linking agent.

3 . 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.

4 . 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.

5 . 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.

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

7 . The ink as recited in claim 6 , 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.

8 . A method of forming a porous ceramic material, the method comprising:
obtaining an ink, wherein the ink comprises a mixture of metal oxide nanoparticles and a polymer; 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 the polymer and for forming a porous ceramic material from the metal oxide nanoparticles.

9 . The method as recited in claim 8 , 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.

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

11 . The method of claim 8 , wherein the additive manufacturing process is direct ink writing, wherein the ink is extruded through a nozzle.

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

13 . The method of claim 8 , wherein the ink includes a photoinitiator and an inhibitor, wherein the additive manufacturing is projection micro-stereolithography.

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

15 . The method as recited in claim 8 , wherein the formed body is a free standing porous structure, wherein the formed body has an average diameter of greater than one centimeter.

16 . A method for separating gases with a system of porous ceramic material and an aqueous sorbent, the method comprising:
infilling a porous ceramic material in a sorbent solution; placing the infilled porous ceramic material in a container, wherein the container contains a known pressure of a gas; measuring an absorbance of the gas in the porous ceramic material, wherein the ceramic material is infilled with the sorbent solution; and heating the porous ceramic material with CO 2 absorbed in the sorbent for releasing the CO 2 from the sorbent and regenerating the system of porous ceramic material and the sorbent.

17 . The method as recited in claim 16 , wherein the ceramic material is a plurality of crushed pieces porous ceramic structure, wherein each of the crushed pieces have an average diameter of about 400 microns or smaller.

18 . The method as recited in claim 16 , wherein the sorbent solution is an ionic liquid.

19 . The method as recited in claim 18 , wherein the sorbent solution is an aqueous sorbent solution.

20 . The method as recited in claim 19 , wherein the aqueous sorbent solution comprises sodium carbonate.

Assignees

• L Livermore Nat Security Llc

Inventors

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

Classifications

• B01D71/024

  Oxides · CPC title

• B01D69/14111

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

• B01D67/00793

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

• B01J20/06 Primary

  comprising oxides or hydroxides of metals not provided for in group B01J20/04 · CPC title

• B01J20/3204

  Inorganic carriers, supports or substrates · CPC title