US 12,251,758 B2
Additively-manufactured structure for reactionary processes
Fateme Rezaei, Rolla, MO (US); Ali Rownaghi, Rolla, MO (US); and Shane Lawson, Rolla, MO (US)
Assigned to The Curators of the University of Missouri, Columbia, MO (US)
Filed by The Curators of the University of Missouri, Columbia, MO (US)
Filed on Jan. 31, 2022, as Appl. No. 17/589,440.
Claims priority of provisional application 63/144,193, filed on Feb. 1, 2021.
Prior Publication US 2022/0241863 A1, Aug. 4, 2022
Int. Cl. B22F 10/64 (2021.01); B22F 1/107 (2022.01); B22F 1/145 (2022.01); B22F 10/22 (2021.01); B22F 10/62 (2021.01); B33Y 10/00 (2015.01); B33Y 40/10 (2020.01); B33Y 40/20 (2020.01); B33Y 70/00 (2020.01)
CPC B22F 10/62 (2021.01) [B22F 1/107 (2022.01); B22F 1/147 (2022.01); B22F 10/22 (2021.01); B22F 10/64 (2021.01); B33Y 10/00 (2014.12); B33Y 40/10 (2020.01); B33Y 40/20 (2020.01); B33Y 70/00 (2014.12)] 14 Claims
OG exemplary drawing
 
1. A method of additively manufacturing a structure for use in a catalytic process, the method comprising:
forming a first ink and a second ink,
wherein the first ink includes a first material including a first binder and a first active agent, and
wherein the second ink includes a second material including a second binder and a second active agent,
wherein each of the first active agent and the second active agent include metal nanoparticles;
depositing the first ink and the second ink onto a build platform; and
curing the ink to form a structure for use in the catalytic process, wherein the structure is a lattice structure comprising a plurality of layers,
wherein the plurality of layers alternate between the first material formed by the first ink and the second material formed by the second ink between each of the plurality of layers,
wherein each of the plurality of layers comprise a plurality of ribs arranged in a grid pattern to form a plurality of channels extending through the layer,
wherein the grid pattern of each of the plurality of layers is offset by 90° from the grid pattern of the adjacent layer of the plurality of layers such that the plurality of ribs of each of the plurality of layers are perpendicular to the plurality of ribs of the adjacent layer,
wherein the plurality of ribs partially occlude the channels from the adjacent layer of the plurality of layers to form a tortuous flow path,
wherein the structure includes the first material and the second material including the metal nanoparticles, wherein the metal nanoparticles are insoluble and are suspended within the structure, wherein the metal nanoparticles are configured to provide a reaction when exposed to a reactant in the catalytic process.