Enhanced microchannel or mesochannel devices and methods of additively manufacturing the same
AssigneeBattelle Memorial Institute
InventorsWard E. TeGrotenhuis, Paul H. Humble, Christopher K. Clayton, Timothy G. Veldman, Robert S. Wegeng, Richard F. Zheng
Life of this patent
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Abstract
Chemical processors are configured to reduce mass, work in conjunction with solar concentrators, and/or house porous inserts in microchannel or mesochannel devices made by additive manufacturing. Methods of making chemical processors containing porous inserts by additive manufacturing are also disclosed.
Claims14
A method of fabricating a microchannel or mesochannel device comprising the steps of forming layer-by-layer a first portion of a channel via an additive manufacturing process;
- embedding a porous catalyst structure with a solid material in the pores that can be removed by heating or reacting into the first portion of the channel;
- and forming layer-by-layer a second portion of the channel over the first portion by additive manufacturing wherein the solid material protects the catalyst structure from substantial intrusion of an additive manufacturing powder;
- and removing the solid material by heating or reacting to convert the solid material to a fluid.
A method of fabricating a microchannel or mesochannel device comprising the steps of forming layer-by-layer a first portion of a channel via an additive manufacturing process;
- embedding a porous insert into the first portion of the channel;
- covering the porous insert with a protective layer;
- and forming layer-by-layer a second portion of the channel over the first portion;
- wherein the protective layer comprises a sacrificial material that is removed after the step of forming layer-by-layer a second portion of the channel over the first portion.
A method of fabricating a microchannel or mesochannel device comprising the steps of forming layer-by-layer a first portion of a channel via an additive manufacturing process;
- embedding a porous insert into the first portion of the channel;
- covering the porous insert with a protective layer;
- and forming layer-by-layer a second portion of the channel over the first portion;
- wherein the porous insert is made by joining a protective layer onto a porous metallic support and then coating the porous metallic support with a metal oxide and nickel or a noble metal to form a methane reforming catalyst followed by calcining prior to disposing the insert into the channel.
Dependencies are inferred from the claim text.