Three dimensional nanometer filters and methods of use

• US 10,589,204 B2
• Filed: 01/08/2018
• Issued: 03/17/2020
• Est. Priority Date: 05/01/2014
• Status: Active Grant

• Current Assignee: Imagine TF, LLC
• Original Assignee: Imagine TF, LLC
• Inventors: Richardson, Brian Edward
• Primary Examiner(s): Clemente, Robert
• Application Number:
  US15/865,093
• Publication Number:
  US 20180126311A1
• Time in Patent Office: 799 Days
• Field of Search: 55523
• CPC Class Codes: B01D 2239/0258 comprising nanoparticles
• CPC Class Codes: B01D 2239/065 More than one layer present in the filtering material apparatus incorporating such gas filtering material B01D2275/10
• CPC Class Codes: B01D 29/0093 Making filtering elements not provided for elsewhere
• CPC Class Codes: B01D 39/20 of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires porous ceramic material C04B38/00 ; sintering metals C22C1/04; making porous sintered metal bodies B22F3/10, honeycomb filters B01D46/2418, materials used for filtering exhaust gases of an internal combustion engine F01N3/022, ceramic honeycomb structures C04B38/0006
• CPC Class Codes: B01D 39/2068 Other inorganic materials, e.g. ceramics
• CPC Class Codes: B01D 39/2075 sintered or bonded by inorganic agents
• CPC Class Codes: B01D 46/0001 Making filtering elements

Abstract

Three dimensional nanoparticle filters are provided herein. In one embodiment a filter device includes a base material, alternating layers of sacrificial material between layers of structural material being deposited onto the base material to create a layered base material, and filter sidewalls etched into the deposited alternating layers of the layered base material to remove the layers of sacrificial material between the layers of structural material to form filter slots in the filter sidewalls as well as create channels between the filter sidewalls, where a size of the filter slots is selectable based on a thickness of the layers of sacrificial material utilized.

Claims

1. A method for creating a filter panel, comprising:

providing a substrate panel; and

creating at least one filter sidewall on a surface of the substrate panel by;

alternatingly depositing layers of structural material and sacrificial material; and

etching away at least a portion of each of the layers of sacrificial material to create spacers that separate the layers of structural material, and to create filter slots.

2. The method according to claim 1, wherein at least a portion of the layers are created from a porous material.

3. The method according to claim 1, wherein the spacers are globular.

4. The method according to claim 1, wherein a rear surface of a second substrate panel is placed onto an upper surface of an uppermost layer of structural material.

5. The method according to claim 1, wherein the layers of structural material and sacrificial material are deposited on the substrate panel so that the at least one filter sidewall is continuous across the substrate panel.

6. The method according to claim 5, wherein the layers of structural material and sacrificial material are deposited on the substrate panel so that the at least one filter sidewall forms connected rectangles that extend from a top of the substrate panel to a bottom of the substrate panel.

7. The method according to claim 6, wherein the connected rectangles form inlets and outlets.

8. The method according to claim 1, further comprising depositing posts on the substrate panel from a non-sacrificial material prior to alternatingly depositing layers of structural material and sacrificial material.

9. The method according to claim 8, further comprising planarizing an upper surface of the posts of a layer of sacrificial material so as to be co-linear with a top surface of a subordinate layer of structural material.

10. The method according to claim 1, further comprising stacking a plurality of the filter panel together to form a filter device.

11. A filter panel, comprising:

a substrate panel; and

at least one filter sidewall on a surface of the substrate panel comprising;

alternatingly depositing layers of structural material and sacrificial material; and

filter slots created from etching away at least a portion of each of the layers of sacrificial material to create spacers that separate the layers of structural material, and to create filter slots.

12. The filter panel according to claim 11, further comprising a layer of covering layer applied to one or more of the layers of the structural material to enhance filtering.

13. The filter panel according to claim 12, wherein the covering layer is selected from any of silicone dioxide, titanium dioxide, copper, carbon, and any combinations thereof.

14. The filter panel according to claim 11, wherein the at least one filter sidewall extends across the substrate panel to form alternating inlets and outlets, wherein a fluid filtered by the filter panel enters through the inlets and exits through the outlets.

15. The filter panel according to claim 14, wherein the inlets are located at a top of the filter panel and the exits are located a bottom of the filter panel.

16. The filter panel according to claim 11, wherein the at least one filter sidewall extends across the substrate panel to form alternating v-shapes.

17. The filter panel according to claim 11, wherein the at least one filter sidewall extends across the substrate panel to form alternating rectangular shapes.

18. The filter panel according to claim 17, wherein the substrate panel is constructed from a material selected from any of PET, polycarbonate, or a metal.

19. The filter panel according to claim 11, wherein a cross sectional area of each of the filter slots is defined by spaces between adjacent spacers and a distance between adjacent layers of structural material.

20. The filter panel according to claim 19, wherein the cross sectional area is selected based upon a desired particular filtering size.