EP4196248A1

EP4196248A1 - Monolithic membrane filter

Info

Publication number: EP4196248A1
Application number: EP21765855.8A
Authority: EP
Inventors: Ulrich Meyer-Blumenroth; Gisela Jung
Original assignee: Innospire Technologies GmbH
Current assignee: Innospire Technologies GmbH
Priority date: 2020-08-17
Filing date: 2021-08-16
Publication date: 2023-06-21
Also published as: WO2022038093A1; US20230321607A1

Abstract

Disclosed is an additive manufacturing process for manufacturing a part having an at least partially or at least regionally porous material structure, in particular in the form of a filter element or filter device, the process comprising the steps of providing a starting material that is or can be rendered porous, applying said material that is or can be rendered porous, to form the part, and during the application step, adjusting the porosity of the starting material that is or can be rendered porous.

Description

Monolithic membrane filter

description

field of invention

The present invention relates to a method for producing monolithic components and monolithic components, in particular as membrane filters.

Background and general description of the invention

Membrane filters for filtering or separating substances from mostly liquid mixtures are known as such. Such a mixture can be a disperse medium or, for example, a solution in which further components are dissolved in a base substance.

Membrane filters are used in various areas of application, e.g. E.g. in the treatment of water and food, in the manufacture of pharmaceutical products, in biotechnological or chemical processes. An example of such an application can be the separation of alcohol from beer to produce non-alcoholic beer. A particularly gentle process enables preferential alcohol removal with minimal impairment of taste. Another application can be the separation of cells and cell fragments from active ingredient solutions in the biotechnological production of pharmaceuticals. There is still an intensive search for further developments here, for example to increase the throughput of medium to be filtered or to further reduce costs. In contrast to medical apparatus, much larger membrane surfaces are required for technical systems.

Since each different area of application has different requirements, especially in terms of the material, design or size of the filter, and process requirements such as temperature, pressure, volume and aggressiveness of the media in contact, or special hygiene requirements have to be taken into account, the membrane filter market is currently still in its infancy Development. A universal approach that is able to cover at least a number of different areas of application has not yet been achieved.

In addition, it is not uncommon for filtration systems to fail due to the only limited mechanical and/or chemical stability of known modules. For example, hold modules made of polymeric materials such as. e.g. E.g. PP typically does not withstand higher loads such as temperatures of over 60 °C or higher transmembrane pressures (over 3 bar) or at least not over long periods of time without damage. However, this is desirable for numerous areas of application.

Steam sterilization, e.g. carried out at 121 °C, which is required above all in hygienically demanding areas, can only be repeated in a small number of cycles - if at all. Cleaning at elevated temperatures, high and/or low pH values or with oxidizing cleaning agents also limits the service life of the modules. Ceramic filters, on the other hand, react sensitively to temperature shocks or mechanical influences.

Due to the partly automated manufacturing processes, membrane filters are nowadays manufactured as standardized products with a given geometry, whereby adaptations to special requirements from the process control, such as for high viscosities and/or low pressure losses during flow or for difficult installation environments, are practically impossible or not planned. since the resulting lower quantities would drive unit costs into regions that cannot be sold.

It is the knowledge base of the present invention that the described limitations of currently available filters and those described in the literature result very significantly from their structure, because they are assembled from ready-made components.

In the context of the present invention, looking back at these known filters, it was recognized that there is a problem when filter modules typically consist of different, in particular different, components that are produced using different methods and are then reversibly or irreversibly connected to one another. The separate components include membranes as flatware or tubes, components for fluid supply and removal (e.g. pressure pipes, connectors, permeate pipes, aeration pipes, ...) and components for fluid distribution and mixing (e.g. spacers, ATD's,...). So far, filter modules have been used which are provided in particular with sealing rings or other sealing means and are installed in a separate housing with separate connections. The sealing to avoid cross-flows between the envelope side and the lumen side is expensive and limits the possible areas of use for membrane filters to a decisive extent. An example of known welded tubular membranes is described in European published application EP 88 108 462 A. It is typical that various joining methods, such as in particular welding or the filling in of potting compound, are necessary in order to achieve a seal and/or targeted liquid routing in the filter module. With such a "modular structure" it is basically interesting that different materials can be used precisely and therefore possibly more cost-effectively and can therefore be selected in a targeted manner according to the requirements.

However, it was recognized within the scope of the present invention that it can be disadvantageous that the different components behave differently from one another, for example under stress, such as temperature changes, pressure changes or swelling of the material, and thus impair the performance of the filter or fail .

Typically, the membranes are bonded or welded to the other components to form a filter element. Also mechanical seals that are clamped between membranes and housing, z. B. common with ceramic membranes. Connectors (filter element to piping system) are often detachably connected to the filter unit, e.g. E.g. supply and discharge caps via clamps, flanges or threads. Seals prevent a "short circuit" between feed and filtrate.

For capillary modules z. For example, there are always capillary breaks in the embedding, detachment of adhesive (potting) from the housing wall or even encapsulation. In the case of flat membranes glued over the entire surface, e.g. For example, in submerged modules, delamination between the laminate layers is observed. In the case of ceramic tubular membranes or multi-channel elements, the elastomer seal used often represents the limiting weak point of the entire filter unit. Both the ceramic of the constructed membrane and the typically used stainless steel of the housing can show a significantly higher temperature and/or chemical resistance than the material used sealing material.

Another disadvantage of known multi-part filter modules is that the joining processes used have repeatedly proven to be error-prone. It is typical that various joining methods, such as in particular welding or the filling in of casting compound, are necessary in order to achieve a seal and/or liquid flow in a filter module. For example, when welding tubular membranes (European published application EP 88 108 462 A), no foreign materials or different substances are used, but the surfaces that come into contact before welding are often inadequately prepared for the welding, so that no tight and reliable connection is to be made. The surfaces of the welding tools used must also be absolutely clean for each welding process. Adhering polymer melt from a previous welding operation, for example, can adversely affect the result of the weld. Even with fully automatic welding of an entire tube module, leaky welds, which are detected during quality control during integrity tests, are the most common cause of errors and then require rework or lead to rejects. Particularly critical are those welds that do not show up as a leak in the integrity test, but are still not completely welded. Such connections have an increased risk of failure and lead to leaks after a short period of operation, resulting in failure or customer complaints.

Capillary membranes are usually glued into the housing. During the curing of the casting compound, the material can shrink as a result of the crosslinking reaction. The transition from the casting block to the housing of such a filter is therefore typically under tension, which in practical use under changing temperatures and/or pressures can lead to at least partial detachment of the casting compound from the housing wall. A reliable separation between the flow on the lumen side and the flow on the envelope side is therefore no longer guaranteed.

Other disadvantages of known filters arise from the limited design options. When casting capillary or tubular membranes, the transitions in or between the components, such as between the membrane and an end plate connected to it, cannot be freely selected. Rather, they are determined by the flow and wetting behavior of the potting compound used. Advantageous configurations that would improve the mechanical stability and/or could improve the flow guidance of the fluid cannot be produced in a targeted manner. This leads to mechanical fractures at this transition point and unfavorable flows, which lead to pressure peaks and wear. Typically, the membranes with the casting compound are also cut off flush with the end of the housing on the inflow side. The cut edges of the membranes are sharp and depending on the membrane and the application, these must be Cut edges are sealed. This significantly affects the flow of the incoming fluid.

In ceramic membrane filters, the currently common design leads to a lack of robustness against mechanical influences, such as shocks when falling or improper handling. The membranes are usually only anchored at their ends in the housing and/or in a casting compound. The brittleness of the material therefore regularly leads to membrane ruptures between the end plates, which can occur as a result of the action of mechanical loads, such as shock loads or shear loads. A very similar situation also arises with rapid temperature changes. For example, if a hot fluid suddenly flows through the membranes, they expand. The housing, which is still cold, may not allow this expansion under certain circumstances and considerable stresses build up in the membranes, which also regularly lead to membrane rupture.

Against the general background of the invention described above and the recognition process also described there in the context of the disclosure of the present application and the disadvantages found there, the present invention has therefore set itself the task of solving the aforementioned problems or at least introducing improvements thereto. Specifically, the invention has set itself the task of providing filter modules or membrane filters or components that are considerably more robust with regard to their handling, alternatively or cumulatively also with regard to the applicable process and operating parameters. The invention solves the problem that the described aging processes of known filters are avoided or improved and that the number of failures of entire filter modules is reduced both in production and in operation.

The present invention thus also fulfills the further partial aspect of increasing the service life of filter modules or components in tough technical use and thus improving economic efficiency.

The present invention also fulfills the partial aspect of providing filter modules or components that achieve further improved mixing of the fluids used and/or further increase the filtrate throughput. In this way, on the one hand, the yield can be increased and/or the throughput quantity can be increased. In addition to the aforementioned and numerous other aspects that the present invention solves, the present invention also provides a filter that can be adapted with simple means and that can be optimized in the manufacturing process for the specific later application with regard to, for example, the parameters of filtration capacity, delivery capacity, with regard to the volume or mass flow of fluid and/or the mechanical resilience or resistance to mechanical influences.

Alternatively or cumulatively, the invention has also set itself the task of simplifying the manufacturing process of filter modules and/or making it available more cost-effectively, or even individually adaptable to the specific requirement.

The object is solved by the subject matter of the independent claims. Advantageous developments of the invention are the subject matter of the dependent claims.

In addition to numerous other aspects, the improvements and new designs proposed in this description concentrate on providing a component which is suitable for separating components from a fluid. Such a separation is, for example, the filtration of a fluid, i.e. the extraction of substances from a solution, for example, or the stripping or separation of suspended matter from a disperse medium such as a suspension. However, the invention is not limited to this.

In an underlying idea and in a further aspect of the invention, the present invention concentrates on providing monolithic components for the production of filter modules. Such monolithic components, such as membrane filters in particular, can be formed additively in the light of the present invention and/or have an intrinsic porosity. For example, in the case of a monolithic component, all components can be provided from a uniform starting material.

Also, monolithic components are typically manufactured in one piece and without interruption. Due to the lack of joined component-to-component transitions, they can be characterized by extreme robustness in the application and can also be optimized in terms of flow technology as well as their size and thus the filtration capacity for their intended use. There are various already known methods of additive manufacturing, which offer great freedom of design. Typically, the elements to be manufactured are built up in layers. However, the additive manufacturing processes known to date are particularly suitable for use in the construction of membrane modules insufficient in various respects and are only ready for use with the present invention.

Additive manufacturing also allows, for example, the production of geometries that are not possible with previously known processes for membrane or membrane module production. In particular, three-dimensional geometries should be emphasized that are prepared in such a way that a damping or force-absorbing shape can be kept ready. For example, in the longitudinal extension of the membrane modules there is often an application of force, whereby even if the membrane modules are inserted into the respective holder or device without tension, a change in length can occur during operation due to a change in temperature or chemical action and the membrane module or modules are subjected to tension. The membrane module or modules are therefore preferably designed to be stress-tolerant, in particular longitudinal stress-tolerant. The stress-tolerant construction of the membrane modules can be achieved by a three-dimensional geometry of the membrane tubes of the membrane module, i.e. a stress-tolerant shape of the membrane tubes. These geometries of the membrane tubes, of which a few particularly preferred embodiments are described below in this application, which could not be produced in this way or at least not economically in earlier production methods, have proven to be advantageous in test cycles within the scope of the present disclosure.

For example, the membrane module(s) can be provided in a stress-tolerant manner in that an inherent spring action of the membrane module(s) is present or can be utilized, so that compression of the individual membrane tubes causes the membrane tubes to yield. The deflection of the membrane tube can be caused by twisting, arching or the like. In the same way, the stress-tolerant design of the membrane tubes or membrane modules can also include a transverse stress-tolerant provision. Membrane modules are also occasionally exposed to transverse stresses, for example if they are not inserted precisely into the respective holder and the membrane module compensates for the imprecise installation by twisting. This twisting can be transferred to the membrane tubes inside the membrane module.

The use of porous material systems for additive manufacturing described in the present invention also allows, for example, the reproducible production of porous components with an average pore size of down to less than 1 m, which has hitherto not been solved represents a challenge. Previous attempts in this regard required an immense amount of time for a single filter due to the required high resolution, which is unacceptably long for series production. From a technological point of view, the relationship between the achievable component size and the resolution of the component structure was an obstacle to the effect that such filters could not be produced in technically relevant sizes. Precisely this problem is solved particularly elegantly by the approach shown in the present description.

The geometric resolution that can be provided by an application device, such as a 3D printer, particularly preferably no longer represents an obstacle with regard to the achievable pore size. In a particularly advantageous embodiment, the geometric resolution of the application device is then only for the general shape of the component or the membrane filter relevant, but not for the specific pore size of the membrane filter.

The method according to the invention for producing a component with an at least partially or at least regionally porous material structure, in particular as a filter element or filter device, comprises a number of steps. In the step of providing a porous or porous starting material, the starting material for the application is provided. In one example, the starting material is provided using an extruder. The starting material is already porous or it is provided in a porous form. This means that the starting material is initially not porous when it is provided, but is influenced, changed or composed differently in connection with the application of the starting material in such a way that the starting material can be interspersed with pores in the temporal connection with the application of the starting material.

In other words, the provision of the porous or porous starting material means the transfer of a primary material to the component being produced. Thus, the provision can also include conveying the porous or porous starting material to the site where the material is applied. The provision can also include the thermal adaptation to desired application conditions, as well as the setting of an advantageous physical pressure at the moment of application of the starting material for the production of the component. In the example of the extruder, providing comprises conveying and pressing in the extruder screw, with the porous or porous starting material finally being provided at the outlet of the extruder. The method according to the invention also includes the application of the porous or porous starting material for the construction of the component. During application, the method also includes adjusting the porosity of the porous or porous starting material. In other words, in connection with the material application of the starting material to or on the component, the porosity is adjusted at the location of the material application. For example, this setting takes place immediately before, during or immediately after the specific application of material. Here, for example, machine parameters of an application machine can be changed, such as an extruder, or a mixing ratio of the starting material can be changed, or process parameters can be set during the solidification of the starting material in order to set the porosity at the point where the material is applied. The decisive factor here is that the material permeability is set intrinsically in the material in order to provide a corresponding filter performance. This means that a similar or better filter performance can be achieved than with conventional filter modules, and at the same time the production can be significantly more flexible and/or cheaper or materials can be used that were previously difficult to use for the production of filter modules because they could not be processed or were difficult to process Without the new manufacturing process, it would not have been possible to recognize that the corresponding filter performance could be achieved with it.

For example, a little or no porous material can be provided in this way in order to build up parts of the housing of the component therefrom. A porous material structure can be created elsewhere on the component using the same starting material but different physical parameters or different composition or different additives. The various component areas, such as the housing and porous material structure in the aforementioned example, are constructed monolithically, ie in one piece with one another. It is therefore characteristic that there are no conventional component-to-component transitions, but rather areas of the component with different porosity can be built up, with all areas being produced together in one piece and typically bonded to one another, i.e. fused, baked, sintered or glued, for example are. The process is continued until the component is manufactured as a whole. In particular, the method is continued without interruption or without a break, so that the additive manufacturing method is carried out in one piece. For example, an advantageous application temperature can be kept constant or maintained in a material application zone, so that there is a continuous application of material for the production of the ok

component comes. Thanks to the monolithic structure of the components of the component that were previously provided as separate parts, it is advantageously possible to dispense with bonding, casting and/or sealing between the components that were previously provided as separate parts. It is precisely these bonds, casting compounds and/or sealing elements that have severely limited the service life or the range of use (temperature ranges, pressure ranges, chemical resistances, etc.) for the component.

In an advantageous embodiment, the additive manufacturing method for producing a component can comprise the application of the porous or porous starting material pointwise, linearly or in layers of the porous or porous starting material. In other words, the starting material is preferably applied point by point, i.e. in particular point by point in a point target matrix, with the material being applied successively. The material application can nevertheless be continuous or quasi-continuous, e.g. "caterpillar-shaped", and a point-target matrix can still be approached point by point, which can be described as a quasi-continuous material application.

In this case, it is not necessary and typically also not provided for material to be applied at every point of the point-target matrix. Thus, in the point-target matrix, points are provided which are not approached and those points which are approached and starting material is applied there. The material is typically applied from the bottom up, following gravity, with a bottom layer first being deposited on a component carrier, with the bottom layer being able to be applied pointwise, linearly or in layers. Even the bottom layer is not necessarily a continuous layer, but rather it can include areas with and without material application.

The application of material can also advantageously take place in a layer target matrix. In this way, a number of points to be approached can be combined in such a layer. Layers of the layer target matrix are arranged one above the other, for example, at a further, for example, equidistant distance from one another. The application of material can also be prepared in layers and an entire layer can be connected or crosslinked as a unit, for example if the starting material is in powder form, layer by layer can first be deposited and one layer as Whole are prepared, so for example heated with a radiation source and integrally connected to each other.

Layers as well as points can also be provided in other coordinate systems, such as cylindrical coordinates, for example if a tubular structure is to be produced as a component. In this description, the point-target matrix is understood as the best possible resolution or subdivision of the component to be produced in spatial coordinates, since this describes the smallest possible subdivision of the component to be produced. The point distance from one point to the next neighboring point does not have to be identical; Rather, it can be advantageous to vary the point spacing, to vary it within one direction depending on the application and/or to express it differently in different directions of the coordinate system. For example, an area of particularly complex geometry can be provided with a narrower grid of points, whereas simple structures can be described with fewer points. This is easy to understand, for example, in the case of pasty starting material, when the starting material is applied in a "bead-like" manner and a long straight layer is applied, where only the start and end point of the straight layer would have to be defined. However, equidistant point-target matrices can also be advantageous. The layer target matrix, in turn, typically includes target points in each application layer, into which the component to be produced and, if appropriate, intermediate spaces or cavities of the component to be produced are subdivided.

Point-by-point application can include moving to a point of the point-target matrix to be approached, to which point the porous or porous starting material is to be applied. From a technical point of view, various configurations can be implemented here for approaching a point to be approached. In principle, approaching a point to be approached means that the starting material is provided in such a form and manner that it is available at the corresponding point in the point-target matrix. The approach can thus take place by means of an application tool. Such an application tool can be the extruder already mentioned, in which case the application tool can be moved in a three-dimensional manner to the point of the point-target matrix to be applied, or a component carrier is designed to be adjustable in such a way that a movable system of the point-target matrix is created, whereby the point-target matrix is shifted in front of the application tool and the point of the point-target matrix to be applied comes to rest on the application tool. An application tool is preferably used when the starting material is in a liquid, pasty or solid form. If the starting material is in powder form, the point of the point target matrix to be approached can also include directing a heat generator, such as in particular a laser or a radiation source, at the point of the point target matrix to be approached be understood in order to bring the powdery starting material deposited there at least into a kind of pre-melt at the point of the point-target matrix, so that it connects to the surrounding component or the surrounding starting material, possibly as a preparation for a later sintering of the component as a whole. For example, the starting material in powder form can be an inorganic, ie for example ceramic and/or metallic, filled polymer powder.

In general, targeting a target point of the point-target matrix means changing, preparing, or positioning the target point of the point-target matrix so that the starting material at the target point can be integrally bonded to the monolithic component.

When applying at the point to be approached, the porous or porous starting material is preferably set, specifically at the point of the point-target matrix to be approached. The setting of the porous and/or porous starting material can also take different forms. Adjusting the porous or porous starting material means, for example, adjusting a mixing ratio in the starting material if, for example, a filler is provided in a variable mixing ratio, the mixing ratio of the filler defining the porosity of the starting material. Setting the starting material at the point to be approached in the point-target matrix can also implement the setting of the radiation source or the source for thermal treatment of the starting material at the point to be approached. For example, the intensity of a laser to be used can be adjusted in such a way that a higher intensity produces a different porosity than a lower intensity.

What the examples mentioned have in common is that the porosity of the starting material at the point to be specified in the point-target matrix is influenced, changed, composed or generally adjusted. The porous or porous starting material adjusted in this way is preferably applied at the point. The additive manufacturing method for producing a component can also include the step of approaching at least one first point of the point-target matrix and setting the porous or porous starting material at the at least one first point in such a way that a porous material structure is formed at the at least one first point . In other words, the starting material is adjusted at the at least one first point, for example at a plurality of points that form a common area in the component, such that a porosity in the component can be adjusted in an additive manner. Thus, a porous material structure is built up successively by approaching the point or points of the point-target matrix.

The method can also include the step of approaching at least one second point of the point-target matrix and adjusting the porous or porous starting material at the at least one second point in such a way that an impermeable material structure is formed at the second point. In other words, the starting material is adjusted at this second point or at these second points, which form a region in the component, for example, such that the resulting structure has an impermeable structure. A structure is impermeable, for example, which has comparatively few pores or no pores at all, or which is constructed with closed pores, so that no fluid exchange and/or mass exchange between fluids is ensured. An impermeable structure within the meaning of the invention therefore preferably prevents a fluid from flowing through the impermeable material structure, but on the other hand also prevents in particular the exchange of substances from a first fluid on a first side of the impermeable material structure to a second fluid on a second side of the impermeable material structure. An exemplary structure that can be advantageously constructed with an impermeable material structure is a casing around the component for protection of the same, as well as for the purpose of keeping an enveloping fluid in the component in particular and at the same time providing an enveloping side for the enveloping fluid.

The points of the point target matrix can be arranged in storage layers. In this case, the point-target matrix can be approached in layers, so that first the points of a first storage layer are approached, it not having to be possible to approach all points of the first storage layer. Subsequently, ie after moving to the first deposit layer, points of a second deposit layer are then approached, it again not being necessary for all points of the second deposit layer to be approached will; Rather, it is intended to provide cavities in a continuous form in the component.

The application step can include the application of the porous or porous starting material in such a way that at least one storage layer has areas with an impermeable material structure. The application can also be designed in such a way that at least one storage layer has areas with a porous material structure.

The application can also be designed in such a way that at least one storage layer has both an impermeable material structure and a porous material structure, which is applied with the same porous or porous starting material. In other words, both an impermeable material structure and a porous material structure can be built up in a storage layer using the present method. The basic idea of the present invention remains that all areas are monolithic, d. H. are integrally connected. Within the scope of this invention, it was possible to realize that areas with an impermeable material structure are constructed in one piece together with areas with a porous material structure. This can be achieved by adjusting the starting material at the point to be approached.

The application of the porous or porous starting material can be carried out in such a way that the partly or regionally porous material structure of the component is arranged or built up chaotically. In other words, the porous material structure has a chaotic arrangement or a chaotic structure. In this context, chaotic means that the specific microporous structure that is achieved with the application of the porous or porous starting material is not so exactly reproducible in its specific microporous design, that a component meets a second component at a specific point of the point target Matrix equals. Rather, the idea of the present invention is, at least in one aspect, that the specific pore structure is not defined exactly in the micrometer range, but is only adjusted with regard to the effect. In principle, an achievable pore size can be set when the material is applied, but not the exact arrangement and structure of the pores achieved. In terms of technical effect, this is neither a difference nor a disadvantage. On the contrary, the aspect has the advantage that an exact modeling of each individual pore can be dispensed with and only a desired porosity is adjusted. The specific arrangement of the pores in relation to one another is not important here. The porosity created and provided in this way can therefore be used as intrinsic porosity can be described. In the present case, the inventors have recognized that it is sufficient and particularly advantageous to provide such an intrinsic porosity, since this allows components to be produced considerably more quickly and at the same time more cost-effectively than with known methods.

The idea of adjusting the porosity of the starting material - in contrast to modeling each individual pore - can also be used with wet-precipitated flat membranes or capillary membranes made of polymers (NIPS). This can also be used in such a method, for example for polymer membranes that are produced by means of thermally induced phase inversion or phase separation (TiPS).

The partially or regionally porous material structure of the component can result from the application of the starting material in or on the component and can have a non-repetitive structure, i.e. a “chaotic” or “non-deterministic” structure or arrangement. As described above, the structure or construction of the porous material structure cannot be repeated in such a way that an exactly identical pore arrangement could be achieved by repeating the component production. Rather, a second component will have a comparable porosity with regard to a comparison to the first component at a specific point of the point target matrix, the porosity being set or adjustable in the method according to the invention, but not the exact pore distribution and arrangement in the component. The starting material can therefore preferably be made or prepared to be intrinsically porous. In other words, it is particularly advantageous not to precisely adjust the position of each pore with the method according to the invention or with the application machine according to the invention, but rather the porosity in a material structure.

The porous material structure preferably has an open porosity. The impermeable material structure, on the other hand, can have closed porosity or no porosity at all, in any case no open porosity.

The porous material structure can be characterized in that it is at least partially permeable to the fluid or at least to components of the fluid. The porous material structure can be characterized in that there is less resistance to the flow or penetration of a fluid through the porous material structure than in the impermeable material structure. It can prove to be advantageous if the pores are at least partially connected to one another, so that a fluid can flow from one pore to the next and a flow can take place overall through the porous Material structure can form. The open porosity therefore preferably means that a pore is typically in fluid communication with at least two other pores when a fluid flows through the porous material structure. The liquid can be made to flow by conveying the liquid through the component with the application of a pressure gradient, for example generated by gravity and without an external pump device, or also by the action of a pump device.

The porous material structure can have an open microporous or mesoporous structure. The average pore size can be less than 40 μm, preferably less than 5 μm and more preferably even less than 1 μm. Such mean pore sizes have not been achieved with comparable processes to date.

The porous material structure preferably has an average volume porosity of 20% or greater, preferably 35% or greater. Depending on the manufacturing process, the average volume porosity can even reach 50% or more.

The impermeable material structure can have a higher density than the porous material structure. The ratio of the density of the impermeable material structure to that of the porous material structure is in particular 1.2: 1, preferably 1.5: 1 and even more preferably 2: 1. In other words, the material structure is denser in impermeable areas than in Areas of porous material structure. The ratio of the density of the impermeable material structure to the porous material structure can also be specified in intervals, for example in an interval between 1.2:1 to 1.5:1 and preferably in the interval from 1.5:1 to 2:1 .

The step of adjusting the porosity of the porous or porous starting material can include, for example, adding additives or fillers to the starting material to adjust the porosity at the moment the material is applied. In particular, this is carried out at the point of the point-target matrix to be approached in each case. The adjustment can also include the adjustment of hardening parameters for the respective point of the point-target matrix to be approached.

The adjusting step can also include the selection of a starting material to be used from a plurality of at least two starting materials, wherein the at least two starting materials can be supplied alternately or simultaneously. In particular, this can be configured so that the at least two Starting materials are provided at the point of the point-target matrix to be approached in each case for the production of the monolithic component.

The adjusting step can also include providing a location-dependent radiation intensity with a radiation source that is directed at the material application, i. H. i.e. in particular to the point of the point target matrix to be approached. Alternatively, the adjustment step can include the location-dependent adjustment of the light absorption capacity of the porous or porous starting material, so that the component construction can be carried out in particular by means of a location-independent radiation source.

Polymeric or inorganic nanoparticles can be used as an additive. Particles with an average diameter of typically 100 nm or less are referred to as nanoparticles. For example, the nanoparticles can have an average diameter of 900 nm or less, 500 nm or less, 100 nm or less or 50 nm or less. An inorganic or organic filler can be used as the filler.

The pores of the porous or porous starting material can during material application, i. H. ie in particular at the specific point in time and the specific location of the point of the point target matrix to be approached, are designed or prepared in such a way that they form a coherent porous material structure in the component.

The pores can also be provided to have a rounded or potato-shaped single structure.

The porous material structure of the component can be constructed and/or arranged in such a way that it is suitable for separating an envelope side from a carrier side in a permeable manner. In other words, the component is prepared in such a way that the porous material structure forms an envelope side on its first side and a carrier side on its second side. Specifically, in one example, the porous material structure can be referred to as a membrane, with the membrane having two flat sides and the first flat side being swept by an enveloping fluid, with the second flat side being swept by a carrier fluid.

A monolithic component is also described within the scope of the invention, in particular as a device for separating components from a fluid, further in particular produced by the method as described above. The monolithic component comprises a first and a second end face opposite the first end face. A porous structure is arranged between the first and the second end face, which with the End faces is constructed in one piece and connected. In any case, the porous structure is designed to be permeable in some areas or at least in part.

The porous structure is also prepared and arranged in such a way that an envelope side can be separated from a carrier side at least partially and/or at least in regions in a permeable manner. A carrier fluid can be provided on the carrier side.

The porous structure is designed to ensure mass transfer of the carrier fluid with the shell side. A mass transfer means in particular a transfer from the carrier fluid into an enveloping fluid and/or from an enveloping fluid into the carrier fluid.

The monolithic component can be designed as a membrane element for a filter device or as a filter device as a whole. The filter device is then constructed monolithically with the porous structure as a membrane element.

The monolithic component can further comprise a housing monolithically formed with the porous structure and the first and second faces. The porous structure is preferably surrounded by the housing together with the first and second end faces.

An enveloping fluid can preferably be provided on the enveloping side of the monolithic component, so that both the carrier fluid and the enveloping fluid can flow in or through the monolithic component. The carrier fluid is then separated from the sheath fluid by means of the porous structure. The monolithic component can also be provided in such a way that the porous structure is designed to be semipermeable or selectively permeable.

With regard to the porous structure, the monolithic component can be prepared in such a way that it is set up for substances and/or particles with a size smaller than 10 μm, preferably smaller than 2 μm and more preferably smaller than 0.5 μm, for which the porous structure permeable, semi-permeable or selectively permeable.

The monolithic component can be prepared for receiving and discharging the carrier fluid on the carrier side and a sheath fluid on the sheath side. The carrier fluid as well as the sheath fluid can then flow through the monolithic component to provide a carrier flow and a sheath flow in the monolithic component.

The porous structure of the monolithic component can include filter capillaries, in particular membrane capillaries.

The first end face of the monolithic component can be designed in the form of a plate. The porous structure is formed in one piece on the first end face, ie in particular formed integrally together with the first end face. The porous structure is then monolithic, ie formed integrally with the first end face. Particularly preferably, the first end face and the porous structure consist of the same material.

The second end face can also be designed in the form of a plate. As described for the first end face, the porous structure can be formed in one piece on the second end face, in particular formed integrally with the second end face.

The porous structure may comprise a plurality of elongate membrane tubes or filter capillaries. The membrane tubes or filter capillaries connect the first end face of the monolithic component to the second end face in one piece and preferably integrally.

The membrane tubes or filter capillaries preferably have an inside. The inside of the membrane tubes or filter capillaries form the carrier side. The carrier fluid can therefore flow along the inside. Membrane tubes or filter capillaries are particularly preferably tubular, so that the carrier side is formed in the tubular structure and the carrier fluid flows there.

The membrane tubes or filter capillaries preferably form the shell side on their outsides. The sheath fluid can therefore flow along the outside.

The membrane tubes or filter capillaries typically have a tubular or tubular design. The diameter of the tubular or tubular configuration can vary along the length. The membrane tubes or filter capillaries are preferably essentially straight and tubular.

In a preferred embodiment, the membrane tubes or filter capillaries are designed to be stress-tolerant, in particular longitudinal stress-tolerant, but also transverse stress-tolerant. If the first end and the second end are arranged parallel to one another, a longitudinal tension may imply a force application to the membrane tubes or filter capillaries, in which the end faces remain arranged parallel to one another, but possibly are shifted parallel; A longitudinal stress that increases beyond a certain point can therefore result in a evasive movement of the end faces towards one another. In this case, the membrane tubes or filter capillaries are subjected to a force along their main extension direction, that is to say they are typically compressed, but also lengthened. The membrane tubes or filter capillaries can break. A transverse stress can imply that a force is applied to the membrane tubes or filter capillaries, in which case the end faces are tilted relative to one another, ie a force is applied perpendicularly to the main direction of extension of the membrane tubes or filter capillaries. If the membrane tubes or filter capillaries are designed to be stress-tolerant, they can be subjected to a higher degree of longitudinal stress and/or transverse stress than a comparable straight membrane tube or filter capillary. In other words, in particular the geometry of the membrane tubes or filter capillaries is constructed in such a way that a higher longitudinal stress or transverse stress can be absorbed without the membrane tubes or filter capillaries breaking. An embodiment of a membrane tube or a filter capillary that is designed to be stress-tolerant is a spring-like compressible membrane tube or

filter capillary. For example, the membrane tube or the filter capillary can be compressed by 1 mm or more without being damaged or destroyed, preferably by 2 mm or more, more preferably by 5 mm or more, even more preferably by 10 mm or more, finally preferred by 20 mm or more. On the other hand, the change in length tolerance - i.e. the change in length that results when voltage is applied due to the voltage tolerance of the membrane tube or the filter capillary - 0.1% of the original length or more, preferably 0.2% or more, more preferably 0.5% or more, even more preferably 1% or more, and finally 2% or more of the original length of the membrane tube or the filter capillary.

Stress-tolerant can also be understood as elastic, stress-distributing or stress-reducing, because stress peaks in inelastic areas are distributed over a larger component area, but may even be reduced overall if the component allows deformation as a result. It is particularly preferred that the membrane tubes or filter capillaries are designed to dissipate stress, because if the membrane tubes or filter capillaries can yield under the application of force, e.g. compress like a spring, and at the same time the component housing is designed to be sufficiently rigid, then the applied stress, e.g. the compressive stress, can be derived from the component housing and be accommodated by it.

The membrane tubes or filter capillaries can extend helically or helically, in particular as a double helix or triple helix, in which two or three membrane tubes or filter capillaries run around one another. Such a helical or helical extension of the membrane tubes or filter capillaries has several advantages. This intensifies the mass transfer on the inside of the membrane tube or the filter capillary; also the resistance to external mechanical influences, such as a shock or torsion of the component is improved. This represents a suitable design for equipping the membrane tubes or filter capillaries to be stress-tolerant, as described above.

The membrane tubes or filter capillaries preferably each have a first or second opening through which a fluid can flow. The mouth is preferably designed integrally with the first or second end face. In other words, the first or second end face merges in one piece from a flat extension into the mouth.

The orifice can have a flow-guiding surface configuration. The flow-guiding surface design reduces flow resistances for a fluid flowing through, for example by avoiding or reducing turbulence and/or pressure fluctuations in the course of the flow. Such a flow-guiding surface design of the orifice can have, for example, a conical, cone-shaped, parabolic or torus-shaped inner surface design. The flow-guiding surface configuration is in particular arranged or constructed concentrically around the mouth and embedded in one piece in the first or second end face. In other words, the mouth merges into the first or second end face in one piece.

The monolithic component can further include a first carrier fluid collection port formed monolithically with the first end face and the porous structure. The first carrier fluid collection port is in particular an inlet for the carrier fluid.

The monolithic component can also comprise a second carrier fluid collection connection which is constructed monolithically with the second end face and the porous structure, ie in particular an outlet.

Furthermore, the monolithic component can comprise a sheath fluid connection formed monolithically with the porous structure. The enveloping fluid connection can also be formed monolithically together with the porous structure via the first or second end face.

The porous structure can have at least one connection, cross-connection or stiffening made monolithically with the porous structure in order to increase the mechanical stability of the porous structure.

The connection, cross-connection or stiffener may directly integrally connect the porous structure to the housing. In other words, the connection, cross-connection or reinforcement can be arranged in such a way that it directly and immediately connects the porous structure to the housing, ie the latter is arranged between the porous structure and the housing. The connection, cross-connection or stiffener can also connect porous structures to each other, for example when a plurality of porous structures together define a filter element.

The porous structure can have at least one turbulator for mixing the carrier fluid and/or for mixing the enveloping fluid. A turbulator can provide turbulence in the corresponding fluid, so that there is improved mixing and thus an improved mass transfer between the enveloping fluid and the carrier fluid.

The porous structure can provide a flow cross section that is variable over the length for the carrier fluid and/or the sheath fluid.

In particular, the porous structure has a higher or lower porosity and/or pore size distribution in some areas or in parts. The porous structure can have impermeable areas, permeable areas and other areas that have a different porosity compared to both the impermeable areas and the permeable areas. Such a further different range of porosity can be materialized in such a way that, for example, a type of coating is applied to the inner surface inside the membrane capillaries. The coating can be applied monolithically from the same starting material.

The first and/or the second end face has an integral fluid barrier or is designed as an integral fluid barrier, with the fluid barrier separating the flow of the carrier fluid from the enveloping flow. Advantageously, the use of potting compound is completely avoided here, so that the associated disadvantages are eliminated.

The monolithic component is preferably made up entirely of the porous or porous starting material.

The porous or porous starting material preferably has inorganic, ie, for example metallic and/or ceramic, components. Such inorganic components can be provided in particular as an inorganic paste, for example a ceramic paste. The starting material can also have polymers, in particular provided as a polymer powder, including, for example, polypropylene or polyvinylidene fluoride (PVDF) or polyether sulfone (PES), polysulfone (PSU), polyamide (PA), polyacrylonitrile (PAN), peloyether ether ketone (PEEK), polyethylene terephthalate (PET) or the like. The starting material can thus comprise, in the form of polymers, at least one of polyolefins, for example polypropylene, polyamides, polyvinylidene fluoride (PVDF) and polyether sulfone (PES). The starting material can also comprise a polymer-solvent mixture, for example in melted form. The porous or porous starting material can also be provided as a polymer solution with inorganic fillers, in particular ceramic, metallic and/or polymeric fillers. In other words, the starting material can comprise ceramic, metallic and/or polymeric components, optionally in a mixing ratio to one another.

The invention also includes a monolithic component which is produced using a method as described above.

The invention also describes a monolithic filter module for a device for separating components from a fluid. The filter module of monolithic construction comprises a first end face and a second end face lying opposite the first. The filter module also includes a filter housing, in particular an elongate or tubular one, formed in one piece with the first and second end faces.

The filter module also has a porous structure which is arranged in the filter housing and is constructed and connected in one piece to the end faces and the filter housing. In any case, the porous structure is designed to be permeable in part or in certain areas. The filter module also has at least one carrier fluid collection port and at least one sheath fluid port.

The first end face and the second end face of the filter module are each designed as an integral fluid barrier to prevent a cross flow between the carrier fluid collection port and the sheath fluid collection port.

The porous structure is prepared and arranged in such a way that an envelope side is separated from a carrier side in an at least partially and/or at least regionally permeable manner.

A carrier fluid can be provided on the carrier side. The porous structure is prepared in such a way that mass transfer of the carrier fluid with the shell side is ensured.

The invention is explained in more detail below using exemplary embodiments and with reference to the figures, in which identical and similar elements are sometimes provided with the same reference symbols and the features of the various exemplary embodiments can be combined with one another.

Brief description of the figures

Show it: 1, 1a, 1b perspective view of a monolithic tube bundle as a component with details,

2, 2a, 2b a monolithic component in a sectional view,

3, 3a, 3b a monolithic component with housing,

4, 4a, 4b a monolithic component as an insert module,

5, 5a, 5b a monolithic component as a filter module,

6, 6a perspective view of a monolithic component with webs,

7, 7a, 7b monolithic component as a cartridge with webs and detailed view,

8 shows a perspective representation of a monolithic component with membrane tubes arranged to form triple helixes,

8a segment of a membrane tube bundle arranged in a triple helix,

9a, 9b, 9c representations of a segment of a meander-shaped membrane tube,

10 to 10e monolithic component with variable membrane tube diameter,

11-11e Another example of a monolithic component with variable tube geometry

Fig. 12a - 12e monolithic component with internals or internal structures (static mixer)

Fig. 13 - 13b monolithic component with applied coating

Fig. 14 - 16 representation of different heaps that can be achieved with the method according to the invention,

Fig. 17 example scheme for different process sequences for the production of a monolithic filter module,

18 application device for applying powdered starting material,

Fig. 19 heating furnace for the pre-treatment of solid starting material,

Fig. 20 mixing device,

21 further application device with feed,

Fig. 22 System with two selectable application devices,

Fig. 23 system with excitation or activation arrangement,

Fig. 24 adjustment of the location-dependent light absorption capacity,

25 further application device,

26 another example of an application device,

Fig. 27 Combustion chamber with green body,

Fig. 28 washing bath for washing out production aids,

Fig. 29 Flushing device. Detailed description of the invention

Referring to FIG. 1, a first embodiment of a monolithic component 50 is shown, which has a first end face 2 and a second end face 2a and a bundle of membrane tubes 1. FIG. The two end faces 2, 2a are constructed in one piece with the membrane tubes 1 and are directly connected. The membrane tubes 1 and end plates 2 are successively manufactured in one process step. A subsequent connection by joining, welding, gluing, clamping or the like is in particular not required or not produced. The end plates 2 and membrane tubes 1 are made of the same, similar, but at least compatible material, so that the end plates 2 and membrane tubes 1 can be built in one piece. The membrane tubes 1 have membrane inlets 3, which merge into the respective end face 2, 2a. The membrane inlets 3 are therefore at the same time part of the respective membrane tube 1 as well as part of the respective end face 2, 2a. In this example, the membrane inlets 3 therefore also represent the respective connection point between the membrane tube 1 and the end plate 2, 2a, so that mechanical forces can possibly also act on the membrane inlet. The membrane inlet 3 can therefore also be optimized in terms of mechanical resistance in order to reduce the tendency to fracture in the area of the transition from the end face 2, 2a to the respective membrane tube 1. The membrane tubes 1 together form the membrane or the membrane filter 60a.

FIG. 1a shows a detail of the end face 2a, as shown in FIG. The diaphragm inlets 3 are rounded in a hydraulically favorable manner with a rounded funnel area 4a. The rounded transitions 4a from the membrane tubes 1 to the end faces 2, 2a also ensure a mechanically favorable coupling of the membrane tubes 1 to the respective end plate 2, 2a.

1b shows a detail of the end plate 2, the rounded transitions 4 being visible from the outside in the perspective view.

FIG. 2 shows a cross-sectional view of a longitudinal section through the monolithic component 50 along the line marked A-A in FIG. 2b.

Fig. 2b shows a plan view of the end face 2 of the monolithic component 50. Thus, three cut membrane tubes 1 are shown in FIG Connection collar 58, for example in order to couple the monolithic component 50 to another connection piece (not shown).

FIG. 2a shows the detail "B" from FIG. 2, the membrane inlets 3 of the end face 2 being shown more clearly. The shell side 10 is located between each membrane tube 1 and the next membrane tube 1. The membrane inlets 3 are rounded in order to improve the mechanical load-bearing capacity as well as the flow profile at this point.

Referring to Fig. 3, a monolithic component 50 is shown with an inlet 7 and an outlet 7a on the respective end face 2, 2a of the monolithic component 50. The membrane tubes 1 extend from the end face 2 to the end face 2a and connect the two end faces 2 , 2a integral with each other. Furthermore, the monolithic component also has an outer side 5 in the form of a housing 5, which also closes the shell side 10 off from the environment, in particular in a fluid-tight manner, apart from the connections provided for the shell fluid inlet and shell fluid outlet 8, 8a.

FIG. 3b depicts a top view of the filter 50 shown with FIG. 3, with the line A-A depicting the sectional plane in which FIG. 3 is shown as a sectional view. A sheath fluid collection port 56 is arranged on one side of the monolithic component 50 as an inlet or outlet for the sheath fluid. The sheath fluid collection connection 56 can be designed as a flange, so that a connection line for the sheath fluid can be connected there, for example by means of a screw connection. A carrier fluid collection connection 52, which can also be designed as a flange for the screw-type or clamped connection of a connection line for the carrier fluid, is arranged on one longitudinal side, specifically on the inlet 7 in particular.

FIG. 3a shows the detail "B" of FIG. 3, the structure of the inlet 7 being further clarified. The inlet 7 forms a carrier fluid chamber 54 in which the carrier fluid is supplied to the individual membrane tubes 1 communicating with the carrier fluid chamber 54 or is discharged from the membrane tubes 1 . The inlet 7 is formed in one piece with the end face 2 and in one piece with the housing 5 and the membrane tubes 1 . The membrane tubes 1 are formed in that the side walls 9 of the membrane tubes emerge in one piece from the end face 2 and are lengthened to form a tubular structure. The carrier fluid can flow inside the membrane tube 1, ie on the inside of the side surface 9 of the membrane tube, in order to get from one end face 2 to the opposite end face 2a. In other words, the carrier fluid flows typically from the end face 2 to the end face 2a (or in the opposite direction), with direct fluid-dynamic communication between the carrier side and the envelope side not occurring or being prevented as far as possible. Rather, the side surface 9 of the membrane tube provides a porous surface in order to ensure a mass transfer between the enveloping fluid on the enveloping side 10 and the carrier fluid in the membrane tube 1 . The side walls 9 of the membrane tubes 1 therefore form the porous structure 60, which is designed to be permeable, semi-permeable or selectively permeable. The transitions 6, 6a between the housing 5 and the membrane end plates 2, 2a are also rounded. Subsequent or non-material connection by joining, welding, gluing, clamping or the like is not required in a particularly advantageous manner. End plates 2, 2a and housing 5 are in particular made of the same, but at least compatible, material in order to ensure the monolithic construction of component 50.

The fluid to be separated or the carrier fluid reaches the housing 5 via the inlet 7 , more precisely the membrane tubes 1 there. It enters the respective membrane tube 1 via the membrane inlet 3, flows through the membrane tubes 1 from their first side to their second side and at the other end of the housing the fluid exits again at the opposite end face 2a. The filtrate penetrates through the walls 9 of the membrane tubes 1, i. H. through the porous structure 60, possibly collects in the filtrate chamber 10 and can leave the housing via one of the filtrate connections 8.

1 and FIG. 3 together, it becomes clear that a membrane tube bundle 1a according to FIG. 1 can also be designed as a porous structure 60 as an insert for a separate housing 62, as is shown, for example, with FIGS. 4 to 5 is further specified.

As can be seen in FIG. 4, a groove 11 for a possible seal can be provided on the end faces 2, 2a. In this example, the membrane tube bundle 1a from the plurality of membrane tubes 1 is in any case formed in one piece with the end plates 2, 2a, so that the separation of the carrier fluid from the enveloping fluid is completely ensured by the monolithic component 50 and here the particularly vulnerable casting compound is already dispensed with can be. This already represents a significant further development compared to the well-known dialysis filters.

FIG. 4a shows detail “B” from FIG. 4, the structure with the groove 11 in the connecting collar 58 being further illustrated. The connection collar 58 is shown rounded with the fillets 4, 4a, as shown in detail with reference to FIG. FIG. 4b shows the top view of the second end face 2a, with the line AA showing the sectional plane for FIG.

Referring to FIG. 5, a further embodiment of the monolithic component 50 is shown, which has the two end faces 2, 2a formed in one piece with the porous structure 60. FIG. An inlet piece 13 and an outlet piece 13a are flanged on by means of a clamping ring 15. The housing 62 is designed as a separate component which is slipped over the porous structure 60 in a tubular manner.

FIG. 5b shows a top view of the end face 2a, with the section line A-A clarifying the section plane of FIG. The carrier fluid collection connection 52 is arranged concentrically in order to enable a supply line to the porous structure 60 and thus to the filter element, consisting of the membrane tubes 1 .

FIG. 5a shows the detail "B" from FIG. 5, with an exemplary structure for connecting the monolithic component to the inlet piece 13 being shown. The separate housing 62 is placed sealingly against the flat sealing element 14 via the sealing element 12 and is clamped to the inlet piece 13 by means of the clamping ring 15 . An overhang 16 of the inlet piece 13 improves the axial fixation of the membrane tube bundle 1 in the separate housing 62. The clamping ring 15 can be subjected to a corresponding contact pressure in order to produce a sealing connection between the separate housing 62 and the inlet piece 13. In this example, an identical connection is also realized on the second end face 2a. Of course, one end face 2, 2a could also be designed integrally with an inlet 7 and one side as separate components .

Referring to FIG. 6 , another embodiment is shown in perspective, wherein the monolithic component 50 is characterized as having support structures 17 to provide mechanical reinforcement of the monolithic component 50 . Especially in the case of brittle membrane materials such as ceramics, the connection between the individual membrane tubes 1 and thus the sensitivity to impacts with the risk of membrane rupture can be significantly improved.

FIG. 6a shows the detail marked “A” in this regard, with webs 17 being shown, which represent a suitable connection in order to improve the mechanical stability mentioned above bring about. Such webs 17 or a support structure 17 can also be continued up to the housing 5, see for example Figure 7a.

FIG. 7 shows a further illustration of a monolithic component 50 with a support structure 17 in a side view, the housing 5 being omitted for reasons of better visibility.

FIG. 7a shows the sectional plane B-B of FIG. 7, although the housing 5 can be shown here. The support structure 17 extends between the individual membrane tubes 1, with 19 membrane tubes 1 being shown in this embodiment, which together form the porous structure 60 or the filter element. The support structure 17 is also connected to the repositioning 5 with housing webs 17a in order to further improve the mechanical stability, in particular of the prosize structure 60.

7b shows a further detail of an embodiment of the monolithic component 50 with support structure 17 in a sectional view. The 17 membrane tubes 1 also shown in this representation, which together form the membrane filter 60a, are each connected to one another with the adjacent membrane tube 1 by means of the support structure 17 .

Referring to Fig. 8, another embodiment of a monolithic component is shown, wherein the porous structure comprises curved membrane tubes 1. In this embodiment, the membrane tubes are helically shaped, specifically divided into triple helixes 1b. Helically shaped membrane tubes 1 offer the advantage of better mass transfer on the inside when carrier fluid flows through them. The advantage over straight membrane tubes 1 is that helically shaped membrane tubes 1 have elastic resilience under loads in the direction of the main axis of the membrane tube bundle or the triple helix 1b. Such a load can occur during operation when the temperature of the fluid flowing through changes rapidly. The membrane tube bundle 1a wants to expand according to the temperature, for example, but is prevented from doing so by the still cold housing 5 (cf., for example, FIG. 3). The same applies to rapid temperature drops. The triple helix 1b or, in general, the helical shape acts like a helical spring.

The shape of the membrane tubes shown thus provides a stress-tolerant design that tolerates longitudinal stresses that build up, in that these are stored like a spring in the triple helix 1b and relieved again after the monolithic component 50 has cooled. It is therefore a stress-tolerant monolithic component 50, in particular longitudinal stress-tolerant, which higher stresses, in particular by Longitudinal stresses caused by temperature differences can absorb before fatigue or even fracture of one or more membrane tubes 1 takes place. In addition, the helical structure 1b can also be provided to be tolerant of transverse stresses, with the membrane tubes 1 having a higher capacity to absorb transverse stresses before fatigue or fracture occurs. This increases the service life and service life of the monolithic components 50 and further simplifies handling. In this embodiment, the membrane filter 60 is made up of seven triple helixes 1 b and thus of 21 membrane tubes 1 . The membrane tubes open out in one piece on their first side into the first end face 2 and on their second side into the second end face 2a. They have the curves 4, 4a already described to improve the mechanical stability and the flow guidance for the carrier fluid.

8a shows a membrane tube bundle segment consisting of three helically shaped membrane tubes which together form the triple helix 1b. In this embodiment, the membrane tubes 1 are designed in such a way that they have an impermeable structure 64 at their front ends and the porous structure 60 only in the central part, which is prepared for the exchange of substances with the enveloping fluid.

A further embodiment of a membrane tube 28a is shown in FIGS. 9a, 9b and 9c, which is shaped like a meander or a wavy line. The monolithic component 50 in this embodiment is shaped to improve various requirements. Thus, the wavy membrane tube 28a can, if necessary, bring about a thorough mixing of the carrier fluids flowing inside the tube 28a, so that overall the mass transfer towards the enveloping flow is also improved. In other words, with the embodiment shown in FIGS. 9a, 9b, 9c, a direction-variable flow direction is generated, which can bring about the formation of turbulence in the carrier fluid. The meandering or wavy membrane tube 28a can be provided in such a way that the curves of the membrane tube 28a alternate with the curves of an adjacently arranged membrane tube 28a, so that overall no increased space requirement arises despite the wavy design of the membrane tube 28a.

Moreover, wavy membrane tubes 28a have the same advantages as the helical membrane tube bundle 1b described above, namely mechanically a damping effect or elastic flexibility in the direction of the main axis of extension of the membrane tube 28a. In other words, this embodiment is also a suitable stress-tolerant design of the monolithic component 50. The wavy membrane tube 28a is shown in FIG. 9a in a perspective three-dimensional view, in FIG. 9b in a perspective side view and with FIG. 9c in a side sectional view through the corrugated membrane tube 28a.

Referring to Figs. 10 to 11 show further possibilities that can be implemented in a particularly simple and efficient manner with the present invention, namely the introduction of variable cross-sectional geometries of membrane tubes 1. FIG. 10 shows a sectional view through a membrane tube 1 with variable cross-sectional geometry. The membrane tube cross section is varied in the flow direction. Due to the variable cross sections in the flow direction, the flow speeds and flow directions also change with the cross sections, which leads to better mixing of the flowing carrier fluid.

10a shows a top view of a correspondingly shaped membrane tube 1 with a variable cross section, with section line BB showing the widest cross-sectional geometry also shown in FIG. 10d, section line C-C showing the narrowest cross-sectional geometry also shown in FIG. 10c.

FIG. 10b shows a top view of an inlet opening 3 of the membrane tube 1, the plane AA showing the sectional plane of FIG.

Finally, FIG. 10e shows a perspective view of the membrane tube 1 with variable cross-sectional geometry. The narrower cross section 20 alternates with the wide cross section 21 in an alternating manner. Impermeable material structures 64 are shown at the two ends, and the membrane tube 1 is designed as a porous structure 60 in the middle region.

Fig. 11a shows a perspective view of another embodiment of a membrane tube with variable cross-sectional geometry 19. Here, too, the narrowest cross-section 20 alternates with the wide cross-section 21, the ends are designed as an impermeable structure 64, and the porous structure 60 is in the central region for a material exchange or mass exchange of the carrier fluid formed with the sheath fluid. The membrane tube segment has a variable elliptical cross-section, the long axis of the elliptical cross-sections being alternately aligned in the starting position according to the section BB shown in FIG. 11d and rotated by 90° thereto, as shown in FIG. 11e. A longitudinal section along the section line AA marked in FIG. 11c is reproduced in FIG. The changes of Directions of flow and thus, depending on the fluid, also the mixing can be more pronounced here than with the circular cross-sections.

It has been shown that an even stronger mixing of the carrier fluid flowing through can also be achieved by suitable turbulators 29 . Internals, such as static mixers as turbulators 29, are known as such in process engineering in order to improve the thorough mixing of a flowing fluid. In membrane tubes, however, this does not work easily, but at least not permanently. Static mixers cannot be fixed well in conventional membrane tubes or can they be fixed at all with third materials and therefore regularly perform movements relative to the membrane surface during operation. The membrane surface is permanently damaged by the resulting friction and it can no longer fulfill its separation task.

Due to the advantageous method in which the component is built up monolithically, it is now possible to form turbulators 29 in one piece with the porous structure 60, so that in any case the problem of relative movement no longer arises. The individual segments 29a of the turbulators or the static mixers are thus an integral part of the porous structure 60, i.e. in particular the tubular membrane 1, 19, 28. The monolithic composite of turbulators 29 with a porous structure 60 as an integrated component eliminates the problem of relative movements, so that Damage to the membrane at this point is reduced or even ruled out, thus ensuring reliable long-term operation. FIG. 12b shows the embodiment of FIG. 12a in a perspective representation.

Fig. 12c shows a membrane tube 28 with a plurality of turbulators 29 arranged next to one another or one after the other, which are each arranged at an angle to one another, for example offset by 90° to one another, and thus far greater mixing of the carrier fluid and thus better mass transfer with take care of the sheath fluid. FIG. 12d shows a top view of an inlet 3 of the porous structure 60 in the form of the membrane tube 28, the line AA illustrating the sectional plane of FIG. 12c. Finally, Fig. 12e shows a perspective view of the membrane tube 28. The aforementioned or other turbulators 29 can also be used monolithically in the other embodiments, for example in the helical membrane tube bundles 1a, 1b, or in the wavy or meandering membrane tubes 28a Intensifying the mixing of the carrier fluid flowing through the membrane tube 1, 28, 28a. Referring to FIG. 13, a further embodiment of the monolithic component 50 is shown, the membrane tubes 1 having an additional layer 30 on the side surfaces 9, which is either applied monolithically and thus consists of a compatible or identical material to the porous structure 60, or which is applied as a coating 30 after the production of the porous structure. This can involve one or more layers 30 on the inside 9, which have a different porosity and/or pore size distribution.

This is shown enlarged in FIG. 13a, with the coating 30 being applied to the inner surfaces 9 of the membrane tubes 1. FIG. The coating 30 is also extended to the surface of the end plate 2 in order to further improve the transition from the membrane tube 1 via the inlet 3 to the end plate 2. The coating can be produced as a separate track in the layered structure of the filter body during the additive manufacturing process.

These traces for producing the coating 30 can be laid by a separate print head, which deposits, for example, an inorganic mass, for example an unfilled or ceramically or metallically filled polymeric mass, which leads to a finer pore structure than in the base body. One or more coatings can also be applied subsequently after the base body has been fired and, for example, sintered at a lower temperature, particularly if inorganically filled polymeric masses are used. In one example, a ceramic coating can be applied to a metallic base body.

Finally, FIG. 13b shows a top view of the end face 2, with the line A-A representing the sectional plane of FIG.

Referring to FIG. 14, an exemplary heap 31 of porous structure 60 achievable with the method of the present invention is illustrated. The heap 31 has a plurality of pores 32 . The resulting pore structure, as shown in FIG. 14, can be produced, for example, with additive manufacturing using the principle of thermal phase separation.

In principle, in this process at least one polymer is dissolved at an elevated temperature in a solvent which is poorly soluble at room temperature. The composition of the solution is chosen - if necessary by adding further additives - so that a phase separation takes place during cooling and the polymer solution is divided into a polymer-rich phase (membrane matrix) and a polymer-poor phase (pores) separates. The membrane is shaped by continuous extrusion through an annular die in the case of tubular membranes or through a slit die for flat membranes. The dimensions of the membrane that can be achieved depend on the geometry of the nozzle and can only be varied within narrow limits. The membranes are then freed from the auxiliary materials by extraction, then dried and, in further steps, connected to various components to form a filter.

In a new process, the aforementioned solution is formed into a membrane using an extrusion printer. The TiPS solution or the starting material is fed to the printer nozzle above the demixing temperature and deposited in the form of thin filaments in a desired shape, such as a tubular membrane 1 . Phase separation occurs as the TiPS solution cools. The phase separation can be additionally influenced (N-TiPs) by providing a non-solvent, such as in particular water vapor or glycerol.

Sandwich structures with different pore structures can also be built up by depositing TiPS solutions with different compositions.

In addition, a polymer melt can be extruded at the same pressure, which forms a non-permeable layer when it cools down. This polymer can be printed into impermeable housing parts of the filter, such as a filtrate collection tube or filtrate discharge tube, an aeration unit or even filter heads with connections.

As an alternative to two-head printing, nozzles with a mixing function for two or more components can also be used. This results in the possibility of changing the composition during the printing process and thus producing areas of different porosity up to impermeable areas with just one head. This is therefore a mixing head.

A pore structure resulting from such a method is shown in FIG. 14, the pore structure being essentially determined by the composition of the polymer solution of the starting material 70, 71, 72, 73, 74. A solid matrix 31 made of polymer material with ceramic particles optionally enclosed therein is produced by a phase inversion. Depending on the volume fraction of the solvent, cavities 32 are formed, which are typically connected to one another. The size and number of cavities depends on the composition of the polymer solution (polymer content, possibly with ceramic content or metal content, solvent content and/or additives) and the precipitation conditions or the ambient conditions (temperature, medium, etc.).

The resulting microporous structure 60 is fundamentally suitable as a filter medium for micro- and ultrafiltration. Defined particles cannot be recognized in the solid matrix. The solvent can be removed from the finished filter in a separate step or even when the filter is put into operation and, depending on the composition of the solvent, protect the filter during transport and installation. This also reduces clogging of the filter with foreign matter, such as dust.

In general, additive manufacturing methods, such as 3D printing, are preferred for the structures of the porous structures 60 described here in order to produce material systems with intrinsically porous components. An extrusion process can thus be used.

For the membrane filter 60a according to the invention, it typically applies that the resulting pore structure of the porous material 60 does not have to be specified as a predetermined pattern in a control program and the production head therefore does not have to produce the concrete pore structure at the micrometer level. Rather, the pore structure of the porous material 60 can be produced by the composition of the recipe used, for example in the extraction process, optionally with subsequent steps to solidify the starting material 70, 71, 72, 73, 74, such as the sintering of inorganic, e.g. ceramic, green bodies.

The melt extrusion of polymer pastes generally results in dense, non-porous structures. The use of formulations in which inorganic or organic fillers or additives are added to the pastes to create pores opens up further scope. With a suitable composition, the desired microporous structures are formed when the deposited "beads" cool down. This structural change, also known as phase inversion, can be controlled by suitable environmental conditions in the installation space for constructing the component 50 . For example, the process of phase inversion or crosslinking can be influenced by the atmosphere in the installation space (temperature and humidity) or UV radiation.

For example, in the example of the Multijet Fusion process, a powder bed is used. Sintering is triggered by infrared sources. With this method, different light absorption rates can be realized depending on the location using suitable inks, which lead to areas of different densities. Additives can be added to these inks for example, polymeric nanoparticles that are embedded during the sintering process and provide additional scope for the design of location-dependent pore structures. In other words, a location-independent radiation source or energy source can be used in this method for the thermal post-treatment of the starting material 70, 71, 72, 73, 74, with the location-dependent adjustment of the porosity of the starting material 70, 71, 72, 73, 74 by means of the supply is realized by suitable inks.

In selective laser sintering (SLS) of polymer powders, depending on the polymer, infiltration is required to produce truly non-porous components. With suitable polymers, e.g. polypropylene, the body can be made porous or impermeable by adjusting the sintering parameters. The degree of porosity can also be adjusted. Porous and impermeable areas can be produced in a component 50 by setting the sintering parameters as a function of location, which can be possible by means of suitable software adaptations. For example, non-porous housings 5 and end plates 2, 2a on the one hand and porous structures 60, such as membrane tubes 1, can be monolithically connected to one another in this way. In the area of the membrane filter 60a, areas of different porosity can even be implemented. Membranes 60a can be produced with a porosity gradient towards the membrane surface or layers of different porosity. This variation is only caused by the sintering parameters.

For inorganic materials such as ceramic or metallic materials, 3D extrusion can be used as a manufacturing process to produce so-called green bodies or precursors for subsequent sintering in a sintering furnace. Another advantage here compared to extruded inorganic filter elements is the lower possible wall thickness. This results in shorter times in the sintering furnace due to the lower heat storage, which has an advantageous effect on the production costs.

Different priorities can be generated here by different formulations of the inorganic masses. A prerequisite is a multi-head system with an extrusion head for each desired porosity, with which the corresponding inorganic paste, ie metallic or ceramic paste, for example, is deposited at the intended location. In other words, the setting of the porosity is realized in this example in that the corresponding head of the system deposits a corresponding starting material 70 , 71 , 72 , 73 , 74 and this is connected monolithically to the rest of the component 50 . Referring now to FIG. 15, another embodiment of a heap 31a is shown with pores 32a. Such a configuration of the pile 31a can be achieved, for example, by means of the production of polymeric membranes in the sintering process, polymeric particles being sintered together by the action of heat. The sintering conditions are set in such a way that the polymer particles bond, but still retain their particle shape to a certain extent. The resulting pore structure is thus essentially determined by the polymer particles, in particular by their shape and size. The polymer particles are connected to one another by the sintering process, cavities 32a being formed between the polymer particles, which are typically connected to one another and form a continuous cavity 32a. The size of the cavities depends on the size of the polymer particles. The resulting microporous structure is fundamentally suitable as a filter medium for micro and ultra filtration. The pore size desired in each case can be set by suitably selecting the particle size, with the particles being larger than the pores.

Referring to FIG. 16, a pile 31b is shown which can be achieved with a further manufacturing method, the pile having inorganic particles, for example metallic or ceramic particles, which form cavities 32b between the particles. To produce inorganic membranes 60a, for example, a green body (precursor) can first be produced from an inorganic paste. For example, the paste essentially consists of ceramic or metallic particles, organic binders and additives. After the paste has dried or solidified, the green body is obtained, which is formed into a microporous inorganic body 60 in a subsequent firing step, depending on the composition of the paste. The resulting pore structure, as shown in FIG. 16, is essentially determined by the inorganic particles. The inorganic particles of the heap 31b, ie ceramic particles and/or metal particles, for example, are connected to one another by the sintering process, but retain their particle shape to a certain extent. There are cavities 32b between the inorganic particles, which are advantageously connected to one another to form a common cavity. The size of the cavities depends on the size and shape of the inorganic particles. The organic components of the starting material 70, 71, 72, 73, 74 decompose at the high firing temperatures. The resulting microporous structure is fundamentally suitable as a filter medium for micro and ultra filtration. The desired pore size leaves are set by the appropriate choice of particle size, with the particles being larger than the pores.

The resulting microporous structure, possibly with a high inorganic content, e.g. in the form of ceramic particles and/or metal particles, represents the green body for the subsequent firing process, e.g. as part of a manufacturing process according to or analogous to the TiPS process. The microporous structure 60 changes only slightly as a result of the firing process and is fundamentally suitable as a filter medium for micro- and ultrafiltration. Defined particles cannot be recognized in the solid matrix or inorganic particles of the heap 31, 31a, 31b that may be recognizable are smaller than the pores that have formed.

Sintering or baking of the green bodies can be carried out, for example, at 1600° C. or more. A degree of filling of the inorganic particles in the heap 31, 31a, 31b in the polymeric phase can be between 50 and 70%. With such mixing ratios, it is advantageous to use dynamic mixers.

Alternatively, the resulting microporous structure 60 can be used without inorganic fillers, e.g. without ceramic or metallic fillers, without a further firing process. It is advantageous here to remove the washable components to complete the filter.

Referring to FIG. 17, the sequence of the method for producing a component 50 is shown in a schematic diagram representation. In the provision step 100, the porous or porous starting material 70, 71, 72, 73, 74 is provided. starting material

70, 71, 72, 73, 74 can, for example, but not exclusively, as a powdered starting material

71, as a liquid starting material 72, as a solid starting material 73 or as a pasty starting material 74. The starting material 70, 71, 72, 73, 74 is set, adjusted or prepared to be intrinsically porous. The starting material 70, 71, 72, 73, 74 can be provided in various ways. For example, providing 100 the starting material 70, 71, 72, 73, 74 includes storing 102 an extruder device with starting material 70, 71, 72, 73, 74. The providing step 100 can also include placing or preparing 104 powdery starting material 71, for example by means of a depositing device 80. The step of providing 100 can also include the mixing 106 of the starting material 70, 71, 72, 73, 74 or the heating 108 of the starting material 70, 71, 72, 73, 74. The provision 100 therefore includes the possible preparation of the Starting material 70, 71, 72, 73, 74, for example at a specific point, in particular a point of a point matrix of the monolithic component 50 to be produced, for a subsequent application of material. Thus, providing 100 can also include moving to the point to be approached by means of the application device if the application device has to be moved and/or adjusted accordingly for this purpose. The step of providing 100 can also include the preparation of a radiation source for later activation or heating of the point to be approached.

After the preparation, the porosity of the porous or porous starting material 70, 71, 72, 73, 74 is adjusted 110 for the material application to be carried out. The setting can also be done in different ways. Thus, the admixture 112 of additive or filler to the starting material 70, 71, 72, 73, 74 for adjusting the porosity can be included at the moment the material is applied. Furthermore, the adjustment of curing parameters 114 can be included in order to adjust the porosity of the porous or porous starting material 70 , 71 , 72 , 73 , 74 in step 110 .

The adjustment step 110 can also include the selection 116 of a starting material 70, 71, 72, 73, 74 to be used from a plurality of at least two starting materials 70, 71, 72, 73, 74. The selection can also lead to a mixture if the starting material 70, 71, 72, 73, 74 comprises two starting materials 70, 71, 72, 73, 74, which can be fed in simultaneously or alternately in order to have a material mix at the point to be approached to generate the point-target matrix.

A location-dependent radiation intensity can be provided according to step 118 in order to set the porosity of the starting material 70 , 71 , 72 , 73 , 74 in step 110 . Thus, in step 118, based on the point of the point-target matrix selected or to be approached, a radiation intensity stored in a table, for example, can be retrieved and supplied to the radiation source for output.

The adjustment step 110 can also include the location-dependent adjustment 119 of the light absorption capacity of the starting material 70, 71, 72, 73, 74. This can be the location-dependent supply of ink if, for example, the construction of the component is carried out using a location-independent radiation source. The aim of setting step 110 is that the porous or porous starting material 70, 71, 72, 73, 74 is designed or prepared when the material is applied in such a way that it can form a coherent porous material structure in the component, which is preferably at the respective point to be approached the porosity of the point-target matrix can be adjusted in a variable manner in order to construct a porous material structure 60 on the one hand, but also impermeable regions 64 formed monolithically therewith. Ideally, this can be carried out in a common process sequence such that the monolithic component 50 is produced in one piece continuously, preferably without interruption. Depending on the procedure used, this can also be done step by step and with appropriate breaks between the steps if this should be necessary for the procedure. Finally, the monolithic component 50 that is produced is characterized in that there is a material connection between all of the components of the monolithic component 50 in such a way that the component appears to have grown from one piece, so that the areas that are prepared for a flow passage are already in place during construction or installation the fabrication of the monolithic component 50 so that these areas allow fluid flow; on the other hand, that the impermeable areas, which are intended to prevent a flow of flow, and the housing, are already set to be correspondingly impermeable during the production of the monolithic component. Particularly preferably, the entire monolithic component 50 consists of mutually compatible material or of the same starting material 70, 71, 72, 73, 74, to which different filling materials or additives may be added if necessary.

The set starting material 70, 71, 72, 73, 74 is applied to the point to be approached in step 120. The application can have different characteristics. Depending on the monolithic component 50 to be produced, this can be understood to mean the dispensing of adjusted starting material 70 , 71 , 72 , 73 , 74 by means of an application machine according to step 122 . Such an application machine is, for example, an extruder. It can also include an additional depositing of powdered starting material 71 according to step 124 at the point to be approached if this cannot be carried out completely with step 104 . The application 126 , for example the manual application of a paste, can also be included in the application 120 step. The application 120 leads to the starting material 70, 71, 72, 73, 74 being applied to the monolithic component 50 in a form that there are areas with an impermeable material structure on the one hand and areas with a porous material structure on the other hand, with the areas with a porous material structure also can be further subdivided into areas with different porosity.

Finally, in step 130, the application 120, the setting 110 and any sub-steps thereof are continued until the monolithic component 50 is finally completed. je Depending on the selected underlying method, the steps 110, 120 are carried out repetitively, for example for each point of the point-target matrix again, or again for each layer of the layer-target matrix, or the starting material 70, 71, 72, 73, 74 are initially set in step 110, for example for contiguous areas of the monolithic component, and then approached or applied throughout step 120.

FIGS. 18 to 32 show, by way of example, how some of the method steps described above can be carried out. Fig. 18 shows the application 104 of powdered starting material 71 to a partially finished monolithic component 50 by means of a depositing device 80. The starting material 70 is deposited in step 104 in such a way that, for example, the powdered starting material 71 is deposited in a matrix plane 90 in a depositing area 92, whereas in an area 94 no starting material 71 is deposited.

Fig. 19 shows an example of the heating 108 of solid starting material 73 in a heating furnace 81 by means of heat 81a.

20 shows an example of the mixing 112 of starting material 70 with additive 75 and/or filler 76 in a mixing device 82. Starting material 70 is supplied to the mixing container 82c in an adjustable feed quantity by means of the quantity controller 82a; Additive 75 and/or filler 76 is also supplied to the mixing container 82c in a supply quantity that can be set separately by means of the quantity controller 82b. Depending on the process conditions, at least one of the quantity regulators 82a, 82b may also be dispensable. The mixing device 82 can also have three filling containers if additive 75 or filler 76 is to be provided separately. The illustration in FIG. 20 does not differ in the basic form shown if either additive 75 or filler 76 or both are to be mixed together with the starting material 70, so that these variants are combined in one figure 20 to keep things short.

The quantity controller(s) 82a, 82b allows/allow the setting 110 of the subsequent porosity of the starting material 70 and thus of areas of the monolithic component 50 to be created. The mixed starting material 70a is circulated in the mixing container 82c, for example when using liquid starting material 72. The mixing container 82c has an output quantity regulator 82e in the outlet, by means of which the quantity to be applied for the application 120 can be adjusted. For example, FIG. 20 shows a punctiform application for this purpose 120 of the starting material 70a on the outlined monolithic component 50, the punctiform application 120 being achievable, for example, by opening and closing the output quantity regulator 82e.

21 shows a further embodiment of a storage device or application machine 80 for applying starting material 70 to a component carrier 80b or, if the monolithic component 50 has already been partially applied to the component carrier 80b, to the partially finished monolithic component 50. By means of a feed 80a, for example, a coolant or also a precipitant or a hardener can be supplied during application 110 and thus hardening parameters 114 can be set.

Yet another alternative for setting the porous or porous starting material 70 is shown in FIG. 22 with the provision of two storage devices 80, 80'. Thus, according to step 116, an already preset starting material 70, 71, 72, 73, 74 can be selected in that the material application 110 onto the component carrier 80b or the partially applied monolithic component 50 is carried out with the corresponding depositing device 80, 80'.

23 shows an example of the provision 118 of a location-dependent radiation intensity for converting the starting material 70 into material connected to the monolithic component 50 . An excitation or activation arrangement 83 has, for example, a radiation source 83a and a deflection or guide device 83b in order to direct radiation 83c onto the target point 50a of the point matrix on the monolithic component 50 or the component carrier 80b.

Referring to FIG. 24, the location-dependent setting 119 of the light absorption capacity of the starting material 70, 71, 72, 73, 74 is based on a mobile or mobile activation device 84. The activation device 84 has one or more spray heads 84b. For example, an absorption modifier 77, such as an ink, can be applied to the prepared starting material 70 by means of the spray head or spray heads 84b, not at every point of the component 50 to be produced, but specifically so that at the points 50a where the absorption modifier 77 is applied is, the porosity of the component 50 can be adjusted differently than at the points 50a where no absorption modifier 77 is applied. It is the light absorption capacity of the starting material 70, 71, 72, 73, 74 by means of (additional) application of the absorption modifier 77 in step 119 is set depending on the location, so that in a later irradiation, such as For example, also shown in FIG. 23, a location-dependent porosity can be produced in the component 50. The activation device 84 can also include one or more radiation source(s) 84a for emitting an activation radiation 84c. The areas previously covered with ink 77 are activated differently compared to the areas not covered with ink 77. For example, an area of the component 50 to be produced to which absorption modifier 77 has been applied can absorb more radiant power 84c from the radiation source 84a, thereby merging more densely and have a lower porosity at point 50a compared to other areas of the component 50 to which no absorption modifier has been applied 77 was applied.

FIG. 25 shows the application 122 of starting material 70, 71, 72, 73, 74 by means of a depositing device 80 onto a component 50 that has already been partially deposited. The storage device 80 is designed to be movable horizontally, that is to say at least in two axial directions, so that each point on the component carrier 80b can be approached. Vertical movement, i.e. moving up and down, is also possible. Alternatively or cumulatively, the storage device 80 can be designed to be movable in order to allow movement in all three spatial directions in total, in order to make it possible to approach each point of the point matrix with the storage device 80 . Application 122 of starting material 70 , 71 , 72 , 73 , 74 is shown “in strands” or “in caterpillar form”.

Referring to FIG. 26, the annular or snail-shaped application 126 of pasty starting material 74 by means of a depositing device 80 is shown.

Firing 132 of a green body is shown in FIG. In this case, the green body is inserted into the heating device 81, ie, for example, into a combustion chamber, and heated by means of a heat source 81a.

Referring to Fig. 28, a washing-out step 134 is shown, in which case any auxiliary materials required for the application of the starting material 70, 71, 72, 73, 74 or for the production of the component 50 are washed out of the component 50, so that these can be removed. For this purpose, the component 50 is placed in a bath 85 with rinsing solution 85a and rinsed.

Finally, FIG. 29 shows the removal of any excess powder in step 136 in a rinsing chamber 86, for example by means of compressed air.

It is obvious to a person skilled in the art that the embodiments described above are to be understood as examples and that the invention is not limited thereto is, but can be varied in many ways without leaving the scope of the claims. Furthermore, it is evident that the features, regardless of whether they are disclosed in the description, the claims, the figures or otherwise, also individually define essential components of the invention, even if they are described together with other features. In all figures, the same reference symbols represent the same objects, so that descriptions of objects that may only be mentioned in one or at least not with regard to all figures can also be transferred to these figures, with regard to which the object is not explicitly described in the description.

Reference character list:

I carrier side, membrane tube, filter capillary

1 a membrane tube bundle

1 b triple helix

2, 2a end face, end plate

3 membrane inlet

4 Transition or fillet

4a flow guide

5 housing, housing

6 transition

7 inlet, outlet

8 Sheath fluid inlet or outlet, filtrate connection

9 side surface of the membrane tube

10 shell side, filtrate space

I I groove

12 sealing element

13 inlet or outlet piece

14 flat sealing element

15 clamping ring

16 overhang

17 jetty

17a housing bridge

19 membrane tube with variable cross-section

20 narrow cross section

21 another cross section

22 longitudinal section

23 elliptical cross-section

24 starting position

25 rotated 90°

26 longitudinal section

27 longitudinal section 28 tubular membrane

28a wave tube membrane

29 turbulator, static mixer

29a turbulator edge

30 coating

31, 31 a, 31 b Connected aggregate of the porous structure, typically with inorganic particles or ceramic, metallic or polymer particles

32, 32a, 32b pore in heap

50 monolithic component

50a target point

52 Carrier fluid collection port

54 carrier fluid chamber

56 Sheath Fluid Collection Port

58 connection collar

60 porous structure

60a membrane or membrane filter

62 separate housing

64 impermeable area

70 starting material

70a mixed feedstock

71 starting material, powdery

72 starting material, liquid

73 starting material, solid

74 starting material, pasty

75 additive

76 filler

77 absorption modifier, ink

80 storage device or application machine

80' second storage device

80a feed

80b component carrier

81 heater 81a Heat generation by means of the heating device 84

82 mixing device

82a flow regulator starting material

82b Quantity regulator additive / filler

82c mixing tank

82d rotary mixer

82e output flow regulator

83 excitation or activation arrangement

83a radiation source

83b deflection or guiding device

83c radiation

84 Activation device or inkjet print head, possibly with radiation source

84a radiation source

84b ink print head or spray device

84c radiation

85 bath

85a rinse solution

86 chamber

90 matrix level

92 storage area

94 other area

100 Deploy

102 stocking up

104 Place

106 mixing

108 heating up

110 Adjust

112 admixture

114 Setting Curing Parameters

116 Source Material Selection

118 Setting the location-dependent radiation intensity

119 Adjusting the location-dependent light absorptivity, adding ink 120 orders

122 Outputting or aligning the coating machine

124 Depositing of powdered starting material

126 (Manual) application of starting material 130 Continuation or termination of the manufacturing process

132 Firing a green body

134 washing out of excipients

136 Removing excess powder

Claims

49

Patent Claims:

1 . Additive manufacturing method for manufacturing a component (50) with an at least partially or at least regionally porous material structure (60), in particular as a filter element (60a) or filter device, comprising the steps of: providing (100, 102, 104, 106, 108) a porous or porous material starting material (70, 70a, 71, 72, 73, 74),

Application (120, 122, 124, 126) of the porous or porous starting material to build up the component, and during the application adjusting (110, 112, 114, 116, 118, 119) the porosity of the porous or porous starting material.

2. Additive manufacturing method according to the preceding claim, wherein the step of applying (120, 122, 124, 126) of the porous or porous starting material (70, 70a, 71, 72, 73, 74) involves applying the porous or includes porous starting material, in particular in a point-target matrix or in a layer-target matrix.

3. Additive manufacturing method according to the preceding claim, wherein the dotwise application (120, 122, 124, 126) comprises

Approaching (120) a point of the point target matrix to be approached, at which point the porous or porous starting material (70, 70a, 71, 72, 73, 74) is to be applied, and

setting (110, 112, 114, 116, 118, 119) the porous or porous starting material at the point of the point target matrix to be targeted and applying the set porous or porous starting material to the point.

4. Additive manufacturing method according to one of the two preceding claims, further comprising the steps

Approaching at least a first point of the point-target matrix and setting (110, 112, 114, 116, 118, 119) the porous or porous starting material at the at least one first point such that at the 50 at least a first point a porous material structure (60) is formed, and/or

Approaching (120) at least a second point of the point-target matrix and setting (110, 112, 114, 116, 118, 119) the porous or porous starting material (70, 70a, 71, 72, 73, 74) at the at least one second point such that an impermeable material structure (64) is formed at the second point. Additive manufacturing method according to one of the three preceding claims, wherein the points of the point target matrix are arranged in storage layers, and wherein the approach (120) of the points of the point target matrix is carried out in layers, so that initially the points of a first storage layer are approached and then the points of a second storage layer. Additive manufacturing method according to the preceding claim, wherein the step of applying (120) comprises applying the porous or porous starting material (70, 70a, 71, 72, 73, 74) in such a way that at least one storage layer has areas with an impermeable material structure (64), and/or at least one storage layer has areas with a porous material structure (60), and/or at least one storage layer has both an impermeable material structure (64) and a porous material structure (60), which is applied with the same porous or porous starting material. Additive manufacturing method according to one of the preceding claims, wherein the application (120) of the porous or porous starting material (70, 70a, 71, 72, 73, 74) is carried out in such a way that the partially or regionally porous material structure (60) of the component (50 ) is arranged or constructed chaotically, and/or the partially or regionally porous material structure (60) of the component (50) with the application (120) of the starting material in or on the component is formed and a 51 has a non-repetitive structure or arrangement. Additive manufacturing method according to any one of the preceding claims, wherein the starting material (70, 70a, 71, 72, 73, 74) is set or prepared to be intrinsically porous, and / or the porous material structure (60) has an open porosity, and / or the impermeable material structure (64) has a closed porosity, and/or wherein the porous material structure (60) is characterized in that it is at least partially permeable to the fluid or components of the fluid, and/or wherein the porous material structure (60) characterized in that there is less resistance to the flow or penetration of a fluid through the porous material structure than in the impermeable material structure (64). Additive manufacturing method according to one of the preceding claims, wherein the porous material structure (60) has an open microporous or mesoporous structure with an average pore size of less than 40 pm, preferably less than 5 pm, more preferably less than 1 pm. Additive manufacturing method according to any one of the preceding claims, wherein the porous material structure (60) has an average volume porosity of 20% or greater, preferably 35% or greater. Additive manufacturing method according to one of the preceding claims, wherein the impermeable material structure (64) has a higher density than the porous material structure (60), the ratio of the density in the impermeable material structure to the porous material structure being in particular 1.2:1, further preferably at 1.5:1, even more preferably at 2:1. Additive manufacturing method according to any one of the preceding claims, wherein the step of adjusting (110) the porosity of the porous or porous 52

Starting material (70, 71, 72, 73, 74) includes:

Admixture (112) of additive (75) or filler (76) to the starting material to adjust the porosity at the moment the material is applied, in particular at the point (50a) of the point-target matrix to be approached, and/or

Setting of hardening parameters (114) for the respective point (50a) of the point-target matrix to be approached, and/or

Selection (116) of a starting material to be used from a plurality of at least two starting materials, wherein the at least two starting materials can be supplied alternately or simultaneously, in particular at the point (50a) of the point-target matrix to be approached in each case, for the production of the monolithic component ( 50), and/or

Provision (118) of a location-dependent radiation intensity (83c) by means of a radiation source (83a), which is aimed at the application of material, or location-dependent adjustment (119) of the light absorption capacity of the porous or porous starting material, so that the component structure can be produced in particular by means of a location-independent radiation source (83a) is feasible. Additive manufacturing method according to the preceding claim, wherein polymeric or inorganic nanoparticles are used as the additive (75) and/or wherein an inorganic or organic filler is used as the filler (76). Additive manufacturing method according to one of the preceding claims, wherein the pores (31, 31 A, 31 B) of the porous or porous starting material (70, 71, 72, 73, 74) are designed or prepared when the material is applied in such a way that they are in the component (50 ) form a cohesive porous material structure (60) and/or the pores have a rounded or potato-shaped individual structure. Additive manufacturing method according to one of the preceding claims, wherein the porous material structure (60) of the component (50) is constructed and arranged in such a way that it is suitable for separating an envelope side from a carrier side in a permeable manner. Additive manufacturing method according to one of the preceding claims, wherein the porous or porous starting material comprises a solvent and wherein the polymeric components of the starting material are bound or dissolved in the solvent. Monolithic component (50), in particular as or for a device for separating components from a fluid, in particular produced according to one of the above methods, the monolithic component comprising:

- a first and a second end face (2, 2a) opposite the first,

- a porous structure (60) arranged between the first and the second end face and constructed and connected in one piece to the end faces, the porous structure being permeable at least partially or in certain areas,

- wherein the porous structure is prepared and arranged in such a way that an envelope side is at least partially and/or at least regionally permeable to separate from a carrier side,

- wherein a carrier fluid can be provided on the carrier side,

- wherein the porous structure is prepared to ensure mass transfer of the carrier fluid with the shell side, in particular a transfer from the carrier fluid into a shell fluid and/or from a shell fluid into the carrier fluid. Monolithic component (50) according to the preceding claim, which is designed as a membrane element (62) for a filter device or which is designed as a filter device and which is constructed monolithically with the porous structure (60) as a membrane element. Monolithic component (50) according to one of the preceding claims, further comprising a housing (5) formed monolithically with the porous structure (60) and the first and second end faces (2, 2a), the porous structure preferably being shared by the housing with the first and second end is enclosed. 20. Monolithic component (50) according to one of the preceding claims, further prepared in such a way that an enveloping fluid can be provided on the enveloping side (10), so that both the carrier fluid and the enveloping fluid can flow in or through the monolithic element and the carrier fluid is separated from the enveloping fluid by means of the porous structure (60), and/or wherein the porous structure (60) is designed to be semipermeable or selectively permeable, and/or wherein the porous structure (60) is designed to be permeable to substances and/or particles with a size less than 10 pm, preferably less than 2 pm, more preferably less than 0.5 pm.

21 . Monolithic component (50) according to one of the preceding claims, prepared for receiving and discharging the carrier fluid on the carrier side (1) and a cladding fluid on the cladding side (10), so that the carrier fluid and the cladding fluid can flow through the monolithic component to provide a Carrier flow and a sheath flow in the monolithic component.

22. Monolithic component (50) according to any one of the preceding claims, wherein the porous structure (60) comprises filter capillaries (1), in particular membrane capillaries.

23. Monolithic component (50) according to one of the preceding claims, wherein the first end face (2) is plate-shaped and the porous structure (60) is integrally formed on the first end face, in particular is formed integrally with it, and / or wherein the second end face (2a) is plate-shaped and the porous structure (60) is integrally formed on the second end face, in particular is formed integrally therewith.

24. Monolithic component (50) according to any one of the preceding claims, wherein the porous structure (60) comprises a plurality of elongate membrane tubes or filter capillaries (1) which integrally form the first end face 55

(2) of the monolithic component with the second end face (2a).

25. Monolithic component (50) according to the preceding claim, wherein the membrane tubes or filter capillaries (1) have an inside, wherein the insides of the membrane tubes or filter capillaries form the carrier side and/or wherein the membrane tubes or filter capillaries form the shell side (10) on their outsides form.

26. Monolithic component (50) according to one of the two preceding claims, wherein the membrane tubes or filter capillaries (1) have a tubular or tube-shaped configuration, and/or wherein the membrane tubes or filter capillaries (1) are essentially straight tubular, or, the membrane tubes or filter capillaries being designed to be intertwined, ie extending in particular in a meandering, helical or helical manner, in particular as a double helix or triple helix (1b), in which two or three membrane tubes or filter capillaries run around one another.

27. Monolithic component (50) according to one of the three preceding claims, wherein the membrane tubes or filter capillaries (1) each have a first or second opening (3) through which a fluid can flow, which is integral with the first or second end face (2nd , 2a) is executed.

28. Monolithic component (50) according to the preceding claim, wherein the mouth (3) has a flow-guiding surface design (4, 4a) which is constructed in particular concentrically around the mouth and is integral with the first or second end face (2, 2a). transforms.

29. Monolithic component (50) according to any one of the preceding claims, further comprising a monolithic with the first face (2) and the porous structure (60). 56 formed first carrier fluid collection port (7), and/or a second carrier fluid collection port (7a) formed monolithically with the second end face (2a) and the porous structure (60), and/or a monolithically formed with the porous structure (60). trained sheath fluid

connection (8, 8a). Monolithic component (50) according to one of the preceding claims, the porous structure (60) further comprising at least one connection, cross-connection, or reinforcement (17, 17a) made monolithically with the porous structure to increase the mechanical stability of the porous structure. A monolithic component (50) according to the preceding claim, wherein the connection, cross-connection, or stiffener (17, 17a) comprises the porous

Structure (60) with the housing (5) connects directly in one piece. Monolithic component (50) according to any one of the preceding claims, wherein the porous structure (60) has at least one turbulator (29, 29a) for

Mixing of the carrier fluid and/or for mixing of the sheath fluid, and/or wherein the porous structure (60) provides a flow cross section that is variable over the length for the carrier fluid and/or the sheath fluid. Monolithic component (50) according to one of the preceding claims, wherein the porous structure (60) has a higher or lower porosity and/or pore size distribution in some areas or in parts, and/or wherein the porous structure (60) has impermeable areas (64), permeable Has areas and other areas that have a different porosity compared to both the impermeable areas and the permeable areas. Monolithic component (50) according to any one of the preceding claims, wherein the first and / or the second end face (2, 2a) has an integral fluid barrier or 57 is designed as an integral fluid barrier, the fluid barrier(s) separating the flow of the carrier fluid from the enveloping flow. A monolithic component (50) according to any one of the preceding claims, wherein the monolithic component is made of the porous or porous

Starting material is built. Monolithic component (50) according to the preceding claim, wherein the porous or porous starting material comprises inorganic components, in particular ceramic paste or metallic paste, and/or wherein the porous or porous starting material comprises polymers, in particular polymer powder, more particularly comprising at least one of polyolefins , for example polypropylene, polyamides, polyvinylidene fluoride (PVDF) and polyethersulfone, and/or wherein the porous or porous starting material comprises inorganic and polymeric components, in particular polymer solution with ceramic, metallic and/or polymeric fillers, the polymer solution in particular comprising at least one of polyolefins, for example Polypropylene, Polyamides, Polyvinylidene Fluoride (PVDF) and Polyethersulfone. Monolithic component (50) according to one of the preceding claims, produced by one of the methods listed above. Monolithic filter module (50) for a device for separating components from a fluid, the filter module comprising:

- a first and a second end face (2, 2a) opposite the first,

- a filter housing (5, 62), in particular elongate or tubular, formed in one piece with the first and second end faces,

- a porous structure (60, 64) arranged in the filter housing and constructed and connected in one piece with the end faces and the filter housing, the porous structure being permeable at least partially or in certain areas 58 is

- at least one carrier fluid collection port (7, 7a),

- at least one sheath fluid connection (8, 8a),

- Wherein the first end face and the second end face is each formed as an integral fluid barrier for preventing a cross flow between

carrier fluid collection port and sheath fluid port,

- wherein the porous structure is so prepared and arranged, a shell side

(10) to be separated at least partially and/or at least in regions in a permeable manner from a carrier side (1), - a carrier fluid being able to be provided on the carrier side,

- wherein the porous structure is prepared to ensure a mass transfer of the carrier fluid with the shell side.