Eco-friendly Simple Processing of Pure Alkali Silicate Construction Parts Based on Water-glass

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This invention presents a cost-effective, eco-friendly method for producing both porous and non-porous three-dimensional construction parts made from alkali silicate (water glass), without the use of toxic organic additives. The process involves forming a silicate-water solution, gelling it with an alcohol, and using additive manufacturing or extrusion to produce customized 3D shapes. The final product's porosity and material properties can be finely controlled via drying and/or heat treatment, making it highly versatile.

Use CasesContent extracted from patent full text and abstract with AI.

• Bone implants and scaffolds for tissue engineering due to controlled porosity and biocompatibility
• Thermal insulation and fire protection materials
• Heat protection or lightweight structural parts in construction and engineering
• Gas or blood filtration devices
• Catalyst supports for chemical processes
• Eco-friendly, form-fitted food or general industrial packaging
• Parts for applications requiring either porous media (e.g., absorbents) or dense structural materials (e.g., architectural components)

BenefitsContent extracted from patent full text and abstract with AI.

• Eliminates the need for toxic organic additives, resulting in a purer and safer material
• Highly adaptable to both mass production and custom shapes via 3D printing/additive manufacturing
• Eco-friendly and low-cost due to the use of water glass (alkali silicate)
• Enables precise control over porosity and mechanical properties
• Fits a broad range of applications, from biomaterials to insulation and filtration
• The process can incorporate fillers (ceramics, glass, metals, carbon) for tailored material properties (e.g., conductivity, hardness, optical features)
• Energy-efficient: can be conducted at ambient pressure and moderate temperatures, reducing energy consumption and complexity
• Potential for recycling and low carbon footprint in construction applications

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

In a first aspect, the invention relates to a method of making a porous or non-porous three-dimensional structure. To this end, a silicate-water solution is first formed and then contacted with a first alcohol, whereby a gel can be provided. Thereafter, the gel is transferred to an additive manufacturing apparatus and a build part is created Finally, drying and/or heat treatment takes place, in particular to obtain a desired porosity and/or phase composition.In a further aspect, the invention relates to a porous or non-porous three-dimensional structure produced according to the process of the invention.In an additional aspect, the invention relates to a use of the porous or non-porous three-dimensional structure. The porous parts or a hierarchical porous part can be used as a bone implant, in tissue engineering, for thermal insulation, fire prevention, heat protection, gas or blood filters, light weight parts and/or catalyst supports or other scenarios where the porosity is necessary. The non-porous parts can be used as packaging, construction parts or other scenarios where the pores should be avoided.