Design and Fabrication of Hierarchically Porous Polymer Composites by Powder Bed Fusion

Materials with adsorption functions have a wide range of applications in gas storage and separation, water purification, catalysis, etc. However, most of them show weak ability to form a specific shape, which limited their practical application. Additive manufacturing has the characteristic to manufacture complex structures, particularly forming porous structures. This paper demonstrates a universal method to manufacture hierarchical porous functional components by laser powder bed fusion. The porous structure at different scales was created through the design of the part, addition of milled salt as porogen and the addition of active carbon (AC). The active carbon had a dual function: pore integration with microscopic pores and adsorption. Once dissolved, the salt created macropores; while a lattice structure was adopted for the design of the component, which can further increase the macroscopic pores of the component and maximize the adsorption capacity. The CO2 adsorption capacity of sintered components with different AC/PA12 ratios and porous structures was tested. The 40wt% AC content exhibited a high CO2 adsorption capacity of 22.71 cm3g-1 at 1 bar at 25 ℃. The addition of salt as a method of enhancing the porous structure led to approximately 43% improvement over the typical standard AC/PA12 porous structure. The SEM images, CT images and the other data used in the draft is included in this group.具备吸附功能的材料在气体存储与分离、水体净化、催化等领域拥有广泛应用。然而此类材料大多难以成型为特定形貌，限制了其实际应用。增材制造具备制备复杂结构的特性，尤其可构建多孔结构。本文提出了一种基于激光粉末床熔融（Laser Powder Bed Fusion）的通用制备方法，用于制造分级多孔功能构件。通过构件结构设计、添加研磨盐作为致孔剂，以及添加活性炭（Active Carbon, AC），可构建不同尺度的多孔结构。活性炭兼具双重功能：一是与微孔协同实现孔隙整合，二是发挥吸附作用。盐溶解后可形成大孔；而构件设计采用晶格结构，可进一步增大构件的宏观孔隙，最大化吸附性能。本文测试了不同AC/聚酰胺12（Polyamide 12, PA12）比例及多孔结构的烧结构件的CO₂吸附性能：当AC添加量为40wt%时，在25℃、1bar条件下，其CO₂吸附量可达22.71 cm³·g⁻¹。相较于传统标准AC/PA12多孔结构，通过添加盐优化多孔结构的方式可使吸附性能提升约43%。本数据集包含本文稿件中使用的扫描电子显微镜（Scanning Electron Microscopy, SEM）图像、计算机断层扫描（Computed Tomography, CT）图像及其他相关实验数据。