OPEN LOOP ADDITIVE MATERIAL PROCESS AND SYSTEM FOR CREATING A HUMAN-HABITABLE ENVIRONMENT

Abstract

Methods for producing hydrocarbon-based polymers and hydrocarbon-based polymeric structures that are capable of removing carbon dioxide from an ambient environment to produce breathable oxygen. The methods produce enclosed, solar-exposed polymeric structures capable of expanding in area through the reuse of at least a portion of the hydrocarbon-based polymers. As such, the method produces self-sustaining polymeric/hydrocarbon-based structures capable of in-situ resource harvesting and reuse to create a sustainable, habitable area. The methods can be used to create a habitable environment in otherwise harsh conditions, such as those associated with high concentrations of carbon dioxide and low pressure, without the need to use external, non-renewable resources, and instead using renewable, in-situ resources to improve the viability of habitation within the environment of the manufactured three-dimensional structures.

Claims

1. A method of manufacturing hydrocarbon-based polymeric structural elements, the method comprising the steps of: providing a bioreactor including an aqueous mixture and a concentration of atmospheric gases, with a hydrocarbon-based organism disposed within the aqueous mixture; separating the hydrocarbon-based organism from the aqueous mixture; forming a first compound by crushing, hydrolyzing, and dehydrating the hydrocarbon-based organism; reacting the first compound to produce a first set of monomeric units; reacting the first set of monomeric units with a second set of monomeric units to produce a polymeric compound; forming the polymeric compound into a resin; and heating the resin and extruding the resin to form a hydrocarbon-based filament for use in generating a three-dimensional structure via an additive manufacturing machine.

2. The method of claim 1, wherein the atmospheric gases include at least 10% CO.sub.2 and less than 3% O.sub.2.

3. The method of claim 1, wherein the hydrocarbon-based organism is algae.

4. The method of claim 1, wherein the biological reactor is operated at a pressure approximately equal to a pressure of an ambient environment surrounding the bioreactor.

5. The method of claim 1, wherein the first compound is selected from the group consisting of 5-hydroxymethylfurfural, dimethylfurfural, furan, and p-xylene.

6. The method of claim 1, wherein the first set of monomeric units is selected from the group consisting of furandicarboxylic acid, succinic acid, itaconic acid, esters thereof, and diesters thereof.

7. The method of claim 1, wherein the second set of monomeric units is selected from the group consisting of ethylene glycol, 1,4-butanediol, 1,3-propanediol, 1,2-propanediol, esters thereof, and diesters thereof.

8. The method of claim 1, wherein the resin further comprises a material selected from the group consisting of poly-(butylene-succinate), poly-(butylene-2,5-furanate), poly-(butylene-itaconate), poly-(propylene-succinate), poly-(propylene-2,5-furanate), poly-(propylene-itaconate), polyethyleneterephthalate, and mixtures thereof.

9. The method of claim 1, wherein the three-dimensional structure is selected from the group consisting of translucent films, plates, sheets, panels, other planar structures, and combinations thereof.

10. A method of manufacturing a habitable hydrocarbon-based three-dimensional structure in an environment having low pressure and a high concentration of CO.sub.2, the method comprising the steps of: removing atmospheric gases into a bioreactor disposed within an ambient environment in communication with an atmosphere containing the atmospheric gases, wherein the atmospheric gases include at least 10% CO.sub.2 and less than 3% O.sub.2, and wherein the ambient environment has less than 0.1 atm absolute pressure; reacting the removed atmospheric gases with an aqueous mixture including a hydrocarbon-based organism to form a solid biomass, wherein the hydrocarbon-based organism is algae, and wherein the reaction with the atmospheric gases reduces the concentration of CO.sub.2 in the ambient environment and increases the concentration of O.sub.2 in the ambient environment; forming a first compound from the solid biomass by crushing, hydrolyzing, and dehydrating the solid biomass; reacting the first compound to produce a first set of monomeric units; reacting the first set of monomeric units with a second set of monomeric units to produce a polymeric compound; forming the polymeric compound into a resin; and heating the resin and extruding the resin to form a hydrocarbon-based filament for use in generating a three-dimensional structure via an additive manufacturing machine.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] For a fuller understanding of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:

[0021] FIG. 1A is a diagram showing an inverted-trapezoidal bioreactor with the longest side of the bioreactor facing the sun.

[0022] FIG. 1B is a diagram showing the inverted-trapezoidal bioreactor of FIG. 4A, showing the longest side of the bioreactor facing the sun after the bioreactor shifts in orientation.

[0023] FIG. 1C is a diagram showing the inverted-trapezoidal bioreactor of FIG. 4A, showing the longest side of the bioreactor facing the sun after the bioreactor shifts in orientation.

[0024] FIG. 2 is a process flow diagram describing a method of creating and extruding a hydrocarbon-based filament for use in an additive manufacturing system, the hydrocarbon-based filament capable of comprising photosynthetic structures.

[0025] FIG. 3 is a process flow diagram describing a method of using atmospheric gases to create hydrocarbon-based filament for use in an additive manufacturing system capable of photosynthesis.

[0026] FIG. 4 is a process flow diagram describing a method of creating and harvesting hydrocarbon-based materials for use in repeating additive manufacturing systems.

DETAILED DESCRIPTION OF THE INVENTION

[0027] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part thereof, and within which are shown by way of illustration specific embodiments by which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the invention.

[0028] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the context clearly dictates otherwise.

[0029] The present invention includes methods for producing hydrocarbon-based polymers and hydrocarbon-based polymeric structures that are capable of housing organisms for the removal of carbon dioxide from an ambient environment to produce breathable oxygen. Moreover, the present invention includes enclosed, solar-exposed polymeric structures capable of expanding in area through the reuse of at least a portion of the hydrocarbon-based polymers produced therein. As alluded to and discussed in the sections above, objects of the present invention are to produce self-sustaining polymeric/hydrocarbon-based structures capable of in-situ resource harvesting and reuse to create a sustainable, habitable area. By incorporating generic biomass carbon fixation with manufacturing and a known net carbon fixation into plastic and oxygen release, plastic manufacturing provides a certain direction without biological complications. Also accomplished is increasing usable structure and solar capturing area for an increased rate of O.sub.2 production.

[0030] The use of hydrocarbon-based-based filament for use in additive manufacturing has been disclosed in the prior art. For example, Kucherov teaches a method of three-dimensional printing using biomass-derived polymers for the purpose of manufacturing carbon-neutral structures. [1] The Kucherov article discusses the dangers of over-reliance on non-renewable natural resources that produce carbon dioxide and other gases. According to the article, additive manufacturing provides virtually waste-free manufacturing methods, especially in comparison to traditional manufacturing methods. However, in an effort to improve upon the typical polymers that are used as filament in additive manufacturing systems, Kucherov proposes the use of poly(ethylene-2,5-furandicarboxylate), otherwise known as PEF, which is a biomass-derived polymer that is capable for use in additive manufacturing systems. Moreover, Kucherov teaches that it is possible to recycle and reuse objects printed with PEF by melting the objects, converting the melted material into a filament, and using the filament in an additional additive manufacturing process. Importantly, such recycling practices can contribute to sustainable printing practices, in which printed materials can form the basis of future printed objects. US Publication Number 2017/0327704 to Sactipante also teaches a hydrocarbon-based resin for use in additive manufacturing in an attempt to provide a sustainable material alternative to non-renewable resources used in current manufacturing processes. However, neither Kucherov nor Sacripante teaches the use of gases from a high CO.sub.2/low O.sub.2 ambient atmosphere or from the waste gases of a habitable facility of support facility, the harvesting of a portion of the PEF used to print an object, the mixing of PEF with other materials (such as minerals or other hydrocarbon-based substances), or the expansion of an area including PEF-printed materials to expand the production of PEF.

[0031] Moreover, the need to develop and utilize bio-regenerative systems, particularly for extraterrestrial environments, is discussed in Murukesan, which teaches that cellular growth is possible in high-carbon dioxide and low-pressure conditions, such as those that exist on Mars. [2] Murukesan teaches the use of cyanobacteria, which is a prokaryotic bacterial organism, to remove carbon dioxide from the environment and produce breathable oxygen. According to Murukesan, an important consideration is how to shield the cyanobacteria from hard cosmic radiation, such as that experienced on the Martian surface. Expanding upon such carbon dioxide removal system, Lingampalli teaches the reduction of atmospheric carbon dioxide using photosynthetic agents, which would be necessary in the settlement and long-term success and viability of an environment in an extraterrestrial location, such as Mars. [3] Moreover, Dexter further explores the use of cyanobacteria to produce ethanol as an alternative fuel source that would also function as a carbon dioxide removal system. [4] However, similar to Kucherov and Sacripante above, neither Murukesan, Lingampalli, nor Dexter teaches the harvesting, recycling, and expansion of structures or area needed to create truly sustainable structures from hydrocarbon-based materials.

[0032] Gurudayal further teaches solar-driven carbon dioxide reduction methods used to provide alternative energy sources, thereby creating more sustainable energy sources. [5] in the Gurudayal article, a copper-based cathode is used in an electrolysis cell to produce hydrocarbons in a solar-assisted method. The results described in the Gurudayal article suggest that efficient carbon dioxide reduction is possible; however, the article is limited to cathode-anode electrochemical reactions to reduce carbon dioxide, and does not touch on the harvesting, recycling, and expansion needed to create truly sustainable structures from hydrocarbon-based materials. Markou also teaches the use of algae as a food source and fuel source, further explaining how hydrocarbon-based agents can be used to provide both food and fuel for a potential settlement (or as alternatives to currently-used resources on Earth). [6]

[0033] Dashtban teaches the production and use of furfural from biomass. [7] As those of ordinary skill in the art would recognize, and as explained in the Dashtban article, furfural is an extremely promising chemical that can be used for a variety of different purposes. However, Dashtban recognizes that furfural production from biomass has not been explored in-depth; in extraterrestrial and other harsh environments, the ability to produce and use furfural could be paramount to the success of an otherwise unsuccessful settlement. As such, Dashtban explores various methods of producing furfural with varying degrees of success, but the article ultimately concludes that more research is necessary within the field.

[0034] With the discussion of the relevant prior art attempts to provide hydrocarbon-based organisms in a usable polymer format, and to provide methods of carbon dioxide reduction in places with unusually high concentrations of carbon dioxide, the present invention involves novel methods for in-situ resource utilization, improving upon the teachings of the prior art. In particular, the present invention provides methods to increase a reactive area for photosynthetic activity and/or thermal capture/cooling, as well as a material connection between an output of an additive manufacturing system and an input to the additive manufacturing system, thereby creating an open loop system that is self-sustaining and expands as needs expand. Aspects of the methods and system will be discussed in greater detail below.

Overview of an Open-Loop System

[0035] Improving on the technologies discussed above, an aspect of the present invention includes a bioreactor produced with extrusion-based 3D printing (fused filament fabrication (FFF)) from predominantly in-situ resources (CO.sub.2, and H.sub.2O), with the system having the ability to scale upwards and expand to a greater area through the use of the product of the facility to make additional facilities. The bioreactor has a low initial mass and volume, and has the ability to increase a solar irradiance area over time as resources are processed into 3D filament and subsequently used to print more bioreactors. A variety of bio-based plastics are produced through a variety of production methods. The ability to fabricate additional partitioned bioreactors allows for multiple biological, chemical, and thermal production sites for target compounds used for manufacturing in a given space. The bioreactor size and number can therefore be adjusted to meet output ratios for processing and manufacturing needs.

Bioreactor/Growth Chamber

[0036] In an embodiment, a bioreactor, or a growth chamber, includes design characteristics to enable the ability to scale upwards, thereby adding additional solar irradiance area. Characteristics include critical properties of porosity, light/radiation transmission as well as unique design considerations including partitioning, redundant circulation pathways, thermal distribution, solar tracking ability, internal space to pressurize to grow higher plants increasing range of options for compound production, food production, nutrient recovery, and separation. The chamber also enables rerouting of the pathway by creating a bypass, if need be. As shown in FIGS. 1A-1C, the growth chamber 100 may be trapezoidal in shape and may be oriented as an inverted trapezoid along the ground surface 110, such allows for variation in positioning for solar tracking of the sun 120 by the growth chamber, thereby increasing photosynthetic possibilities within the growth chamber. When utilized with photosynthetic organisms for feedstock, production species with high light levels productivity can be grown on plane facing the sun, while 3 other sides have organisms that thrive under lower light levels. The growth chambers can also be positioned next to each other to enable reflected light off of high light plane to be directed to adjacent chamber. As the growth chambers are modular, numerous such growth chambers can be combined in series or parallel to form larger volume and surface area facilities.

[0037] Advanced bioreactor systems may include associated hardware and software for system monitoring and control, while meeting the unique challenges of an unmanned, compact system. These will include layout, pumps, sensors, harvesting and separating biomass from solution, circulation, and aeration. Moreover, within the bioreactor, biomass may be processed into filament feedstock fed to an incorporated 3D printer, in processes that will be discussed in greater detail later in this disclosure. In addition, thermoregulation incorporating radioisotope thermoelectric generator (RTG) and photovoltaic options can provide power.

[0038] Constant thermoregulation via radioisotope or fission power systems provides constant day and night heat source to maintain adequate temperatures for biological based system. During night, when there is no sunlight on exterior of structure and temperatures decrease, aqueous biological solution can be drained from exterior shell to interior portions.

3D Printed Windmills

[0039] Following on from the previous discussion of bioreactors that can be created through the processes described throughout this specification, 3D printed windmills can also be created including biological material. If employed in an environment with wind, such as Earth or Mars, wind power can be captured by the 3D printed windmills to mechanically circulate algal or other liquid solutions about the structure and about external, coupled structures. The algae can be aerated with atmospheric CO.sub.2 and pressure can be maintained through the system, thereby reducing power requirements. Examples of 3D printed windmills can be found in prior art references [14] and [15].

Hydrocarbon-Based Filament for Additive Manufacturing

[0040] Various plastic materials as feedstock for 3D printing are available and can be biosourced. Currently the preferred Biofeedstock appears to be PEF (polyethylene-2,5-furandicarboxylate), produced through various processes. Direct synthesis of plastic feedstock without using biology has been attempted and could be incorporated into the design as well. The thermal regulation of tilting chamber would be utilized.

[0041] 3D printing with polyethylene-2,5-furandicarboxylate (PEF) can be performed, with PEF being made from cellulose. PEF is also clear-to-transparent, which is a useful characteristic if bio energetically sourced. A commercially available 3D printer has been used elsewhere under standard settings to successfully print objects with PEF filament. The individual layers of the printed objects were firmly bound to each other and the surface was smooth and of high quality. Tests demonstrated that the objects were resistant to dichloromethane, one of the most aggressive solvents. Due to the high thermal stability of the PEF, the printed objects could be repeatedly melted, made into filaments, and printed again. Computer calculations indicate that the individual building blocks of PEF may contain non-linear fragments and form a spiral twist, which gives an access to new types of geometry. Another important feature is a greater polarity of PEF.

[0042] Bio based Polyethylene terephthalate (PET) is another option with wide range use applications. PET is a product of terephthalic acid and ethylene glycol, and is made of 32.2 wt % monoethylene glycol (MEG) and 67.8 wt % purified terephthalic acid (PTA), combined in an esterification reactor and converted to polymer in a polycondensation reactor.

Method of Creating a Habitable Environment

[0043] Using the teachings above, a habitable environment can be created or produced by using hydrocarbon-based plasic whereas in the production from biomass hydrocarbons fixes carbon to release net oxygen from the ambient environment or various waste streams. Multiple methods of manufacturing with plastic are possible, specific methods described in the process flow diagrams of FIGS. 2-4, which will be described in greater detail below with filament 3D printing.

[0044] As shown in FIG. 2, a general method of creating a hydrocarbon-based filament is described. The method includes the step of growing a hydrocarbon-based organism, such as algae, within a bioreactor, such as a growth chamber. Such hydrocarbon-based organisms and growth chambers are discussed in detail above. The method also includes reacting the hydrocarbon-based organisms to produce monomeric units, as is described throughout the prior art. The monomeric units can then be polymerized by reacting the monomeric units with a second group of monomeric units, creating polymers that can be formed into a resin. The method next includes the steps of heating and extruding the resin, thereby forming a hydrocarbon-based filament that can be used in additive manufacturing processes to form 3D structures capable of photosynthetic activity.

[0045] FIG. 3 expands upon the method described in FIG. 2 with more specific reactions and products shown therein. As shown in FIG. 3, the method includes capturing and obtaining atmospheric gases in a bioreactor, such as carbon dioxide. A hydrocarbon-based organism is also contained within the bioreactor, as described in FIG. 2 above. Biomass is obtained from the bioreactor, and the biomass is reacted with an acid to form pentose or hexose sugars. The acid is removed from the bioreactor via distillation, and a solvent is added to the bioreactor. The sugars are dehydrated to produce 5-hydroxymethylfurfural, which the prior art discussed above recognizes as an important chemical for sustainable life. The 5-hydroxymethylfurfural is oxidized to produce 2,5-furandicarboxylic acid, which is reacted with in monomethyl ethylene glycol to form polyethylene furandicarboxylic acid and methanol. The polyethylene furandicarboxylic acid can then be extruded to form 3D structures capable of photosynthetic activity, as discussed above.

[0046] FIG. 4 described yet another method of forming structural elements from hydrocarbon-based materials. The method includes the step of providing an enclosed, solar-exposed structure, such as the bioreactor discussed above. An additional step includes providing a hydrocarbon-based agent, such as algae or an algae-based substance, that is photosynthetic—this hydrocarbon-based agent may be disposed within the solar-exposed structure, or may comprise the surfaces of the solar-exposed structure. The hydrocarbon-based agent is grown within the bioreactor in an aqueous medium, together with atmospheric gas, as described in greater detail above. Biomass solids are harvested from within the bioreactor, and the biomass solids are converted into polymeric materials, or from which polymeric materials can be extracted. Structural elements are formed from the polymeric materials, with the structural elements including hydrocarbon-based materials, such as the algae discussed above. As such, the process can manufacture more hydrocarbon-based materials to be used in further reactions for further manufacturing of structural elements, and so on, thereby showing that the system can harvest hydrocarbon-based material therein to continuously produce 3D structures.

Additional Considerations

[0047] Additional examples of known bioderived resilient clear plastics can be found at references [8], [9], [10], [11], and [12].

[0048] While this specification focuses on teachings of additive manufacturing systems, it is important to consider that other fabrication methods may be used, such as injection molding, extrusion blow molder, and other methods of manufacture, so long as the materials are hydrocarbon-based, in accordance with the teachings above.

REFERENCES

[0049] [1] Kucherov, F. A. et al. “Three-Dimensional Printing with Biomass-Derived PEF for Carbon-Neutral Manufacturing.” Agnew. Chem. Int. Ed. 2017, 56, 15931-15935.

[0050] [2] Murukesan, G. et al. “Pressurized Martian-Like Pure CO.sub.2 Atmosphere Supports Strong Growth of Cyanobacteria, and Causes Significant Changes in their Metabolism.” Orig. Life Evol. Biosph. 2015.

[0051] [3] Lingampalli, S. R. et al. “Recent Progress in the Phtotocatalytic Reduction of Carbon Dioxide.” ACS Omega. 2017, 2, 2740-2748.

[0052] [4] Dexter, J, et al. “The state of autotrophic ethanol production in Cyanobacteria.” Journal of Applied Microbiology. 2015, 119, 11-24.

[0053] [5] Gurudayal, J. B. et al. “Efficient solar-driven electrochemical CO.sub.2 reduction to hydrocarbons and oxygenates.” Enegy Environ. Sci. 2017, 10, 2222-2230.

[0054] [6] Markou, G. et al. “Microalgal carbohydrates: an overview of the factors influencing carbohydrates production, and of main bioconversion technologies for production of biofuels.” Appl. Microbiol. Biotechnol. 2012.

[0055] [7] Dashtban, M. et al. “Production of Furfural: Overview and Challenges.” Journal of Science & Technology for Forest Products and Processes. 2012, 2:4, 44-53.

[0056] [8] van der Hoeven, D. “More biobased plastics for bottles: DuPont accounces PTF.” Bio Based Press. Feb. 2, 2016. Accessed online at the URL: https://www.biobasedpress.eu/2016/02/more-biobased-plastics-for-bottles-dupont-announces-ptf/.

[0057] [9] DuPont. “Sustainable Plastics.” Accessed online at the URL: http://www.dupont.com/products-and-services/plastics-polymers-resins/bio-based-polymers/articles/renewable-biopolymers.html.

[0058] [10] Nestle. “Danone and Nestle Waters Launch NaturALL Bottle Alliance with California Startup to Develop 100% Bio-Based Bottles. Mar. 2, 2017. Accessed online at the URL: https://www.nestleusa.com/media/pressreleases/nestle-waters-launch-alliance-naturall-bio-based-bottles.

[0059] [11] Synvina. “Publications.” Accessed online at the URL: https://www.synvina.com/multimedia/publications/.

[0060] [12] Pellicori, S. “Coatings Used in Space Requirements and Solutions.” Materion Coating Materials News. Accessed online at the URL: https://materion.com/-/media/files/advanced-materials-group/ac/ac-newsletter-article-pdfs/coatings-used-in-space_technical-paper.pdf?la=en&hash=14D82EF63631DC7C39D2EAD25FECDE66AD5E3BB0

[0061] [13] Gibson, M. A. et al. “Development of NASA's Small Fission Power System for Science and Human Exploration.” American Institute of Aeronautics and Astronautics. Accessed online at the URL: https://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/20140017750.pdf.

[0062] [14] Thingiverse. “Zen Windmill Powered Water Pump.” Aug. 1, 2015. Accessed online at the URL: https://www.thingiverse.com/thing:950660.

[0063] [15] Holstein-Rathlou, C. et al. “Wind Turbine Power Production Under Current Martian Atmospheric Conditions.” Mars Workshop on Amazonian Climate 2018. Accessed online at the URL: https://www.hou.usra.edu/meetings/amazonian2018/pdf/4004.pdf.

[0064] [16] Raymond M. Wheeler “Agriculture for Space: People and Places Paving the Way” Open Agriculture. 2017; 2: 14-32 Accessed online at the URL: http://sciences.ucf.edu/class/wp-content/uploads/sites/58/2017/02/Wheeler_AgricultureForSpace_PeoplePlaces_OpenAgriculture_2017.pdf.

[0065] All referenced publications are incorporated herein by reference in their entirety. Furthermore, where a definition or use of a term in a reference, which is incorporated by reference herein, is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

[0066] The advantages set forth above, and those made apparent from the foregoing description, are efficiently attained. Since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

[0067] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention that, as a matter of language, might be said to fall therebetween.